Subcontracting competitors had difficulty drilling a 0.3mm diameter hole 9mm deep through a component - now machined in a CNC sliding head auto in 2.5 minutes and not days.

AEL (Dorset) of Blandford Forum, UK, has grown tenfold in its first two years of business. The company that started operating out of one partner's garage, largely credits its success to impeccable customer service and the willingness to invest in high technology equipment such as the Tornos Deco 20a. Until recently, AEL were using two turning and two machining centres backed up by a network of subcontractors to service the aerospace, electronics, medical and defence sectors.

AEL director David Ross says: 'Our work just kept growing and although our XYZ fixed head turning and machining centres were capable of producing the majority of our work, we had no capability for the smaller, more complex, volume parts'.

'For example, we were producing a complex injector assembly for the food industry which was going to five specialist and very expensive machining subcontractors giving major logistics and costing problems.' 'We were subcontracting out GBP 15-17,000 of that type of work each month with the potential to increase sales value with substantially increased margins if we could offer our customers the appropriate capacity and capability'.

'At that point we realised we needed a high specification turning centre and having considered many options, eventually decided on a Tornos Deco 20a which was delivered in April 2005'.

'We now produce these parts in-house with one subcontract brazing operation' Ross added: 'The purchase of the Deco 20a not only solved our immediate problems but also opened doors for us that would have previously been unachievable'.

'Another major customer had been having difficulty finding a UK supplier that could meet the high quality and lead times required on a range of critical parts'.

'After many attempts, they settled into a pattern of buying large quantities at long lead times from the US.

Having seen our Deco and the history we had with them on smaller volume parts, they agreed to conduct trials with us'.

'The Deco was extremely successful in producing the parts; its ability to change from one variant to another quickly enabled us to quote competitively.' AEL competitors with alternate sliding head lathes were bidding for the same job but were having difficulty efficiently machining components from hexagonal bar.

The customer specification dictated that the bar must be bead blasted prior to machining to give the ultimate finish required.

As all users of sliding head machines will be aware, the guide bush will leave a witness, which on normal hexagon work is acceptable.

Competitors using alternative sliding head technology were unable to satisfy the customer's stringent requirements.

In addition to marking, the competitors also had difficulty drilling a 0.3mm diameter hole 9mm deep through the component.

A combination of the rigidity of the Tornos backed up by the Tornos engineers' ability to draw from world wide experience of difficult applications and appropriate tooling, paved the way for AEL to successfully produce samples and ultimately win the contract.

The 13 employee company now produces the component in 2.5 minutes whilst competitors could only manage a handful of parts in two weeks'.

' 'We won the contract to supply on a yearly order in Kan Bans of 700 parts'.

'On the strength of this performance, the customer has now asked us to consider seven further parts,' continues Ross.

The purchase of the Deco has considerably reduced AEL's subcontract base and taken huge cost out of the business.

The company now has plans to add further Tornos machines to its portfolio.

Machining anything from brass and aluminium to stainless steel, inconel and mnemonics, the Dorset based company has recently won a contract to produce small connectors for the aerospace industry.

This would have previously been beyond its scope without the addition of the Deco 20a.

Ross concludes: 'It is the Deco's exceptional build quality combined with superb technical backup, unbeatable cycle times and rigidity, but most importantly, efficiency; that has complimented our business'.

'The Deco epitomises quality and has given us a real advantage in a highly competitive field'.

'I want a machine that I can set, hit the start button and walk away from'.

'The Tornos gives me that confidence'.

'In my opinion, for the best all round package, Tornos is the only choice.'