62
female as well as male parts. “We have technical apprentices, six male and one
UIforwardUIforwardUIforward
undertaken significant investment in
female, are following a three-year course,
these machines in order to offer the market
dividing time between a local technical
an extensive product portfolio of female
college, the training school -
fasteners, specialist forgings and forged
part classroom and part
machine environment -
tubular parts,” says Ian Clarke. Throughout the
and the production floor.
plant, other acquired machinery has been
CAF now also has a
commissioned and is maintained to provide a
commercial apprentice.
versatile, ‘ready for use’ resource.
The apprentices
decorated and fitted out
Currently CAF has four heat treatment lines. the school, including
Around 80% of heat treatment is carried out painting all the
in-house – exceptions are case hardened parts machines.
and long bolts requiring jigging prior to heat There are other
treatment to prevent distortion. A examples of what
dephosphating cleaning line is used for heat represents a
treated parts and also to clean components fundamental transition
destined for critical secondary operations. A for CAF, generating an
thoroughly equipped materials laboratory environment in which
exercises stringent control over incoming raw personal commitment
materials and heat treatment. and flexibility is
recognised as an
Separate incoming inspection is applied to essential element of
parts that have been coated or heat treated modern manufacturing.
off-site, most of these services being provided Recently an experienced
through a strong relationship with the operator took
Anochrome Group. responsibility for a
complete forging cell.
Most CAF parts are also subjected to final “The initiative came from applications
inspection using a mix of camera and laser the operator as a way to are a particular
equipment – a clear indicator of the precision increase productivity,” says competence.
market in which CAF now competes. The final Gary Dixon. Similarly, Strength grades range up
inspection and packaging facility will play a threading machines have been relocated to an to Grade 12.9 in carbon steel, with production
growing role in ensuring customer specified associated header cell, allowing cross training capabilities in stainless steel including high
quality assurance. Some parts manufactured of operators to work on both machine temperature materials.
outside the UK are received at Darlaston and technologies.
inspected before delivery to one of CAF’s
Application engineering is at the core of CAF’s
major engine customers. Nowhere is technology and experience so
relationship with its customers, with reduced
tightly allied as in tooling design, where CAF
assembly time and cost savings critical foci.
Increasingly, finished product is stored either
uses advanced simulation software to design
The rapidly growing demand to achieve
as bonded stock, ready for call off by
or redesign tooling to meet both new
reductions in overall vehicle weight – the
customers whose own storage capacity is
demands for complex parts and to tease out
target for one major OEM’s next generation of
restricted, or held against contract to allow
more efficient ways to produce existing parts.
vehicles, for example, is a 20% reduction – is
CAF to manufacture economic batches. “As we
Tooling is maintained and re-engineered in
now enshrined in what CAF calls its
continue to transfer production of certain parts
CAF’s extensive tooling room.
‘Weightwatchers’ program. Currently the CAF
to our sister facilities, making way for complex management is coy about progress, but there
parts manufacturing here in the UK, our
These days it is evident that CAF is a highly
is an air of quiet confidence that suggests CAF
logistics capability becomes more and more
focused business, generating sales through
will not be long in announcing a significant
important,” says Ian Clarke. Most recently this
direct supply to a list of OEM and Tier 1
breakthrough in this area.
has included extending the logistics
customers that reads like the Who’s Who of
competence to being able to provide direct
the European automotive sector. Tight
In the final analysis, though, CAF feel that
line feed services to existing CAF customers.
relationships with major OEM dedicated
being part of Caparo is fundamental to the
logistics and distribution companies account
Ultimately, of course, it is people just as much
for a significant proportion of the balance of
future. Ian Clarke is clear, “Roll together all the
as equipment that ensure high-grade special
the business.
capabilities and technologies of CVP and our
fasteners consistently meet customers’
value proposition to the prospective customers
requirements. CAF has a rich resource in
An extensive list of manufacturing licences,
is infinitely more interesting. No question that
experienced personnel throughout its
including Taptite®, Powerlok® and the type of customers with whom we are
operation. Core members of the team are
Whizztite® plays a crucial role in CAF’s offer.
now talking would not have given us
design & test engineers and application
Bolt manufacturing capability now extends
houseroom a few years ago. There is no doubt
engineers who work with Customers to design
from M3 to M33 diameters, and up to 200mm
in my mind that part our attraction is in
application specific solutions. The correlating
long. Wheel nuts and female parts can be
having roots in India. Many companies desire
challenge, though, is to ensure continuity as
produced up to M40, and studs are cold
that crucial resource ages. CAF’s training
forged from M6 to M14, up to 120mm long,
to access low cost country manufacturing but
school represents a clear commitment to
and bar turned from M6 to M24 and 400mm
desire and capability are two different things.
meeting that challenge. Currently seven
long. Engine and high temperature
For Caparo it is a reality today.”
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