With almost 1 million square feet of dedicated production and logistics space, Nuttalls design, manufacture and install interiors and display equipment for all areas of food service, retail, leisure, commercial, education and healthcare. Offering unique in-house testing facilities and extensive prototyping resources, they remain at the forefront of new product development, whilst providing tailored solutions built to their clients’ specification. Whether requiring retail shop fitting, fresh food display, foodservice counters, signage and point of sale, or a principal contracting service for any commercial interior fit-out, Alan Nuttall Ltd offers complete turnkey solutions for projects, large or small.
Biesse designed the cell around the space available and were quite innovative in their approach.
Why did Alan Nuttall Limited choose Biesse? Production Director Bob Williams: “We believe in the machines. Biesse’s Total Care was also a huge influencing factor as it really does protect our investment. The 5 year warranty, planned servicing and cover for operator error, coupled with the fact that Biesse conducted a full site survey, provided all the offloading, cranage, siting and installation, meant that the whole ordering process was seamless. Our wood shop is now 100% Biesse, which means that programming is compatible, tooling is easier, preventative maintenance is more effective and Biesse have multi-skilled technicians, together with a help desk, so we have one central point of contact. One other big advantage, is that we have complete operator skills continuity, as the systems are similar across all machines so if one operator is absent, someone else can easily ‘fill-in’ for them. We also have an on-going training programme with Biesse which helps our existing operators gain experience and also provides part of our induction process when new operators join the company”.
The Winstore board storage system, beamsaw and flat table CNC have been installed as a working cell. How has this made a difference to Nuttalls manufacturing process? “We’re still on a learning curve with the Winstore but the major benefits so far are: The nature of our business means we have a mixture of reasonably large volume products as well as the ‘one’s and two’s’. The Winstore has definitely helped with material efficiencies and much better stock control. We now have a label printing system, so everything is traceable and parts come off ready for assembly. It also made us look into our manufacturing process. Because we now ‘nest’ with the Rover A, we now use surface mounted fittings for our cam and steel dowel construction, which cuts out a secondary process of edge boring and saves even more time. The Winstore, Rover A and WNT710 cell is now three times quicker than our previous experience. In fact, the WNT710 with the twin pusher has seen a 60% increase in efficiency for the sawing operation alone. We now manufacture at the speed of the machines and this has made us much more competitive, especially against Eastern Europe and China. It’s also meant we have better utilised our workforce and kept people in jobs as we gain market share”.
Works Manager Neil Hurley continues, “Programming is much easier. We use BiesseWorks for the Rover C Edge and AlphaCam for most of our other processes. As Bob has already said, changing the construction of carcasses has been one of the biggest benefits. Using front face fixings is much quicker and cheaper and the method we now use with the Rover A is three times faster than our previous method. The automatic loading and unloading means less handling, less damage, higher material yield and greater efficiency. “We now design around the machines. Previously we had multiple processes. For instance the secondary operation was drilling and this has now been eliminated as we nest and drill in one operation. Also, most of the mitres used to be cut on a spindle moulder. These are now done on the Rover A which has really improved efficiency”.
Bob concluded: “Biesse designed the cell around the space available and were quite innovative in their approach. We’ve had one or two problems but Biesse’s helpdesk is very good. Being able to ‘dial in’ to the machines has been excellent in quickly resolving issues without the intervention of an engineer”.