Business to Business conference

Matthew Jones Director-Business Development

andre russell Customer Liason Manager

friday 30th March 2012 British eMBassy,35 rue du fauBourg st honoré,75363Paris

World class engineering solutionsPreci-Spark is a leading European contract manufacturer for the high technology

industries delivering manufacturing solutions to the global market place.

Established in 1960 the company employs 450 people across 6 manufacturing

facilities in the United Kingdom.

As a process based manufacturing specialist, Preci-Spark delivers an array of

components, complex fabrications and assemblies to the Aerospace and Industrial

markets. Our extensive portfolio of in-house processing capabilities allows greater

production control, accelerated lead times and reduced costs.

exceeding customer expectations

Being customer focussed in all our activities,

Preci-Spark embraces the requirements defined in

AS9100 Revision C.

We are committed to maintaining a Quality

Management System of the highest possible

standard.

Our NADCAP approved processes include: vacuum

brazing, heat treatment, electro-discharge machining,

laser machining, welding and non-destructive testing.

cost efficient enabled by robust quality systems

HistoryRalph Jones, our Chairman, founded Preci-Spark in 1960.

The company was born into special process manufacture with the

purchase of 2 Wickman electro-discharge machines.

With the firm principle of investment in people and technology the

company has grown organically.

Over the decades, Preci-Spark has had ventures in other markets,

however its core business operations have always been high tech

manufacturing, of which currently Aerospace forms about 60%.

a backWard glance at past acHievements

continually striving for excellence

mission statementTo sustain world class supplier status within the

high technology engineering sector, employing

best industry practices and upholding the highest

professional standards to maintain market

leadership.

Ralph Jones

Chairman

our peopleApprenticeships & Training

Preci-Spark clearly understands that whilst investment in new technology is

important, investment in people is essential and prides itself in its commitment to

its employees.

Throughout its history Preci-Spark has benefited from 82 employees exceeding

25 years service to the company. Over the years we have had 130 apprentices

complete their apprenticeships. Many of whom are in managerial, supervisory or

skilled positions.

people synergy boosts efficiency and drives productivity

apprenticesHips are tHe key to developing tHe next generation of skills

To date we have trained over

450 people to NVQ level 2 and

level 3. It is compulsory for

all semi-skilled employees to

undertake the NVQ programme.

processesLaser Machining

Having recognised the potential for YAG laser machining over 30 years ago Preci-

Spark remains at the forefront of the technology. Having designed and developed

our own machine tools we have the knowledge, skills and experience to deliver

bespoke laser processing solutions to our customers.

Our laser machining service enables flexibility in development and robustness in

production, whilst always maintaining cost efficiency and price competitiveness.

Preci-Spark offers laser cutting and laser joining technologies. Our laser machining

scope extends from 3 axis through to 6 axis, up to 1.5m³ envelope, laser cutting

from 0.15mm to 7mm and laser welding from 0.25mm to 8mm penetration.

laser macHining offers HigH productivity enabling cost efficiency

Electro-Discharge Machining

Preci-Spark’s foundations were based on electro-

discharge machining. Since the acquisition of our

first Wickman EDM, Preci-Spark has strived to stay

at the forefront of the process technology through

innovation and investment. This process still delivers

cost-effective solutions in many applications, multi-

head and multi-channel generators enable high levels

of production throughput whilst maintaining part to

part repeatability.

Across our 6 manufacturing facilities we have 125

electro-discharge machines available for sub-contract

work. This extensive portfolio of machine tools

covers almost all applications. When required we

have the expertise to build special-purpose machine

tools and generators.

multi Head and multi cHannel generators boost productivity

processesConventional Machining

We have two state of the art conventional machine shops. The core of our

conventional machining capacity is based around simultaneous 5axis mill/turn

machining centres. In our experience this configuration of machine offers the

optimum level of flexibility, enabling almost all machining operations to be

performed within the given envelope.

Grinding capabilities combined with high pressure flushing allow the machining

of honeycomb structures to demanding specifications. Using our rotary surface

grinders we are able to machine components to tight tolerances up to Ø800mm.

5 axis mill/turn macHining centres offering optimum flexibility and productivity

Vacuum Brazing

Vacuum brazing and heat treatment cycles can be run automatically up to a maximum

temperature of 1350°C without oxidation of discoloration. We operate 6 vacuum

furnaces located within a process cell within out Falcon Street Facility. Our furnaces

are in the ‘clam shell’ configuration and have a capacity for components 1000mm in

diameter and 1000mm high for heat-treatment or brazing in either high vacuum or

partial pressure.

This process is key to the fabrication of many of our assemblies. A wide range of

alloys can be brazed using a variety of filler metals such as gold, silver or nickel. It is

an essential alternative to welding where thin sections, cracking or distortion can be

problematic.

Preci-Spark’s overall machining and brazing facility allows the removal and

replacement of damaged or worn honeycombs. Brazing of honeycomb segments onto

rings, heat shields or vanes is routinely carried out on new and repaired components.

Sophisticated machining capabilities enable the braze gap to be carefully controlled.

tHe vacuum brazing process enables tHe jointing of even tHe most intricate fabrications

processesInspection

Preci-Spark has full inspection and metrology capability to ensure quality of

product is assured.

Quality engineering input into product development is critical and through quality

planning and measurement systems analysis we ensure product compliance and

robust processing.

We produce first article inspection reports to AS9102.

On-going compliance is assured with conventional measurement techniques along

with co-ordinate measuring machines utilising the latest software systems. Co-

ordinate measuring machines are integrated into all of our machining cells.

Nadcap approved non-destructive testing capabilities of fluorescent penetrant

inspection along with final visual inspection by trained and competent staff

provide customer eyes over-check of all products prior to despatch which

contributes to maintaining class leading quality standards.

a complete portfolio of inspection tecHniques

Advanced metal forming

Preci-Spark has become renowned for its ability

to produce some of the world’s most challenging

components.

We have an extensive range of forming techniques

at our disposal which with the correct application

enable us to form even the most complicated

geometry.

As with all of our engineering activities our forming

techniques are process-based and deliver robust and

dependable performance. We operate two metal

forming process based product cells. Our capacity

allows for pressing up to 1000 tons with an envelope

of 1.2m².

multi process application alloWs complex material forming

processesWelding

With complex fabrications and assemblies being the mainstay of our

manufacturing operations TIG welding is a key process. We have vast experience

in welding thin sheet components to super alloy castings. Our pulse welding

technology enables the welding of advanced single crystal materials. For

applications where conventional argon backing will not suffice we utilise argon

chambers; this technique is essential when welding titanium or certain aerospace

alloys.

So whether it be welding cooling inserts into nozzle guide vanes or circumferential

welds on combustors, our experience and technology delivers high quality welds

time and time again.

HigHly skilled and experienced engineers fitting and Welding

productsCooling Inserts

Preci-Spark has been involved in the product

development and manufacture of air impingement

inserts for the cooling of gas turbines since 1960.

Our tried and tested proprietary method for

forming inserts has enabled us to deliver cost

effective solutions for inserts with even the most

complex geometry.

These forming methods ensure that profile

repeatability is maintained throughout the product

life cycle. Our manufacturing capacity allows for

high production volumes to be handled with ease.

1.8 million cooling inserts produced in tHe last 5 years

productsHoneycomb Assemblies

Preci-Spark manufactures honeycomb seals for high pressure turbines, low

pressure turbines and compressors. The company has secured significant market

share for the production and supply of both fabricated seal segments and seal

rings to the major OEMs.

Our manufacturing methodology delivers consistently high quality products and

enables us to supply over 20,000 honeycomb seals per annum across multiple part

numbers.

The synergy of sharing the customers design and our production expertise has

resulted in a culture of design for manufacture and delivered a step change in

product quality.

preci-spark manufactures and array of macHine Honeycomb seals

3 Dimensional Vanes

Preci-Spark has over 20 years of experience in

developing and manufacturing three dimensional

vanes. We produce an array of different types of

vanes with tapered and twisted shapes in alloys of

aluminium, steel and nickel.

Fabricated hollow airfoils are produced from sheet

metal with exacting contour definition. Airfoils from

forgings or bar stock can be produced with the use

of multi axis machining.

With demand for exacting quality and repeatability

of airfoil definition Preci-Spark has established

itself as a market leader in the production of these

components.

consistent product conformity

productsComplex Fabrications

With our extensive range of forming, welding, brazing and machining resources

Preci-Spark offers complex fabricated solutions to customers across multiple

industry sectors. Our capabilities allow us to manage even the most complicated

multi part assemblies.

Preci-Spark has been involved with combustion chamber development for the last

10 years, working in conjunction with leading engine manufacturers we produce

prototype combustion chamber components.

We were instrumental in the successful development of fabricated vane rings

which has enabled turbocharger manufacturers to obtain assemblies with specific

throat areas on vastly accelerated lead times.

Working in the semi-conductor industry we have developed some of our most

complicated fabrications. We have produced gas delivery systems with over

30,000 components and 80,000 braze joints.

specialist in complex fabrications and assemblies

General Components

Servicing the needs of a multi-industry customer base

we have developed expertise in the manufacture of a

diverse range of products from tungsten busbars to

titanium silencers.

We offer a comprehensive sub-contract facility and

with 125 EDM Machines and 25 YAG Lasers the

company is able to offer immediate capacity and

accelerated lead-times.

Whether it be impingement plates, heat shields or

gas purge manifolds our robust and dependable

processing delivers optimum productivity.

robust and dependable processing delivers optimum productivity

engineeringNew Product Introduction

New product introduction is a process for ensuring ‘Waste reduction and

Right First Time’ product realisation to agreed cost and timing, using available

Engineering and Quality tools.

Preci-Spark’s NPI process defines proven steps for product design and delivery.

Key milestone reviews are implemented to monitor progress. Our experience

in utilising the process assures quality through the early application of APQP,

budgetary control with an FMEA interface for risk mitigation and on time

delivery to customer expectation.

Product introduction is concluded with final sign-off to agreed specifications thus

ensuring that all necessary documentation and manufacturing aids are available to

begin production.

Allied to the NPI process, Preci-Spark operates a production validation process

that can utilise either First Article Inspection Reports (FAIR) or Production Part

Approval Process (PPAP) based on our customer requirements. Through these

processes we ensure that all of the customers’ engineering design and specification

requirements are correctly understood and that the manufacturing processes have

the capability and capacity to meet these requirements in production at a specific

rate.

resident experienced personnel

Solid Modelling

Preci-Spark offers its customers solid modelling

solutions. Our team of skilled engineers can

produce solid models from engineering functional

specifications. We utilise SIEMENS NX7 parametric

solid modelling system which significantly accelerates

the design process, lowers costs and improves

decision making.

With solid models becoming a standard across many

industries we use Team Centre Engineering for our

product data management. This system ensures

the project content and documents are revision

controlled and available via a central database for

concurrent engineering activities.

parametric solid modelling accelerates product realisation

engineeringValue Engineering

We provide a value analysis and value engineering service. Through detailed

analysis of products we enhance the value of key components with the objective

of increasing overall product value and decreasing cost.

With 50 years in multi process manufacturing our extensive knowledge base

enables our engineers to systematically improve value whether it be through

design for manufacture or simply applying the correct manufacturing technology

to deliver optimum performance.

Preci-Spark prides itself on creating and maintaining close relationships with its

customers. Many of our most effective solutions have been created through this

symbiosis.

fabrications are often key to enHancing cost saving

Tool Making

High quality tools, jigs and fixtures are essential to

almost all manufacturing activities. Our tool making

activities fall perfectly in line with our approach

to new product introduction and form an essential

part of the ‘concept to production’ solution we offer.

Through being able to control and adapt our tool

making operations we are in a very strong position

to be both flexible and dependable managing even

the most complex and extensive tool suites in

accelerated lead times.

With predictive tool life systems in place our tool

makers are continually maintaining the quality of

our tooling ensuring production continuity.

HigH quality tools, jigs and fixtures are essential

quality systemsQuality Standard

Preci-Spark is committed to maintaining a Quality Management System of

the highest possible standard expected by our customers and chosen industry

sectors. In support of this, the company holds certificates of accreditation to

the International Aerospace Quality Group (IAQG) initiative AS EN 9100

Revision C for our Aerospace and Gas Turbine operations and International

Quality Management System ISO9001:2008 for all of our plants. Our NADCAP

approved processes include vacuum brazing and heat treatment, electro-discharge

machining, laser machining, welding and non-destructive testing.

nadcap approved in-House laboratory facility

Production Control

The Preci-Spark Production Control process is all about ‘Risk assessment and

mitigation’ in our manufacturing environment utilising our industry experience and

tools at our disposal;

Quality tools

• Design Failure Modes and Effects Analysis for our tooling and gauging items

• Process Failure Modes and Effect Analysis

• Control Plans detailing critical and significant characteristics

• Statistical Process Controls (SPC) for on-going monitoring for compliance to

specifications and standards

People

Our operators and inspectors are highly trained fully skilled professionals to the

highest industry standards for their areas of expertise, from using basic measurement

devices, multi axis CMM, Metrology and Non-Destructive testing (NDT) to a fully

operational Fluorescent Penetration Inspection (FPI) facility within our premises.

Continuous improvement

We are constantly looking for ways to improve and optimise our operations to

maximise value added benefits to our customers. We consistently introduce Lean

principles to every aspect of our operations without exception. By applying Lean

principles in bespoke ways, we exceed customer expectations and achieve business

transformation with superior performance year on year.

risk assessment and mitigation

Preci-Spark Ltd

Chapel Street

Syston

Leicestershire

LE7 1HN

Tel: +44 (0) 116 260 7911

Preci-Spark Ltd

Morley Street

Loughborough

Leicestershire

LE11 1EW

Tel: +44 (0) 1509 236 655

manufacturing facilitiesPreci-Spark operates 6 manufacturing facilities

in the United Kingdom.

Total manufacturing floor space 138,000ft²

(12,850m²) Total office space 17,200ft²

(1600m²)

All sites are data linked ensuring a seamless

integrated operation.

Preci-Spark Ltd

Franks Road

Hill Top Industrial Estate

Coalville

Leicestershire

LE67 1TT

Tel: 00 44 (0) 1530 277 200

Preci-Spark Ltd

Falcon Street

Loughborough

Leicestershire

LE11 1EH

Tel: +44 (0) 1509 236 655

Preci-Spark Ltd

Railway Terrace

Loughborough

Leicestershire

LE11 1HW

Tel: +44 (0) 1509 236 655

Preci-Spark Ltd

Trenant Industrial Estate

Wadebridge

Cornwall

PL27 6HB

Tel: +44 (0) 1208 814 655

www.Preci-sPark.co.uk