Closing the skills gap

Closing
the skills gap
High Value Manufacturing
ALSO IN THIS ISSUE
New initiatives to help companies
compete
Royal opening for
research factory
Giant CMM offers
unrivalled accuracy
Namtec joins AMRC family
Member news
Q3 2012
news
ISSUE 8
NuclearAMRC
SKILLS FOCUS
One-stop shop for skills: Annette Valentine in the
Knowledge Transfer Centre workshop
Skills Academy tackles
critical gaps
A new specialist team based at the Nuclear AMRC
is tackling the most urgent skills gaps facing the
nuclear manufacturing industry.
The NSA Nuclear Manufacturing will develop
new training and skills products, based firmly on
industry requirements. Key areas include project
management, high-integrity welding, quality and
training, non-destructive evaluation, and design
engineering.
The National Skills Academy Nuclear
Manufacturing is a collaboration between the
National Skills Academy for Nuclear; Semta, the
sector skills council for advanced manufacturing
and engineering; and the Nuclear AMRC. It is
supported by the Skills Funding Agency at the
Department of Business Innovation and Skills (BIS),
and backed by industry leaders including EDF
Energy, Areva, Westinghouse and Rolls-Royce.
The team will also review existing products and
training providers, and expand the established
High Quality Provider Network into the nuclear
manufacturing sector.
“We need to make sure that training products
are fit for purpose,” says Valentine. “It’s all
about giving companies the means to build
their knowledge and demonstrate the capability
of their workforce through recognised
qualifications.”
“We’re a one-stop shop tackling the priority skills
gaps for nuclear manufacturing, bringing together
the capabilities and specialist knowledge of the
three organisations,” says Annette Valentine, skills
and training manager for the Nuclear AMRC,
who leads the four-strong team. “It’s all about
helping companies compete – we’re making
sure that all our development activities can help
companies succeed in their business.”
Nuclear AMRC news
Q3 2012
The team is based at the AMRC Knowledge
Transfer Centre, located directly opposite the
Nuclear AMRC on the Advanced Manufacturing
Park in South Yorkshire.
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The NSA Nuclear Manufacturing is a
membership organisation, with membership
fee depending on a company’s number of
employees and proportion of nuclear work.
The Skills Academy and Nuclear AMRC are
continuing to develop joint services for the
benefit of all members.
For more information, see:
www.nuclear.nsacademy.co.uk/
nsa-nuclear-manufacturing
September launch
for skills initiatives
The NSA Nuclear Manufacturing and AMRC
Training Centre are holding a joint launch
event on Friday 14 September at the AMRC
Knowledge Transfer Centre. The morning will
include presentations on a range of nuclear
manufacturing and skills issues.
For more information, contact Stacey Balmer:
s.balmer@nuclear.nsacademy.co.uk
French lessons for suppliers
The Nuclear AMRC is working with founding
member Areva to bring the French group’s
acclaimed supplier training courses to the UK.
Areva’s training team visited the Nuclear AMRC in
May to run a pilot Supplier Excellence course for
selected UK manufacturers. The two-day course is
based on lessons learned from developing supply
chains for the Areva EPR power stations under
construction at Olkiluoto in Finland and Flamanville
in France.
“We looked at Areva’s portfolio of training that they
deliver to their French supply chain, and knew that
we wanted to collaborate to bring some of that to
the UK,” says Annette Valentine, skills and training
manager for the Nuclear AMRC. “We’re now
working with the French team to tailor the course
for the UK market, and roll it out nationwide.”
Rather than just addressing the usual issues of quality
standards, the Supplier Excellence course focuses on
specific issues that have arisen during procurement,
such as the need to understand technical
requirements and how to classify components.
These are placed firmly within the context of
nuclear safety culture, a vital consideration for
companies new to the nuclear market.
The Nuclear AMRC skills team will work with
Areva’s trainers to customise the course for the UK
regulatory framework and industry requirements.
“We may refine the case studies to make them
more relevant for the UK market – there are
cultural differences,” Valentine notes.
The French trainers were also impressed with the
attitude and contribution of the attendees, saying
that “they were very well behaved compared to
our normal audience”.
The attendees, from 15 manufacturing businesses
at all tiers of the supply chain, gave very positive
feedback on the pilot course – one even declared
that it was “the best thing we’ve ever been on”.
The Supplier Excellence course will be rolled out
to more companies in the near future, with other
courses to follow.
Several topics of particular interest to UK
manufacturers were identified for further
development, such as the inclusion of non-safety
critical components, responding to tenders and
estimating, and real-life case studies to encourage
inter-tier working and understanding.
For more information, contact:
annette.valentine@namrc.co.uk
‘Fantastic opportunity’
of Training Centre
The future of learning: design for the AMRC
Training Centre
Plans for the AMRC Training Centre are moving
rapidly forward, with key appointments and
planning approval secured for the 5,500 sq m
building.
Development of the centre is being driven by
the newly appointed AMRC director of training,
Alison Bettac, previously director of HR at metals
engineering group Firth Rixson.
The Training Centre will work closely with the
Nuclear AMRC and its sister centre the AMRC
with Boeing to provide apprenticeship and
higher-level training for advanced manufacturing
companies.
“This is a fantastic opportunity to develop a worldclass hub that will deliver the right skills within the
advanced manufacturing and engineering sectors,”
says Bettac. “Employers demand high-quality
learning frameworks to help them compete
globally. This is their opportunity to help build that
provision, as the delivery through the Training
Centre will be very much employer-led.”
The centre will be located next to the Advanced
Manufacturing Park in South Yorkshire, and will
primarily serve businesses with operations in the
region – including Rolls-Royce, which has started
construction on the first of its proposed three
factories on the Park.
The AMRC Training Centre will provide training in
the practical and academic skills that manufacturing
companies need to compete globally, from
apprenticeship through to doctorate and MBA
level, plus continuing professional development.
Around 250 people will enter each year for
advanced apprentice training, with support from
their employers.
The centre will link with both Sheffield universities
for higher-level education, and with the new
Sheffield University Technical College (UTC),
providing a full progression in engineering training
for the first time in the region.
Kerry Featherstone, previously future capability
and early careers manager at BAE Systems,
has joined as head of training. Recruitment will
continue over the next year.
For more information, contact:
a.bettac@amrc.co.uk
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namrc.co.uk
Royal opening for
research factory
The Nuclear AMRC’s landmark research factory
has been officially opened by the Duke of York.
Prince Andrew visited on 28 May, as part of the
diamond jubilee celebrations, to declare the
8000 sq m centre open for business. He toured
the facilities and met representatives from many
of the centre’s industrial partners to find out how
the Nuclear AMRC is helping them become
more competitive.
The Duke, who acts as the UK’s special
representative for international trade and
investment, voiced his support for new nuclear
power in a short speech to staff and guests.
From virtual to reality: The Duke of York experienced a
VR introduction to the Nuclear AMRC’s facility (above)
before meeting apprentices (top right) and member
companies including ITW Welding Products (right) and
Starrag Group (below).
“Something is going to have to be done to supply
the huge increase in the amount of energy we
need. There has to be some part of the energy
sector delivering nuclear,” he said.
“It’s not just about the UK – nuclear will be used
globally, and we must deliver at least some part
of the supply chain. The ability to harness the
knowledge, skills and innovation of the UK in a
facility like this is hugely important.”
Construction of the Nuclear AMRC building began
in November 2010, with the Queen donning
virtual reality glasses to remotely activate a digger.
The building was completed on schedule by
October 2011, and is now home to a growing
team of engineers, researchers, technicians and
apprentices working on a range of large state-ofthe-art manufacturing equipment.
Nuclear AMRC news
Q3 2012
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“I have met some very talented young people
here today,” the Duke said. “Their skills are going
to be in demand in the years to come. They
are being taught in an environment where their
skills will be transferable across the engineering
community.
“I would like to wish them every success, and
encourage other young people to consider
a career in the wide range of engineering
possibilities that this country can provide.”
Measuring up to
industry requirements
The Nuclear AMRC has ordered one of the
largest metrology machines of its kind, to prove
that parts produced by innovative manufacturing
processes meet the strict requirements of the
nuclear industry.
The DEA Delta Slant is believed to be the largest
gantry coordinate measuring machine (CMM) in
any university research laboratory. It will be able
to measure parts of 6 metre length and 3 metre
width to accuracies of around 25 microns –
a quarter of the width of an average human hair.
Parts under a metre in size can be measured
to 8 microns.
The CMM will be installed later this year in
a customised metrology room within the
Nuclear AMRC’s research factory. The room is
temperature controlled, with measured variation
of less than 0.2°C, to help maintain accuracy.
The floor is being reinforced to allow the CMM
to take parts of up to 15 tonne weight.
For more information about the Nuclear AMRC’s
metrology capabilities, contact:
carl.hitchens@namrc.co.uk
“Out of all the machines of this size
available, this had the fastest traverse
and was the most accurate over the
largest distance measurements,”
says Carl Hitchens, metrology lead at the
Nuclear AMRC. “The gantry construction is
significantly more accurate than other CMM
configurations.”
The Nuclear AMRC’s machine will boast
an 800mm long bore stylus, one of only
two produced by measurement specialists
Renishaw.
“It’s a great way to validate the ongoing
manufacturing research we’re doing for the
nuclear industry, but the oil, gas and renewables
industries will also be very interested in the
capabilities of the long bore,” says Hitchens.
“We will also look to combine this CMM
technology with optical non-contact
measurements as part of our future research.”
The machine is being provided by Hexagon
Metrology, a Tier One member of the
Nuclear AMRC.
Free video from the Nuclear AMRC
The Nuclear AMRC has launched a new
video to highlight the opportunities of
nuclear new build for the manufacturing
supply chain, and to showcase the
facilities and capabilities of the centre.
The 10 minute film includes interviews
with Nuclear AMRC staff and industrial
partners including Rolls-Royce, EDF
Energy, Sheffield Forgemasters, NES and
Newburgh Engineering. An alternative
short edit focuses on key facts and
showing the centre’s facilities in action.
The film was produced by Active Image,
the Chesterfield-based industrial video
specialists.
For a free DVD, contact Nuclear AMRC
communications manager Tim Chapman:
t.chapman@namrc.co.uk
The video can also be viewed on the
Nuclear AMRC website and at
youtube.com/AMRCsheffield
New capabilities for
materials testing
The Nuclear AMRC’s Manufacturing Technology Research Laboratory at
The University of Manchester continues to expand its resources for testing
the material performance of manufactured components.
The latest equipment to be commissioned includes two electo-discharge
machining (EDM) centres, used to extract material samples from
components without imparting additional stresses.
The Laboratory has also installed two Zwick hydraulic machines for
tension-torsion, fatigue and fracture testing; and additional autoclaves to
mimic conditions inside reactors.
For more infomation about our R&D resources, see:
namrc.co.uk/what-we-do/research
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namrc.co.uk
MEMBER NEWS
Forgemasters
launches R&D
venture
Sheffield Forgemasters has launched a new
research and development subsidiary to offer
its advanced engineering expertise worldwide.
The new venture, RD26 Ltd, will allow
the 200-year-old group to provide its R&D
services to outside companies. RD26 is already
working on projects in civil nuclear including
large-scale pressure vessel design. It will also
continue to serve Forgemasters’ own R&D
requirements.
RD26 is headed by Professor Jesus
Talamantes-Silva, director of R&D for
Research master:
Jesus Talamantes-Silva
Forgemasters, who also sits on the research
board of the Nuclear AMRC. The business will
build on Forgemasters’ existing R&D division,
and bring in PhDs and graduates from UK
universities.
“There are few places in the world which
can offer this kind of opportunity to refine
systems away from the academic sphere and
across such a broad series of manufacturing
processes,” says Talamantes-Silva. “The
resources here are enabling us to take on
increasingly technical challenges and to look
at entirely new ways of creating components,
which allows for greater manufacturing efficiency
and stronger, lighter, more complicated end
products.
“Our markets are diversifying all of the time, and
we have created new processes for manufacture
in civil nuclear, such as the integral forging of
nozzles into ultra-large components.”
Sheffield Forgemasters is a founding Tier One
member of the Nuclear AMRC. The world’s
largest independently owned forgemaster, it
is the only UK firm to hold ASME NCA3800
certification for civil nuclear castings and forgings.
NES invests in new nuclear machining
Nuclear Engineering Services (NES) is
investing over £1 million in advanced
machining centres at its Wolverhampton
manufacturing and assembly facility.
and a Hyundai turning centre. The
additional capacity will allow NES to keep
more production in-house, reducing lead
times and helping maintain quality control.
The investment includes Soraluce and
Hyundai machining centres with
10 metre bed and 20 tonne capacity
indexing table, a Hartford vertical miller
“It is an extremely exciting period in the
history of NES,” says Anthony Cundall,
head of nuclear new build for NES.
“The emergent opportunities in the
nuclear new build market provide great
development and growth potential for the
business.”
NES specialises in the design, manufacture,
assembly, test and installation of bespoke
systems for the nuclear decommissioning,
defence and new build markets. It is a Tier
One member of the Nuclear AMRC.
NNL opens labs for academic research
Researchers from 17 universities visited the
Laboratory at an open day in July to find out
more about its capabilities. Access was previously
limited to a small number of groups including The
University of Manchester Dalton Nuclear Institute.
The National Nuclear Laboratory (NNL) is
opening up its state-of-the-art laboratories to
researchers from universities across the UK.
The NNL is offering a tenth of capacity at its
flagship Central Laboratory in Cumbria to
academic researchers who want to work with
radioactive materials but don’t have facilities in
their own universities.
Nuclear AMRC news
Q3 2012
“These facilities are comparable to anything in
the world, and it is a fantastic opportunity for
UK universities to have access to the Central
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Laboratory,” says Professor Andrew Sherry of the
Dalton Nuclear Institute. “It allows us to boost
the quality, quantity and impact of the research
work we do in the nuclear field.”
The NNL is a supporter and associate laboratory
of the Nuclear AMRC. Its Central Laboratory
works in areas including nuclear science, waste
and residue management, and specialist analysis.
Namtec joins AMRC family
The Nuclear AMRC is joining forces with Namtec,
the National Metals Technology Centre, to better
promote innovation and competitiveness among
manufacturers.
From 1 August 2012, Namtec is becoming part
of the University of Sheffield AMRC, the parent
group of the Nuclear AMRC, AMRC with Boeing,
Knowledge Transfer Centre and new Training
Centre.
Namtec’s established team will continue to
provide its core training, consultancy and supply
chain programmes. The combination with the
AMRC’s research capabilities and high-level
industrial collaborations will provide a stronger and
broader base to cascade innovative technologies
and ways of working through the supply chain.
“The merger of Namtec with the AMRC is
a unique opportunity for both organisations,
but more importantly for the benefit of the
UK manufacturing supply chain,” says Dr Alan
McLelland, chief executive officer of Namtec.
“The AMRC is at the forefront of manufacturing
developments, driving forward manufacturing
technologies which can provide the UK, including
the SME supply chain, with significant commercial
advantage in a global marketplace. Namtec, with
an unrivalled access to this supply chain, provides
a fantastic conduit to flow these developments
into our manufacturing companies, encouraging
growth and helping lead the UK manufacturing
renaissance.”
Metals support: Alan McLelland and Keith Ridgway
Namtec was established in 2002 to support the
metals manufacturing supply chain. It has provided
training and consultancy to a base of some 20,000
companies, including nuclear-specific programmes
and events such as the Building a nuclear future
conference.
“Growth markets such as nuclear new build
present huge opportunities for UK manufacturers,
and it’s our mission to help them compete
globally.”
For more information on Namtec, see:
www.namtec.co.uk
“Namtec’s established connections with the
manufacturing base will help us share innovation
right along the supply chain,” says Professor
Keith Ridgway, executive dean of the AMRC
and programme director of the Nuclear AMRC.
Deadline nears for
£15 million R&D fund
Latest members bring
specialist support
The latest companies to join the Nuclear AMRC
as Tier Two members bring a range of specialised
capabilities to help manufacturers compete.
Pemamek Oy is the world’s leading specialist
in welding automation systems and workpiece
handling equipment for process, nuclear and other
heavy metal industries. The Finnish firm will bring
its expertise to the Nuclear AMRC’s welding
development projects, and provide ongoing
support with welding and cladding technology.
Planit Software provides specialist CADCAM
packages and support to the manufacturing
industry. Its Edgecam software is a leading solidsbased CAM system, used extensively by the
Nuclear AMRC machining team. Working with the
Nuclear AMRC and partner companies will help
Planit optimise Edgecam for large-scale machining
operations for nuclear and other markets.
Bids for funding from the Developing the
civil nuclear power supply chain programme
must be submitted before the autumn.
The £15 million R&D programme from the
Technology Strategy Board will back businessled collaborative R&D projects with up to
£1 million match funding (see last issue).
Feasibility studies led by SMEs can win grants
of up to £75,000. Initial applications for this
funding must be made by 5 September.
Rotherham-based Argyll Ruane provides a
comprehensive range of inspection and nondestructive testing (NDT) courses, examinations
and Level 3 consultancy services. It was recently
granted Quality Assured Provider status by the
National Skills Academy for Nuclear. Argyll Ruane
will provide Level III NDT services to the Nuclear
AMRC’s projects, and provide training for staff.
The Nuclear AMRC is working with several
industrial partners to develop bids. By
partnering with us, companies can take
advantage of our unique R&D capabilities to
help solve a wide range of problems. To find
out more, contact Stephen Clements:
stephen.clements@namrc.co.uk
The Nuclear AMRC now has 35 member
companies, including manufacturers from along
the supply chain from reactor vendors to precision
engineering contractors, as well as specialist
equipment and service providers.
For more information about the funding, see:
namrc.co.uk/industry/tsbcall
For more information, see:
www.argyllruane.com
www.edgecam.com
www.pemamek.com
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namrc.co.uk
Work with us
The Nuclear AMRC is here to support businesses, from global giants to SMEs, which are seriously
interested in supplying the new generation of nuclear power stations. If we can help your
business, we want to hear from you.
Our R&D capabilities, training courses and
quality support programmes are open to all UK
manufacturers.
We can collaborate on specific R&D projects,
using our expertise and facilities to help resolve
your manufacturing problems and give you real
competitive advantage. Your company invests
directly in the research and has exclusive access
to any resulting intellectual property. We can
also join or lead externally-funded collaborative
research projects.
Full membership of the Nuclear AMRC
gives access to our generic projects and the
opportunity to determine our research and
support programmes. We are led by our
member companies on a consortium basis: our
members decide what we do, what our core
research projects will be, and what skills and
quality support we provide.
We offer two tiers of membership, based on
the size and market position of your company.
Our members include manufacturers from along
the supply chain, plus specialist equipment and
service providers.
To start discussions, contact Stephen Clements:
stephen.clements@namrc.co.uk
Supported by:
Technology Strategy Board
Driving Innovation
Tier 1 members:
Contact us:
Tier 2 members:
Tel: +44 (0)114 222 9900
Email: enquiries@namrc.co.uk
Online: namrc.co.uk
Twitter: @NuclearAMRC
Nuclear AMRC
The University of Sheffield,
Advanced Manufacturing Park, Brunel Way,
Rotherham S60 5WG
Manufacturing Technology Research
Laboratory
The University of Manchester,
Sackville Street, Manchester M13 9PL
Nuclear AMRC news
Q3 2012
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