The Abbey Group – CONTINUING INVESTMENTS

Our continuing Capital Investment program, which sees us re-investing in the business year on year, includes the following plant and equipment, focused initially on expanding the offering from our powder coating facility.
Future investment plans:

We have further plans for the future and we are actively working with a number of manufacturers towards our next big investment. By the end of Q1 2017 we will have a new 6 kw Fibre Laser with a 4M X 2M cutting bed. Further updates will be given when the new machine is commissioned.

The Abbey Group has already completed a number of investments, including:
Two new spray wash plants to provide a chemical clean and a stronger paint bond to any substrate that we coat. With this process the chance of small pockets of uncleaned material or small blemishes on the finished coat are greatly reduced.
Two new state of the art Gema powder coat guns. These allow us to coat all parts more evenly and reduce our waste through overspray. This investment has the added benefit of improving our environmental performance as well as our overall paint quality.
A new 8 metre X 3.5 metre X 2.5 metre box oven. This is one of the biggest ovens of its kind in the North West of England and enhances our production capacity, as it is additional to our inline powder coat oven. This new facility allows us to coat large items ‘offline’ while continuing to paint small parts on our continuous powder coating line.
A new self-contained shot-blast facility using chilled iron shot to produce a fantastic paint key for heavier duty products and allowing us to provide a new lease of life to any rusty parts sent to us for refurbishment. The shot blast preparation is the perfect key for our Extreme Paint, a powder coating finish which offers extended lifetime in outdoor use.
A brand new fleet of Fork Lift Trucks to improve our material handling capabilities.
An 18 Tonne delivery vehicle to improve our delivery capabilities and lead times, which we have added to our existing fleet
Continual investment in our Machine Shop, from small equipment such as drills and grinders, through to fully automated bar-fed HAAS CNC Turning Centres and HAAS Vertical Machining Centres.
A 4 metre Amada Pressbrake, enhancing our folding capabilities, as an addition to our existing Amada 1 metre and 3 metre Pressbrakes.
CAD / CAM Software. We have continued to invest in software that enhances our production capabilities, including Autocad & Solidworks, Amada bend development Software for our pressbrakes, and an improved CAD / CAM package for our Bystronic lasers. We are committed to continuing investment in this area, and we are in the process of further software evaluation.
A secure, offsite, IT system backup facility which backs up all of our business data on a quarter-hourly basis. This is independently provided with regular tests taking place to ensure that our data can be restored quickly and accurately. In the unlikely event of a total site data outage, we have the ability to run remotely with our IT and telephone systems working as if we were still in the factory! This data resilience is critical for some of our more demanding customers, but is not exclusive, it applies to all.
All of this investment has a cost, but we haven’t been cavalier with our investment plans. Much of what we have done has been self-funding as a result of us buying better, researching service provisions and getting cost savings back in to the business.

 

 

 

The Abbey Group – DELIVERY

We are now beginning to fully reap the benefits of our investment in a full MRP system, Aventa, which meets Aerospace and Nuclear standards. This system was installed 2 years ago and we have been learning about its capabilities ever since. We are using the data generated within the system to make better, more informed decisions about our lead times and manufacturing capabilities, and we are improving our internal reporting on a weekly basis.
To ensure that we have a keen focus on meeting our promised delivery dates, we have now assigned an External Sales Account Manager, Internal Sales Account Manager and a Production Management representative to every customer. From the data contained in our MRP system, there is a daily review meeting for each of the teams to check on progress of all orders. By using this centralised data, linked to live job cards on the shop floor, we are able to accurately track the progress of all orders at all times.
We are fully committed to improving our quality, delivery and service to all of our customers and welcome feedback, good or bad, as this helps us on our journey to providing every customer with what they want.

 

 

 

The Abbey Group – QUALITY

From your first contact with The Abbey Group, you can be assured that our systems and processes are geared up to providing you with Quality Assured Products which conform with your requirements. We have recently promoted from within and have a dedicated Quality Manager, Dave Colburn, who is a qualified RWC (Responsible Welding Coordinator), and is responsible for managing our ISO 9001 Quality Assurance system and our BS EN 1090 CE Marked, structural steel production to Execution Class 2.
To improve our internal processes on quality, we have fully reviewed all of our shop floor based inspection methods and, within the last 3 months, have put new Control Plans in to operation on each and every workstation. The result of the control plans is that we are confident that we will capture any issues on our shop floor, preventing non-conforming parts getting to our customers. This also aids the learning process for our Operators, as people have more responsibility and accountability, and we are seeing an improvement in every department as people strive to ensure that they are making product right first time.

 

 

 

The Abbey Group – ORGANISATIONAL STRUCTURE

2016 has been a challenging yet exciting year for The Abbey Group, as we continue with our Capital Investment Programme and Operational Improvements throughout the business.
We have very recently streamlined and reorganised our Sales and Manufacturing teams with the sole purpose of providing a better service to our customers. As a result of our recent changes, we have a more cohesive and focused team who are all pulling in the same direction to provide excellent customer service. Our full organisation chart is attached to this document showing all key personnel within the business.
As a diverse business with a wide offering to a number of industries and sectors, we recognise that serving all customers is a challenge. To ensure that we retain full focus on all aspects of our business we have split the business into distinct Value Streams. Each value stream team holds full responsibility and accountability, meaning that they are empowered to make business decisions on spending, investment, materials and personnel to ensure that their value stream performs.

 

 

 

The Abbey Group wins Manufacturing & Engineering Business of the Year 2015

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MIB Awards 2015

The Merseyside Independent Business (MIB) Awards is the only ceremony in the region to celebrate the achievements of independent businesses.

From one man operations to large employers the awards sees businesses from all over the county enter the prestigious awards with 12 categories. An overall winner is also picked to win a business package worth more than £10,000.

The awards are judged independently by two panels made up of key Merseyside stakeholders including Liverpool Vision, Liverpool & Sefton Chamber of Commerce, Liverpool BID Company and more.

The ceremony took place at the Rum Warehouse in Liverpool on Thursday 1st October.

See other category winners here

New HAAS ST-20 Turning Centre

 

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The Abbey Group has invested in a new Haas ST-20 Turning Centre.  It is the latest Haas high-performance turning centre – designed to provide heavy cutting ability, extreme rigidity and high thermal stability. It has a maximum cutting capacity of 15″ x 20.5″ (381 x 521 mm), with maximum swings of 31.75″ (806 mm) over the front apron and 20.75″ (527 mm) over the cross slide.
The standard 20 hp (14.9 kW) spindle yields 140 ft-lb (190 Nm) of torque at 2000 rpm, and spins to 4000 rpm. The A2-6 spindle nose is equipped with a 8.3″ (210 mm) hydraulic 3-jaw chuck, and a 12-station bolt-on style tool turret is standard.
High productivity options for the ST-20 include a belt-type chip conveyor, hydraulic tailstock, automatic tool probe, live tooling with C axis, automatic parts catcher, high-pressure coolant systems and much more

Accreditation renewals

We have recently renewed our NIC EIC and Gas Safe accreditation,  for information on all our accreditations please see our Quality/Health & Safety pages.

Renewed – May 2013

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Our Latest Accreditation – September 2013

Achilles UVDB is the community for the UK utilities industry. It enables the utilities sector to use Achilles’ proven supplier pre-qualification system to manage risk within the supply chain and comply with EU regulations. Launched in 1996, Achilles UVDB is the largest Achilles community that is also used by the airports and ports sector. Achilles UVDB is managed by a Steering Group comprising of utility buyers to drive industry best practice.

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New MRP System

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The Abbey Group have invested £50,000 into a new MRP system.

Proven British Software – Aventa is business-process software that’s designed for engineers by engineers. Redthorn do not make it for any other industry. Sub-contractors get software that’s undiluted and specific to their requirements.  Aventa has a built-in standard library of links to OEMs.  These standard EDI’s drastically reduce manual data input and remove any element of incorrect input of critical information.  Companies previously entering customer order schedules over a number of days can now load them in minutes.

Aventa is written and developed in Oracle – Oracle is an industry standard, leading edge application development tool. By harnessing the power of Oracle, Aventa is able to offer standard EDI links to manufacturers.  Aventa is everything the industry has been looking for to increase margins, save time and increase profits. Redthorn customers, who supply to industries such as aerospace, automotive, excavation, rail and electrical divisions, depend on Aventa for managing both the internal business process and the logistics of the supply chain.  Redthorn products are designed around the powerful and secure database, Oracle – which offers speed, reliability, security and a user-friendly environment.

Real Time Data Capture – Through real-time data capture the Aventa scheduling software is automatically updated to enable closer control of the manufacturing environment. Using data capture and touch screen technology Aventa users are able to process payroll, manage shift patterns and monitor employee efficiency.  Shopfloor data capture also enables realtime cost analysis of machine and labour utilisation.  Aventa data capture allows the user to record rejects at the point of error and automatiically notifies the relevant personnel and creating the neccessary documentation.  Data capture can be used for single or multiple time allocation against individual jobs and can also allow single time bookings against multiple jobs.  By using data capture the company can monitor, track and cost not only productivity but lost time, machine breakdown, infact any non-productive time booking.