With a list of customers that reads like a who’s who of the aerospace, telecommunications, avionics and motorsport industries, Benham Manufacturing has earned a reputation for the high quality of its output. Through continued use of Iscar Tools, the company has successfully reduced its purchasing spend whilst maintaining high levels of productivity and quality. Solutions reports.

Founded in 1978 as DA Benham Engineering, Benham Manufacturing began life manufacturing components predominantly for the telecommunications industry. Year on year growth facilitated the strategic purchase of a precision engineering company in 1995 which in turn extended the subcontractor’s customer base. The business’s new acquisition had complementary capabilities to those of Benham and also established links with the aerospace industry. Three years later, the two businesses merged and moved into a purpose-built manufacturing facility on the edge of the New Forest.

Remaining a progressive family business, to keep pace with the growing demand for its now mainly aerospace related output, Benham Manufacturing has recently added three, Mazak 5-axis work centres with pallet loading and gundrilling capability, to its array of machine tools. A new 3,000ft² has also increased the company’s total site capacity to 21,000ft².
Benham’s ability to effectively engage its CAD/CAM and online programming capability, allows the company to execute effective machining processes utilising a range of 3-, 4- and 5-axis machining centres. The multi-axis machining capability of Benham’s mill/turn work centres allows the completion of all machining processes from raw material to finished workpiece in a single set-up.

With fine finishing processing carried out in a temperature controlled environment, Benham Manufacturing is also able to undertake CNC external grinding, conventional internal and external cylindrical grinding and honing. In addition, the company can offer class 1000 clean room conditions.

Close encounters

Although the reasons behind Benham Manufacturing’s growth are numerous, the company says its progressive philosophy of developing close commercial and technical partnerships with suppliers has proven to be a key factor in its success. A proven example of this is Benham’s close collaboration with global tooling manufacturer, Iscar.

With a view to streamlining its cutting tool ordering system, reducing inventory levels and cutting tool use, Benham Manufacturing recently undertook a review of its entire tooling structure and process optimisation techniques.

After meaningful test criteria was established, Benham embarked on a series of cutting trials in which Iscar products were judged against others in terms of speed, tool life, unit price and time advantages. So as to provide ‘real-world’ comparisons, the results of each test were translated into both machining costs and into actual savings per part.

Hard facts

On completion, the project delivered a number of conclusions – one being the advantages that could be gained by Benham’s increased use of Iscar cutting tools.

Managing director, Paul Benham, takes up the story: “The flexibility of Iscar’s products has resulted in Benham Manufacturing using significantly less tools,” he reveals. “Faster cycle times, due to improved tool selection, means enhanced machine tool productivity and the bottom line is that the company’s overall cost of purchasing cutting tools has been reduced.”

A major factor in Benham’s improved output and reduction in machine downtime, has been the adoption of Iscar’s Matrix tool store system. Managed by a local Iscar distributor, Matrix is an advanced computerised, total management system that is able to give users absolute control over cutting tool inventory, streamline purchasing functions and drive down costs.

Matrix combines an automated tool dispenser with Matrix-TM – powerful, yet easy to use management software. Access to an item stored within the system’s locked bins is electronically controlled with entry determined by the establishment of pre-defined authorisations.

Well smart

The modular Matrix system is flexible. Drawer configurations can be swapped-in and out whilst add-on cabinets can be connected with through a simple cable. Multiple cabinets can be deployed within different locations and networked, enabling each to run from one common, central database and advanced Matrix technology includes a patented locking system to prevent unauthorised use, a large high resolution touchscreen interface, plug and play ‘smart’ electronics, ergonomic design features and a remote diagnostic capability. A barcode reader is used for rapid and reliable tool issuing, whilst a manual system override is included, enabling system access in the event of a power failure.

Suitable for small organisations and larger enterprises with single or multiple sites alike, the Iscar Matrix system can reduce tool inventory, machine downtime and production costs, as the planning engine ensures that every required item is always available.

“Having made the decision to review our tooling organisation and use, we found the support provided by Iscar to be invaluable,” Mr Benham adds. “Our goal was to take tooling subjectivity our of the production equation and through use of Iscar tooling and the Matrix system, we have become more productive and competitive. As our local supplier regularly replenishes the Matrix system, out of stock situations have been eliminated, whilst substantial man hours have also been saved on our previously used regime of manual tooling stock checks and ordering.”

Iscar UK
www.iscar.co.uk