Cressall Resistors to install Flexible manufacturing line | Automation.com

Cressall Resistors to install Flexible manufacturing line

Cressall Resistors to install Flexible manufacturing line

September 25, 2013 - Cressall Resistors commissioned a new flexible resistor element manufacturing line for its Dereham factory to help provide the company with a competitive edge. The new machine will allow Cressall to rapidly deliver more cost effective products, and enable them to reduce the lead time to delivery in breakdown situations.

Worth £175,000, the new equipment will allow the company to apply flexible manufacturing techniques and increase its product range.

The machine, manufactured by Stourbridge based rollforming and coil processing specialist Formit, will be installed in Cressall’s Dereham factory in December this year.

The new investment will improve response and lead times, and thus help the company deliver products in very tight timeframes. Most of the resistor elements for ongoing projects will now be produced in-house, shortening lead times and minimising dependence on outside suppliers.

"The new equipment will allow us to provide both new build and replacement services to existing and new clients," explained David Atkins, project director at Cressall.

We now have the ability to offer a fast and cost effective solution for new client needs and also cater for current production demands. This can only translate into us getting a bigger share of the resistor elements market," concluded Atkins.

The new equipment can replicate any of the existing high temperature ranges of resistors quicker and more competitively than the old methods. This allows Cressall to provide an efficient and cost effective replacement service for aftermarket spares.

Roll forming is a continuous bending operation in which a long strip of sheet metal is passed through sets of rollers mounted on consecutive stands, each set performing only an incremental part of the bend, until the desired cross-section profile is obtained. Roll forming is ideal for producing constant-profile parts with long lengths, in large quantities.

The roll feed is fitted onto the entry side of the common base of Cressall's punching and forming equipment. Two hydraulically controlled rollforming units are independently operated to allow a range of forming positions. These are complimented by a die set cut off shear which crops the product to the required length.

"Introducing the flexible manufacturing line will mean we’ll need a layout change at the factory as well," said Cy Wilkinson, managing director and lean specialist at Cressall. "However, we believe that it's well worth the effort; as well improving the service we can offer our traction customers, we'll also be able to extend our standard DBR resistor range using this machine”.

“Although Cressall has a history that spans over a century, we are entirely focussed on embracing technological advancements and continuous improvement – ultimately to improve our relationships with customers," Wilkinson concluded.

About Cressall Resistors: The world's foremost power resistor manufacturer, Cressall Resistors, offers an unrivalled combination of experience and expertise as well as the UK’s widest range of resistor technologies. Cressall’s customers include ABB, Siemens, Areva and Alsthom as well as major utilities such as Central Networks, Yorkshire Electricity, EDF and Scottish Power. The company also works with countless smaller specialists such as Street Crane, Digital Lift Controls and Computer Protek Systems. Indeed, because of the fundamental nature of Cressall’s product almost everyone in the electrical industry will have cause to contact the company at some point; making the Leicester based business a bellwether for the health of the sector itself.

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