manufacturing Magal Metallifacture Limited has its manufacturing facility located on the outskirts of Nottingham. Consistent with motor industry demands, the latest equipment and production techniques have been utilised to provide an efficient blend of quality and output that embrace daily schedules. To address our range of products and their associated volumes we adopt fully integrated manufacturing techniques to meet customer expectations. These range from progression transfer pressings that are subsequently assembled in dedicated cell areas (for high volumes) to the more traditional manual transfer methods for lower volume applications. Key to our continuous improvement philosophy has been the adoption of lean manufacturing techniques. These influence ALL areas of our operation, as follows: • Press Shop Incorporates up to 400 tonne progression machines including four robotic transfer lines and a compliment of manual presses up to 250 tonnes. Tool changes are sequenced by internal kanban requirements and their duration is optimised using Single Minute Exchange of Dies (SMED). • Welding Sub assemblies are constructed using both robotic and manual techniques. Computerised digital technology is employed to check weld areas that have been 'sectioned & etched' for critical analysis. This ongoing monitor records weld integrity. • Machining & Thread Rolling As part of our original core business strategy we continue to produce lead screws (for jacks) in-house. This high volume demand is satisfied using combined CNC & thread rolling techniques. • Painting All parts produced are coated using an electrodeposition unit. A conveyor system is used to transport pre & post painted assemblies to & from their respective areas. The population of parts contained within this process (at any given time) can be varied, thus providing the plant output DRUMBEAT. • Assembly Cells Our trained operators use flexible manpower principles in this controlled environment. In concert with: • Quick change-over (same product, different model) • Poke-yoke (fool-proof control) • One piece flow (next cell station is YOUR customer) • TAKT (optimises time) Using a visual display board all 'key performance indicators' are reviewed at the start & end of each shift. This underwrites our continuous improvement philosophy. • Internal Logistics Transport buggies conduct a 'milk run' service which connects all areas of the plant. This system ensures that standard lots are available in the correct location, at the right time, including (most importantly) being available for CUSTOMER collection or delivery. Nottingham Plant Interior Test Facilities