Aldermans: The Power of Automation

It is no secret that there is a huge shortage of people and skills in the manufacturing sector.  Investment in automation is a key strategy to help manufacturers maintain productivity despite labour and supply chain challenges.

To better understand the potential impact of automation, I spoke with Karen Friendship, the MD at Plymouth sheet metal fabricators Aldermans, about their automation journey.

Karen knew she would need to make some changes when she took on the business; so invested heavily in new CNC laser cutting and punching machines.  The new machines don’t really look any different to the old-style ones, but are computer controlled, and have a screen attached to monitor throughput and efficiencies.

These machines also have an automated sheet loading system attached, which feeds the machine automatically with new sheets of metal as soon as they are needed.  Another rack at the end unloads the cut or punched sheets.  This enables the machines to work without manual intervention until the sheet loading racks are empty; and reduces the amount of time lost due to loading and unloading.

These machines are now operating overnight with material flowing in and out safely.  The last manually operated shift finishes at 01:45 and the next shift starts at 06:30, with the machines operating in between.  The team come in twice on a Saturday and twice on a Sunday to offload and reload the machines.

Automation has advanced other processes in the factory too.  On an old-style press brake (a machine for folding larger pieces of sheet metal), an operator would have to handle and adjust each piece of steel maybe five times to make all the folds required.  Now, the new machines can do three folds of steel without the operator having to put the piece of metal down.

Since 2018, Aldermans has spent £1.5 million on production automation – however, this has helped contribute to a 60% increase in turnover in that four-year period.

From talking to Karen, it is obvious that the company’s culture is another key reason for Aldermans’ success.  Members of the team are empowered to suggest improvements to processes; and this results in more efficiencies and a more engaged workforce.

Karen also notes that focusing on each client and understanding their needs can lead to greater efficiencies.  For example, investment in modern technology might benefit a particular contract.  However, more traditional metal fabrication machines could be used for another client to create a bespoke piece.  Versatility is key. 

Modern manufacturing machines utilise computer technology to the full, often with touch-screens which are particularly intuitive to the younger generation entering the workforce.  This makes training much easier and quicker, which helps to address the skills shortage faced by the sector.

Karen is hugely passionate about training the next generation and will be opening the doors of Aldermans to school groups on Thursday 7 July as part of Make UK’s National Manufacturing Day UK-wide Open House.

“The UK still has a vital and diverse manufacturing sector.  Companies are harnessing innovative technologies to increase efficiencies and create some amazing products,” commented Karen.  “There are excellent career opportunities and a real sense of satisfaction from working in such a dynamic sector.”