BATHFORD CASE STUDY
The Project's Origin:
The project started when Portals announced the closure of the Overton Banknote mill. As Overton Mill manufactured most of the mould covers used at Bathford Mill, a project was started to evaluate the options for future mould cover manufacture to ensure Bathford remained viable in future years.
Scope Definition and Innovations:
The project’s first major task was to determine the project scope and requirements. After thorough surveys and analyses, a decision was made to reconstruct the existing (but non functional) old Mould Office at Bathford rather than relocate the newer, but much larger Autopress and associated equipment from Overton. This meant that the existing Mould Office in Bathford needed to be remodelled to enhance both capability and accuracy beyond its previous benchmarks. This approach reaped numerous benefits, providing Bathford the ability to:
• Sustain product manufacturing without the obsolescence and future technology risks inherent in the legacy Bathford equipment.
• Prolong the Mould Office’s lifecycle significantly beyond that of the previously proposed relocated machinery at Overton.
• Employ a Business Continuity Plan for program completion
• Improve operational capability and accuracy
• Enhance the quality, accuracy, and longevity of Mould covers
Project Initiation and Expertise:
When the chosen manufacturing route for Bathford had been decided and approved by the Portals board, the project timeline was established. Given the challenging timeline, compounded by the unprecedented global shortage of electronic components, Projectek was chosen to oversee the entire program.
Project Scope and Rebuild Elements:
The comprehensive rebuild scope covered several critical mini – projects, including complete replacement or overhaul of most of the mechanical, electrical, control, hydraulic and pneumatic elements. Ancilliary equipment such as a CNC milling machine and several smaller stand alone items were also relocated and upgraded. This work all took place within a project planning framework that allowed for the required building upgrades.
Innovative Solution and Collaboration:
An innovative solution was devised for woven metal cloth embossing that uses an automated robot arm with an integrated laser for annealing and cutting the mesh. This solution was the result of a collaborative effort with suppliers, each contributing their expertise to achieve the desired specifications. This novel approach allows Portals to deliver consistent, highly accurate results, with minimal manual intervention during the pressing stage. The resultant benefits extend to our customers, promising Mould Covers of unparalleled accuracy, enhanced watermark detailing, and an extended lifecycle of the Mould Cover. A Health and safety project ran in parallel to the mechanical and electrical design of this solution to ensure that the new risks presented by the laser installation were properly assessed and mitigated.
The robot arm boasts a repeatability of +/- 0.03 mm (30 microns), and the setup data originates from a thorough process of design and drawing approval to ensure precise setups with no room for errors. Automating the setup process not only accelerates efficiency but also reduces the likelihood of typographical errors.
The driving force behind this innovation was the project goal to provide watermark detail of unmatched quality, accompanied by exceptional accuracy, enabling Mould Covers to endure regular changeovers. Although many mills may opt for the convenience of pre-annealed covers, Portals’ unwavering priority remains centered on quality.
Project Timeline and Achievements:
The project started in October 2022, with the final scope and budget alignment agreed just before Christmas that year. This dictated that Bathford must adhere to existing standards for Cover Manufacture by April 2023 and be fully operational by June 2023. Despite this exceptionally ambitious timeline, the team worked tirelessly to convert this vision into reality.
Milestones:
Feasibility studies – August 2022
Program Scope – October 2022
Business Case – November 2022
Program Sign Off – December 2022
Program initiation – January 2023
First press – March 2023
First Full Cover – May 2023
Mould Office Official Opening – July 2023
The project did not run entirely to plan. The team were forced to make design modifications due to component availability and safety requirements; however, despite these challenges, the team successfully delivered the first pressed patch at the end of March, bang on target.
Viewing Windows:
In a dedication to enhancing the customer experience, we have introduced extra large laser safe viewing windows that transcend the traditional boundaries of observation. These windows not only offer a glimpse into our manufacturing process but also ensure that even larger groups can comfortably witness every facet of our intricate operations. This allows us to share our craftsmanship with a broader audience, fostering a deeper connection between our valued customers and the meticulous artistry that defines our work.
Plotter:
As part of our commitment to precision and excellence, Portals has invested in a cutting-edge plotter, revolutionising our template production process. With an exceptional accuracy of 0.2mm, this state-of-the-art equipment is set to redefine the standards of precision across our operations.
The introduction of this advanced plotter is poised to create a ripple effect of benefits throughout our production journey. By ensuring unparalleled accuracy in template creation, we establish a solid foundation for consistent precision. This consistency bridges the crucial gap between Mould making and Papermaking, fortifying both departments during Quality control processes.
As a result, our customers can expect a product that exemplifies the utmost quality and reliability, a hallmark of Portals’ commitment to perfection. This investment stands as a testament to our dedication to advancing technology in harmony with our time-honored craftsmanship, ultimately propelling Portals to new horizons of excellence.
Craftmanship:
Amidst the project’s ambitious goals, Portals remains dedicated to honoring its legacy and the contributions of its esteemed Mould Makers. With a combined 100 years of service, the experiences and insights of long-standing professionals have proven invaluable. Among them, the experienced mould makers stand out as pillars of knowledge, having dedicated decades to perfecting their craft.
Recognising the significance of their expertise, Portals has conscientiously sought to bridge the past with the future. The mould makers’ wealth of experience has been harnessed, with their guidance serving to navigate the intricate pathways of the project. By integrating the best elements from their extensive careers, Portals is ensuring that time-honored craftsmanship is preserved while embracing the possibilities of the modern era.
Their insights are a testament to the enduring values that underpin Portals’ commitment to excellence. Their collective wisdom provides an invaluable bridge, connecting the foundational traditions of the past to the innovation-driven aspirations of the future. This fusion not only preserves the legacy they’ve helped shape but also propels Portals towards new heights of quality and ingenuity.
Their contributions are a cornerstone of our journey, symbolizing the commitment to craftsmanship that has defined Portals for generations.
Future Outlook and Craftsmanship:
As automation work could run in parallel to production, work on the move to full press and laser automation started in April. At the same time, non-manufacturing but still critical projects, such as completing the building refurbishment and the recruitment and training of new operational personnel were undertaken. This approach not only ensures high levels of health and safety in the department but also secures new talent, vital for preserving the future of mould making craftsmanship and expertise in Portals.
First Impressions:
The feedback from the Papermakers based on the first 1 mould covers manufactured was that the new equipment showed unprecedented accuracy, validating the program’s vision from its inception.