As a subcontractor replaced its early CNC machine tools, the same floor space created twice the number of components - a productivity increase that soon balanced out any price differential.

Investment has always been a high priority for the Harmon Group, a family-owned business founded in 1964 as Harmon Form Tools. Initially the company provided a grinding and tooling service, now known as the Harmon Precision Grinding division, with the focus on the aerospace and defence industries. But in 1987 it entered the sub-contract machining market with the formation of the Harmon Manufacturing division and in 2002 set up the Harmon Metal Treatments division.

All three divisions are located in 32,000ft2 purpose-built premises on the Ferndown Industrial Estate in Wimborne, Dorset, each functioning as a separate business entity accessing shared resources and looking to lean manufacture as the route to remaining competitive in a global marketplace.

As part of its lean manufacturing strategy the 76-employee Harmon Group has recently re-organised its machine shop into four manufacturing cells and added to its complement of Mazak CNC lathes and machining centres with a QuickTurn Nexus 350 MY turning centre.

According to Robert Harmon, group managing director, the decision to take the tally of Mazak machines to 12 was a relatively easy one to make, because of the performance of the existing Mazak machines and the QuickTurn Nexus turning centre's combination of advanced technology, productivity and value for money.

'The Mazak machines are very reliable and in terms of components per hour the output is phenomenal,' saidHarmon.

'As we replaced our early CNC machines with Mazaks, we found that the same floor space was, in effect, creating twice the number of components and this increase in productivity soon balances out any price differential.' However, finding and retaining skilled staff to operate these CNC machine tools is a tougher proposition, although the problem is tackled in typically enterprising fashion.

In addition to encouraging several third-generation family members to enter the business and to follow in the footsteps of Robert Harmon and his brothers, David and Ian, by beginning as apprentices, the Harmon Group has made the most of the switch to the new manufacturing cell layout.

Said Harmon: 'As we set up the next cell of three machines, one of the operators from the previous cell moved to the new cell, allowing us to move a semi-skilled operator to the first cell and then to bring his level of competence up to that of a fully skilled operator.

This has proved to be an extremely efficient way to increase our level of multi-skilled staff and to enable us to continue expanding our business.' This willingness to adapt to new ways of working has enabled Harmon Manufacturing to develop an enviable reputation for its ability to machine intricate components while, at the same time, reducing costs and lead times for a customer base that includes 'preferred supplier status' with Airbus Industrie, BAE Systems, Westland, Goodrich and Smiths Aerospace.

'We do not do easy components,' said Harmon.

'We do high value, complex components and we are very good at what we do.

However, close tolerance aerospace components such as undercarriage legs, actuators and hydraulic cylinders can take several weeks to complete and it is essential to keep track of work-in-progress to ensure on-time delivery.' Part of Harmon's expertise rests with the use of Preactor scheduling software, the basis for one of the four modules in Mazak's Cyber Production Centre (CPC) production management system.

'We now know exactly how our shopfloor capacity is loaded and we have the flexibility to schedule AOG (aircraft on ground) priorities without adversely affecting other work.' Harmon Manufacturing has an annual turnover of around GBP 5 million but current plans envisage this rising to GBP 15 million within the next few years.

And with its extensive experience of machining unusual or exotic materials such as plastics, heat treated stainless steels, Inconel, Monel and Hastelloy, ISO 9002-accredited Harmon is well placed to advise potential customers on methods of manufacture, whether small batch work or large production runs.

'Anyone sitting back and waiting for new business to come to them will not survive,' said Harmon.

'However, we are not looking just to the UK for future growth.

We are looking to companies in France and Italy, for example, that are associated with our existing customers and where existing customer approvals are relevant.

The key attributes are quality and delivery, and maintaining delivery schedules is one of the reasons why we set up Harmon Metal Treatments, because when we were sending out components for treatment we were unable to guarantee their return delivery time.' The QuickTurn Nexus 350 MY chosen by Harmon Manufacturing features a 30kW/3300 rev/min spindle, and can machine components up to 420mm diameter by up to 1538mm long.

It also benefits from the inclusion of a NC electric tailstock that delivers quick set-up with no manual intervention.

The tailstock provides accurate support even for components that can only be supported by low-thrust force.

Added versatility is provided by the 150mm Y-axis and the capability of rotary tools in any of the 12 positions on the drum-type turret.

These tools are driven by an impressive 7.5kW/4000 rev/min motor.

Machine power is matched by agility, with the X, Y and Z axes having rapid traverse rates of 30m/min, 15m/min and 25m/min respectively.

This fast, vibration-free, acceleration/deceleration results from the use of high-gain servo-control and high-power AC servo motors.

The Mazatrol Fusion 640T Nexus CNC unit features the easy-to-use Mazatrol conversational programming format.