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Meet our new Sales Managers

We’re excited to introduce Corey and Rhys, our new Technical Sales Managers at Alpha Manufacturing! Bringing fresh perspectives and valuable experience, Corey and Rhys will lead our customer relations and business development efforts in their respective regions, strengthening our reach and enhancing client engagement.

Corey will focus on the Southern region, while Rhys will take charge of the North. Both began their careers as apprentices at The HEX Group, demonstrating a commitment to hands-on learning and growth within the industry.

Rhys joins the management team at Alpha Manufacturing following his role as Team Lead at HEX Living, where he developed essential leadership skills and industry insights. Corey, meanwhile, transitions from his position as a Technical Sales Engineer, where he gained in-depth technical knowledge that will be invaluable as he guides customers through complex requirements and solutions.

In their new positions at Alpha Manufacturing, Corey and Rhys will serve as primary contacts for both new and existing customers. They’ll handle inquiries, explore client needs in depth, and provide tailored technical advice to help enhance client products. Their roles also include a strong focus on business development as they work to expand our customer base, actively meeting with both current and potential clients to drive growth.

We recently caught up with Corey and Rhys to hear their thoughts on the new role.

Corey shares, “After four years as a Technical Sales Engineer at Alpha Manufacturing, stepping into the role of Technical Sales Manager has been a seamless transition. My previous experience and apprenticeship have made this an exciting and natural next step. This role involves a lot of travel to meet customers in person—a part of the job I’m particularly enthusiastic about, as building strong, lasting relationships is at the core of what we do at Alpha Manufacturing.”

Rhys adds, “I’m excited to be taking on the Technical Sales Manager position at Alpha Manufacturing. The HEX Group Apprenticeship gave me a good technical background and understanding of the business, and I’m eager to leverage this to provide our customers with the best possible service and experience. I’m excited to see where this role leads and to be working alongside Corey.”

Michael Whitfield, Sales Director at Alpha Manufacturing further adds: “Having Corey and Rhys in the team gives us a great structure to support our new and existing customers and grow the business. We’re passionate about developing talent in the engineering sector and these appointments are testament to our in-house Apprenticeship Scheme and the great long-term opportunities it offers. I’m excited to be moving forward with such a great team in place which offers a very bright future for Alpha Manufacturing!”

Please join us in welcoming Corey and Rhys to their new roles. We’re confident their expertise and dedication will enhance our service and growth efforts across Alpha Manufacturing.

Meet Mark Proctor – Atlas Coatings

We are immensely proud to have our own in-house powder coating plant, Atlas Coatings, at The HEX Group.

Committed to growing this business division, we are thrilled to introduce Mark Proctor, who joined Atlas Coatings and The HEX Group in September 2024 as Production Manager.

Mark’s career journey began as a Stamping Press operator at Denso Manufacturing. Mark’s drive for excellence and continuous improvement helped him steadily rise through the ranks during his 15 years of service. His dedication and leadership eventually earned him the position of Production Manager, where he successfully oversaw multiple departments and led numerous teams.

During his tenure at Denso, Mark also pursued professional development, achieving several industry qualifications, including a Level 5 Management certification.

After his successful career at Denso, Mark took on a new challenge at 8 Ball, where he honed his management skills and took his leadership to the next level. His time there was marked by impressive achievements, as he implemented new standards and procedures. Reflecting on his time at 8 Ball, Mark says, “My time there allowed me to show my capabilities and restructure the business, resulting in substantial growth.”

Seeking a new challenge, Mark was introduced to powder coating during his move to Pym & Wildsmith, a metal finishing company. Over five years, Mark’s responsibilities grew, culminating in a promotion to Operations Manager. In this role, he embraced the strategic aspects of operations, which he found deeply rewarding.

Now, as Production Manager at Atlas Coatings, Mark is not just a leader, but a passionate advocate for operational excellence and production efficiency in the powder coating sector. He is committed to bringing his experience and fresh perspective to the role, ensuring that Atlas Coatings reaches new heights and delivers the highest quality to our customers.

Mark shared his vision for Atlas Coatings: “There’s significant growth potential in various areas of the powder-coating plant. I’m excited to take a hands-on approach and eager to dive in, push the business forward, and explore new opportunities.”

In his downtime, Mark is a dedicated family man and Manchester United fan. He enjoys socialising with friends and family and has recently taken up learning to play the guitar.

Welcome to the team, Mark. We are excited to see what the future holds for you within The HEX Group. Your experience and passion for excellence will undoubtedly contribute to our continued success.

Meet the Team – Doug Hughes

At Alpha Manufacturing, we’re always thrilled to welcome new apprentices, and this year, we’re excited to have Doug Hughes join our team. Over the next three years, Doug will work towards his Level 3 Engineering and Manufacturing Support Technician Apprenticeship, gaining hands-on experience and learning the ropes of the business.

Doug recently finished his BTECs in Business and Sport, but it didn’t take long for him to realise that university wasn’t the right fit. During his time in sixth form, he discovered a passion for business, which led him down a slightly different path—a fully office-based apprenticeship in engineering sales.

Starting from scratch in engineering as a Trainee Internal Sales Engineer, Doug will be responsible for preparing everything before a sale takes place, including processes such as checking the feasibility of a customer’s product design, costing, liaising with suppliers and customers regarding requirements and quoting.

Additionally, Doug will take on the duties of post-sales preparation before production takes place, ensuring all relevant sectors of the business have been communicated with the correct information and are ready for our APQP process (Advanced Process Quality Planning).

Just three weeks into the role, we caught up with Doug to see how he’s settling into life at Alpha Manufacturing:

“It’s been a big jump from school, but I’m enjoying my time here. The engineering world is entirely new to me, so there’s a lot to learn, but the team has been great at helping me get to grips with everything. No matter my questions—big or small—someone’s always there to help.

I’ve been learning the basics of engineering sales, doing off-the-job learning at Stafford College, and learning in the apprenticeship classroom with other apprentices. It’s been varied, which I love.

Seeing how successful previous apprentices have been here is exciting and makes me look forward to what the future holds for me!”

Outside of work, Doug loves his sports. He is a big cricket and football fan, both spectating and playing!

Manufacturing for the Healthcare Sector

Manufacturing for a wide variety of sectors is one of the reasons we can call ourselves an industry leader.

From agriculture to healthcare, we have the knowledge and technology to precisely schedule and meet our customers’ project requirements.

At Alpha Manufacturing, we understand and prioritise the importance of producing highly versatile products for the healthcare industry.

We ensure they meet trading standards and adhere to any legislation required to be fully functional and appropriate for medical environments.

From seating to sensory pods, we proudly supply many healthcare and medical providers around the UK.

What Have We Done?

Scanning

Technology, particularly in the form of scanning equipment, is a driving force behind crucial advancements in the healthcare industry.

As it continues to evolve, it empowers healthcare professionals to identify a wider range of previously undetectable issues, revolutionising patient care.

Manufacturing scanning equipment such as X-ray machines requires adherence to industry legislation and, of course, the highest quality to be fit for purpose in a variety of medical settings.

Thanks to our state-of-the-art machinery and technologies, we can manufacture these products with the finest precision and produce an accurate final result, regardless of quantity.

Covid-19 Safety Products

During the challenging COVID-19 pandemic, our team at Alpha Manufacturing worked tirelessly to design, produce, and deliver these critical items for our customers.

From hand sanitiser stations to COVID safety screens, we ensured that during the pandemic, we helped our customers keep everyone that little bit safer.

Frames and Metal Components

We design and manufacture components and frames for a range of products that are supplied to healthcare institutions such as hospitals and care homes, some of which include:

– Adult and children’s reclining chairs

– Reclining beds

– Ward Furniture

– Reception seating

– Dining and other utility structure

Orthopaedic Chairs and Beds

We have been producing orthopaedic chairs and beds for 25 years for one of the UK’s largest manufacturers of adjustable, tailored beds and chairs within the medical sector.

Laboratory Cabinets/ Tables

Since 2020, we have manufactured laboratory cabinets/ tables used in the IVF industry for a world-leading fertility and women’s health company.

Sensory

We design and manufacture immersive multi-sensory hubs offering Personalised Sensory Regulation (PSR) as a new and effective way to regulate people with autism and sensory needs.

We’re here to help

If you’re searching for a manufacturer supplier to produce medical and healthcare sheet metal products, we’ve got the experience and expertise to support you.

Get in touch with our expert team to discuss how we can help you: www.alphamanufacturing.co.uk

Industry 4.0 – Paving the Way for a More Efficient and Dynamic Future in Manufacturing

As a leading subcontractor in sheet metal fabrication in the UK, we are passionate about innovation.

Embracing the latest advancements in technology and software is essential not only to keep pace with automation and Industry 4.0 but also to pave the way for a more efficient and dynamic future in manufacturing.

Leading the Charge in Industry 4.0

Peter Smedley, our programming and automation manager, drives our commitment to staying ahead of technological advancements.

Pete spearheads our efforts in Industry 4.0 and the cutting-edge technologies transforming the manufacturing sector, constantly researching new technologies that Alpha Manufacturing can invest in, ensuring we utilise our state-of-the-art facilities to their fullest potential.

Boosting Productivity with Advanced Automation

At Alpha Manufacturing, we believe that innovation is the key to enhancing productivity and quality. We constantly invest in new software and technology.

The new software enables us to automate the programming process by taking product CAD files and converting them to bend programming files. It can also schedule bend programmes to maximise efficiency by reducing the number of tool changeovers, which are essentially non-value-added operations. This function is called TSO—Tool Setup Optimiser.

This capability not only reduces downtime but also ensures continuous operation, significantly boosting capacity and accelerating product turnover. For our customers, this means faster lead times and larger volumes.

Offline Operations

The ability to operate offline through our Trumpf Boost program is a game-changer for Alpha. Trumpf Boost gives us the ability to programme and schedule fully offline, enabling the press brake to continue to operate fully in production mode. This feature significantly increases our product workload, value-added time, and efficiency.

This flexibility ensures that we can handle larger volumes of work without compromising on quality or efficiency.

Seamless Integration for Total Automation

One of the standout features of our production management software is its ability to cross-link with existing systems.

This seamless integration ensures that all of Alpha’s systems can communicate effectively, allowing for complete automation.

The software links directly to the machines, guaranteeing that every task is executed correctly and up to date.

This streamlined process minimizes errors and maximizes efficiency, ensuring that we deliver high-quality products consistently.

How Industry 4.0 is Transforming Sheet Metal Manufacturing

Now more than ever, technology is developing at a rapid pace.

From artificial intelligence to automation – things have changed a lot since we first set up in 1989.

With ever-advancing technology and equipment in the 21st century, Alpha Manufacturing set out on an ambitious investment programme in 2015 to achieve high levels of factory automation.

Often referred to as Industry 4.0 and Smart Factories – the integration of intelligent digital technologies into manufacturing and industrial is game changing.

With a huge emphasis on digitalisation and the turning of physical tests or labour-intensive processes into virtual or digital forms, Industry 4.0 aims to add value, increase efficiency, and significantly reduce production timescales.

Why is automation so helpful in manufacturing?

Automation of manufacturing processes, in essence, is a powerful tool for optimising operations, reducing waste, and significantly enhancing efficiency.

It addresses many of the wastes, especially in process accuracy and quality, waiting, transportation, motion, and inventory. Alpha Manufacturing has a very clear vision of lean manufacturing, which has factory automation at its core.

So, how can the sheet metal process be automated?

Automated machine loading and unloading:

Many of Alpha Manufacturing’s current processing machines feature automated systems for loading and unloading raw materials and parts. This both reduces the time an operator spends manually loading and minimises any risk of injury.

Automated storage:

Systems such as STOPA use a system called ‘chaotic storage,’ which doesn’t require a pre-defined space for each item. Instead, it records each item as it passes into or out of storage and knows its exact location at any given moment.

Lights-out operation:

This effectively means that machines can be programmed and left unmanned to continuously process raw materials and parts. This has a huge positive impact on productivity and additionally allows for large volumes to be processed in a shorter time.

Alpha has invested in many industry-leading automation machines over the past few years, such as the Trumpf Robot Welder, Salvagnini Metal folder, the STOPA Storage System – which can store up to 600 tonnes of raw material and WIP, and even an automatic cardboard box maker!

As we move into the future, we are ready to embrace more automation technology, aligning with the growing trend of Industry 4.0. Our main aim is to benefit not only our colleagues but also our customers, ensuring that our products remain at the forefront of technological advancements.

How does the end customer benefit?

By optimising the manufacturing process and reducing waste while simultaneously improving reliability and accuracy, we are able to offer a much more efficient and cost-effective service overall.

The leaner the manufacturing process, the more value the customer gets, combined with more reliable and consistent service levels!

Will automation completely eliminate manual input in manufacturing?

In short, no, absolutely not!

By automating the traditional non-value-added tasks performed by a human (such as lifting, transporting and data processing), we are significantly boosting our productivity. This allows our workforce to focus on more value-added tasks such as performing manufacturing processes, and upskilling themselves, leading to a more efficient and dynamic manufacturing environment.

There will always be a need for human input in manufacturing, with automation being used to ensure this resource is best deployed for maximum production.

Meet the Team – Maria Sokalska and Magdalena Neizabitowska

Meet Maria Sokalska and Magdalena Neizabitowska – a niece and aunt duo working in Alpha Manufacturing.

Manufacturing is often perceived as a male-dominated environment, but at Alpha Manufacturing, we’re proud to employ many women across the business who are tremendously passionate about the work they carry out daily.

Maria and Magdalena work in assembly, constructing server cabinets for one of our largest customers.

Originally from Poland, Magdalena joined the Alpha Manufacturing team two years ago. She comments, “I love my role in assembly, I like the people, and the work hours fit my family life. When a space in the team opened up, I quickly recommended the role to my niece, Maria.
With two sons, Magdalena spends her free time as a mum and supporting her boys.

Maria joined the assembly team six months ago and is enjoying the opportunity. She says, “Although I’ve only been here six months, I’ve been offered an opportunity to train in the quality area, ensuring that all cabinets pass quality inspections before they leave the factory.

“Everyone at Alpha Manufacturing is friendly, helpful, open, and honest. I really like that. I enjoy learning new things and am keen to see how far I can go within the company.”

Maria enjoys hiking, especially in the Lake District and walking her dog, a Pomeranian called Elmo. She’s also a big lover of the gym, something she says helps her in her role as it can be quite manual.

Maria adds, “Assembling the cabinets is a very satisfying job. From seeing the parts flat, to fully constructed is a real sense of achievement.”

Product assembly is not just a task but a crucial part of our business. The dedication and passion of our employees, like Maria and Magdalena, are what ensure it’s done correctly.

Without their commitment to doing a great job, we wouldn’t achieve the outstanding results we do, and the fantastic customer feedback we receive.

Bringing Manufacturing Home: Onshoring with Alpha Manufacturing

In recent years, we’ve witnessed a shift in the manufacturing landscape — a resurgence in onshoring that brings production closer to home.

As supply chains overseas present more barriers and delays with shipping, costs, and regulatory charges, UK-based companies are starting to look closer to home for high-quality manufacturing solutions.

As a proud UK sheet metal fabricator, Alpha Manufacturing stands at the forefront of this movement, offering unparalleled expertise, cutting-edge technology, and a commitment to sustainability.

In this blog, we’ll explore the benefits of onshoring in the UK and why Alpha Manufacturing is the partner of choice.

Why Onshore in the UK?

Resilience in Supply Chains: Recent global events have highlighted the vulnerabilities of extended supply chains. Onshoring manufacturing to the UK significantly reduces these risks, offering more control and flexibility, which is essential in navigating the uncertainties of today’s market.

Quality Assurance: British manufacturing is synonymous with quality. By onshoring, businesses can benefit from the high standards of UK manufacturing regulations, ensuring that their products meet the best quality and safety benchmarks.

Sustainability: Onshoring reduces the carbon footprint associated with long-distance transportation of goods. It aligns with the growing demand for sustainable practices and helps companies contribute to environmental conservation efforts.

Economic Benefits: Investing in local manufacturing supports the UK economy, creates jobs, and fosters innovation. It’s not just about keeping the wheels of industry turning; it’s about fuelling the engine of growth and prosperity across the nation.

Faster Turnaround Times: Proximity matters. Onshoring to the UK means shorter lead times, allowing businesses to respond more quickly to market demands and customer needs.

Why Choose Alpha Manufacturing?

State-of-the-Art Technology: At Alpha Manufacturing, we pride ourselves on our investment in the latest manufacturing technologies. Our facilities are equipped with advanced machinery for precision engineering, ensuring high-quality production for every order.

Expertise and Experience: With years of experience in sheet metal fabrication, our team of skilled engineers bring a wealth of knowledge to every project. Our expertise ensures we can tackle complex challenges and deliver bespoke solutions tailored to our clients’ needs.

Commitment to Sustainability: We understand the importance of sustainable manufacturing practices. Alpha Manufacturing is dedicated to reducing environmental impact through efficient production processes, waste reduction, and energy conservation.

Flexibility and Customisation: Our approach is centred around meeting our client’s unique requirements. Whether it’s small-to-medium runs or large-scale production, we offer flexibility and customisation options to suit any project. Our expert team is always here to help you find the perfect solution.

Collaborative Partnerships: We believe in building strong, collaborative relationships with our clients. By choosing Alpha Manufacturing, you’re not just getting a supplier; you’re gaining a partner committed to your success.

Our combination of technological prowess, world-class expertise, and a commitment to quality and sustainability makes us the perfect partner for any company looking to harness the benefits of UK manufacturing.

In embracing onshoring, you’re not just making a business decision; you’re investing in the future—of British companies, British communities, and British people. Alpha Manufacturing is already leading the charge, helping to shape a resilient, sustainable, and prosperous manufacturing landscape in the UK. Let’s build that future together.

Interested in choosing a UK-based sheet metal fabricator for your manufacturing needs? Get in touch with our team by clicking here.

Developing Within – Our People are our Greatest Asset

Great people are a company’s greatest asset. At Alpha Manufacturing, we’re proud to have a passionate, committed, and knowledgeable team that cares about the individuals they manage and support daily.

In March 2023, we took the senior team on a leadership development journey, empowering them with new techniques to get the best results from their functions.

Alpha Manufacturing partnered with local talent, culture and leadership guru Sally Brys from Limitless Development to work with the team to explore new ways of thinking, approaching people and behaviour, and improving department performance.

Sally spent time in the business before planning the training to understand challenges and concerns before producing an engaging, reflective and thought-provoking three-module course for the Alpha Manufacturing team.

Planning Manager, Joanna Sitek, is just one of the Alpha Manufacturing employees who completed the training. She comments, “I have to be honest – I was hesitating at first. Having had a previous disappointing experience with this kind of training course, I thought it might not be for me, but I am one of those people who do not judge before trying it first, so I gave it a go.

“The safe and supportive atmosphere Sally has created encouraged us to take the shield off and be honest about both work-related and personal challenges we experience. One of my personal struggles was always the language barrier, with public speeches being extremely stressful. Therefore, I was avoiding it where I could.

“With the help and support of my group, I understood the barrier I have created in my head for 18 years should no longer be there. Looking back now, it is probably the best decision I have made in a while”.

Nick Moss, Operations Manager, adds, “Being part of the first Leadership Development programme was great, although I was quite sceptical at first. Reflecting on my leadership style and the kind of leader I want to be has helped me identify where I want to be and the part I play in the future of the business. I’m excited to try new coaching techniques to help my team reach their full potential and create a strong team. At Alpha Manufacturing, we have some incredible people, and I’m proud to be able to support them in their growth and development”.

Due to the programme’s success, Sally has tweaked the course content alongside the business to deliver similar training at the team leader level. This allows valued employees to enhance their skills and provide frameworks and models that can be used in the workplace to get better results and improve productivity.

Sally Brys, Limitless Development, comments, “The Alpha Manufacturing leadership programme is a deliberate investment in the organisation’s heart – its people. The programme has been meticulously designed to reflect the needs of the business, to nurture and develop the skills of those who attend and to drive a culture of continuous growth and excellence. It empowers individuals to unlock their full potential, aiming to create a ripple effect that positively impacts those they work with”.

At Alpha Manufacturing, our people are our greatest asset. Without them, we wouldn’t be the business we are today. But we can be better, and with investment in training and supporting employee development and growth, we can achieve even greater things, and we’re incredibly excited about it.

Manufacturing Challenges 2024: Navigating the storm with increasing optimism

Two months into 2024, the manufacturing industry is again facing difficult market conditions, supply chain disruptions and rising costs.

Taking matters into our own hands, we have started the year positively, and despite the challenges, are looking optimistically at the year ahead.

In this article, Sales Director Michael Whitfield outlines the biggest issues facing our industry, and how we’re overcoming them, supporting our customers through unprecedented market volatility.

Supply Chain Disruption

Supply chain disruptions are nothing new. With Brexit, the pandemic and geopolitical tensions all testing the global market in recent years, manufacturing businesses have had to become accustomed to new ways of working. Now, with issues in the Red Sea adding more pressure to import and export markets manufacturers are again facing challenges.

Since the beginning of the year, military activity has been escalating in the Red Sea effecting all trade through the region. Ships carrying anything from clothes and toys, to fabricated parts have been the target of attacks by Houthi rebels, forcing major operators to divert cargo away from the Suez Canal. Adding up to 20 days to journey times, these delays have affected businesses across the UK, driving costs up and leaving some without manufactured parts or products.

Flying the flag for Great British manufacturing, we continue to invest in supply chain integration. With our entire operation based in the UK and very few outsourced processes, we are able to maintain complete control over our manufacturing, reducing shipping reliance and supply chain risk for our customers, while maintaining a high-quality product.

As more and more British businesses look to home to secure their future, we are here to support them. The business climate today, with rising costs and growing uncertainty is difficult enough. If we can support just some of that, reducing reliance on phantom overseas suppliers with invisible customer service, then we’ll be doing our job right. Working with new and existing customers, we offer state-of-the-art services, manufacture innovative products, and meet our customers’ complex requirements.

Skills Gap

Today’s labour market is a challenge for all businesses. The result of Brexit and the pandemic has left a skills shortage across much of the UK manufacturing sector. Recruitment and retention are central to our strategy, and is a key driver for future growth and success. That said, we continue to invest in our people to make Alpha Manufacturing an attractive place to work. Following our recent investment in a cutting-edge Trumpf TruBend 5170S fold machine, we are upskilling several operatives to use our latest machinery. This ensures we maintain our expertise, allowing us to deliver the highest quality products to our customers.

2023/24 also saw our largest intake of apprentices ever, with 18 new apprentices joining across The HEX Group. Since launching our fully accredited apprenticeships in 2010, this has formed a crucial part of our growth strategy and has allowed us to promote careers within our sector. Offering exciting and dynamic programmes, we nurture our young people, offering hands-on learning to produce qualified, ambitious, highly productive colleagues who keep our business moving forward.

Sustainability

Every industry is touched by sustainability and manufacturing is no different. With the drive towards net zero and more environmentally conscious business practices coming to the forefront of all our minds, we have made significant steps to make our processes more sustainable. In 2022, we installed 1770 solar panels covering more than 3500m2 of roof space at our facility in Staffordshire, saving more than 150 tonnes of CO2 emissions each year. We also continue to invest in our future, ensuring we have the latest energy-efficient machinery to reduce our environmental impact. Our latest investment reflects this commitment, offering significant improvements in energy consumption and promoting eco-friendly manufacturing practices.

We are incredibly proud to be a British manufacturer and work tirelessly to maintain our high standards, even in challenging times. We are resilient by nature and continue to work closely with our suppliers to ensure we deliver for our customers.

Robot Welding Vs Manual Welding

Having the capability to offer customers a complete range of solutions for welding and fabrication jobs is just one of Alpha Manufacturing’s unique advantages.

In this article, we explore the benefits of manual and robot welding and explains how Alpha customers benefit from this market-leading service.

There are so many processes involved in the fabrication of just one product, but the beauty of an Alpha Manufacturing made component is that every area of our production uses the best available technology for that particular process. There’s no question, certain methods have their unique advantages and welding is no different – not only from a process and application capability but from a value engineering process too.

The manual welding process has great flexibility and can be involved in a wide range of applications. One of the first differences between manual and robot welding is that manual welders are able to work with a variety of different thicknesses and a mix of products using their own skill and knowledge base, rather than requiring a programmer to set up before each use.

This method also means that high complexity can be achieved as manual welders can navigate hard to reach weld sites. One of the unique benefits of manual welding is that it’s the perfect solution for low quantity runs and prototyping, enabling the welder to use their skills and expertise.

But that’s only half of the welding story. At Alpha Manufacturing, arguably we have the most exhaustive robotic welding capability in the UK including the Yaskawa Robotic Welding Machine. Featuring ‘cold metal transfer technology’, our customers have come to rely on world-class weld standards. While manual welding has many advantages, robotic welding delivers consistently high quality output with a high repeatability rate, as the robot follows the exact same programme.

There’s no question, for Alpha customers having the in-house capability to deliver a broad spectrum of weld techniques is just one of the Alpha Manufacturing differences. Whether a component is welded in one of our weld bays by one of our expert weld team or a component is passed through our automated welding machinery, every component manufactured in our Staffordshire production facility achieves the same world-class standard. That’s our commitment to every Alpha Manufacturing customer. It’s what we’re famous for.

A Comparative Look at Manual and Robotic Welding Processes

At Alpha Manufacturing, our commitment to excellence in sheet metal fabrication has been a hallmark of our identity. In this article, we explore the pivotal topic of welding, specifically examining the distinctions between manual welding and our state-of-the-art robotic welding processes. With our cutting-edge machinery and a team of skilled experts, we stand as a leading sheet metal fabricator in the UK, delivering consistently high-quality products to our valued customers.

Manual Welding Excellence

Alpha Manufacturing takes pride in offering a diverse range of welding techniques through our expert manual welding team. Our weld bays, equipped with the latest technology, allow our skilled professionals to bring their expertise to every component. The advantages of manual welding are numerous, including the ability to adapt quickly to various specifications, intricate designs, and unique challenges. The hands-on approach ensures a personalised touch, allowing our team to tailor solutions to meet specific customer needs.

Robotics Precision with ‘Cold Metal Transfer Technology’

Alpha Manufacturing’s commitment to innovation is evident in our automated welding machinery, featuring cutting-edge ‘cold metal transfer technology.’ This technology enhances the precision and efficiency of our robotic welding processes. Unlike manual welding, where the outcome relies on individual skill and technique, robotic welding ensures a consistently high-quality output with an impressive repeatability rate. The robot meticulously follows the exact program, delivering unparalleled precision and uniformity in every weld.

Consistent World-Class Standards

Whether a component is crafted by the skilled hands of our manual weld team or undergoes the meticulous precision of our robotic welding machinery, Alpha Manufacturing guarantees the same world-class standard for every product. Our Staffordshire production facility serves as the epicentre of quality, where every weld is a testament to our dedication to excellence. This commitment is the essence of what sets us apart, and it’s what we are renowned for in the industry.

In the dynamic world of sheet metal fabrication, Alpha Manufacturing continues to redefine standards through a blend of manual expertise and cutting-edge robotic technology. As we progress into 2024, our unwavering commitment to consistently delivering high-quality products remains the cornerstone of our reputation.

Whether it’s the artistry of manual welding or the precision of robotic processes, our customers can rely on Alpha Manufacturing to exceed expectations.

Interested in discussing what we can do for you? Get in touch with our team today.

To keep up to date with all the latest investments, innovation and industry news from Alpha Manufacturing, sign up to our mailing list by clicking here.

Alpha Manufacturing, a Staffordshire-Based Family Business, Enhances Capabilities with £450,000 Investment in New Equipment

Alpha Manufacturing, a proud member of The HEX Group, is excited to announce a £450,000 investment in the acquisition of the cutting-edge Trumpf TruBend 5170S. This state-of-the-art machinery will not only elevate the company’s manufacturing capabilities but also contribute to its commitment to quality, innovation, and environmental sustainability.

The introduction of the Trumpf TruBend 5170S signifies a significant leap forward for Alpha Manufacturing in terms of quality, accuracy, and efficiency.

The key features of the new machinery include:

Automatic Controlled Bending: The Trumpf TruBend 5170S enables automatic controlled bending, ensuring greater precision and quality in the manufacturing process.

3D Programme Folding: Alpha Manufacturing can now leverage 3D programmes for folding, enhancing visual management and further streamlining the production process.

Part Indicator Technology: The machinery is equipped with part indicator technology, preventing incorrect folding and significantly reducing errors, waste, and production time.

Environmental Impact: Alpha Manufacturing’s investment aligns with its commitment to environmental sustainability. The Trumpf TruBend 5170S contributes to the company’s 2037 carbon neutrality goal by reducing energy consumption and promoting eco-friendly manufacturing practices.

Paul Clews, Managing Director at Alpha Manufacturing, expressed enthusiasm about the investment, stating, “The Trumpf TruBend 5170S represents a significant step forward for Alpha Manufacturing, allowing us to deliver even higher quality products while aligning with our environmental goals. This investment reinforces our commitment to providing the best for our customers, our team, and the planet.”

Gerry Jones, Sales Director at TRUMPF, added: “Alpha manufacturing are a key customer in the UK and a forerunner in terms of technical capability, the TruBend 5170 S strengthens their position.”

We look forward to working with Alpha Manufacturing and supporting their exciting progress.”

Benefits for Alpha Manufacturing and Its Stakeholders:

The Trumpf TruBend 5170S brings a host of benefits to Alpha Manufacturing, its dedicated team, and the environment:

✅ Lift Support: The bend support arm of the machinery can handle parts weighing up to 100KG, enhancing efficiency and capacity.

✅ Reduced Manual Handling: Automation and innovative technology minimize the need for manual handling, promoting a safer and more ergonomic work environment.

✅ Energy Efficiency: The new machinery is designed with reduced energy consumption in mind, contributing to Alpha Manufacturing’s sustainability initiatives.

✅ Offline Programming: The Trumpf TruBend 5170S allows for offline programming, providing opportunities to increase machine uptime and overall output.

Meet Leo: Rising Star in Production Engineering

With great pleasure, we introduce Leo Manifold, a dynamic and ambitious member of our team at Alpha Manufacturing.

Leo joined us in September 2023 as a Higher Degree Apprentice, pursuing a four-year course in Production Engineering. His unique journey to Alpha Manufacturing and outstanding contributions have already set him apart as a rising star within the company.

Leo embarked on his journey with Alpha Manufacturing after completing his 6th-form studies in engineering and business at JCB Academy. Leo’s dedication and skills stood out during his time at JCB Academy, leading him to a 2-week work experience stint with us. This experience showcased Leo’s capabilities and paved the way for an exciting opportunity to join us as a Higher Degree Apprentice. Leo comments on his work experience…

“Work experience at Alpha Manufacturing was great. From day one, I was made to feel part of the team, and the diversity of skills I learnt in just two weeks was incredible.”

Leo’s commitment to his education is commendable. Currently enrolled in a 4-year Higher Degree Apprenticeship programme in Production Engineering, Leo attends college once a week while contributing his freshly acquired knowledge and skills to our projects.

One of Leo’s initial projects involved designing and manufacturing a new product for our HEX Living division. Leo successfully completed this project within an astonishing three months and demonstrated remarkable efficiency and dedication. The prototype is now in our team’s capable hands, and we eagerly anticipate its imminent launch in the coming weeks. Leo discusses this project…

“Being part of the design and manufacturing journey for the new HEX Living product was exciting. It was a privilege for Alpha Manufacturing to put their trust and confidence in me. It was great to see the process from conception to completion”.

Leo’s passion for manufacturing and engineering is evident in every task he undertakes. His enthusiasm is not only limited to his academic pursuits but extends into his work at Alpha Manufacturing. Leo’s drive is not just a professional attribute but a personal one, making him an asset to our team.

Beyond the world of manufacturing, Leo maintains a balanced and active lifestyle. He takes a keen interest in staying fit and healthy, with a particular focus on running and kickboxing.

As Leo embarks on his career journey, we wish him the best of luck! Your hard work and enthusiasm are truly inspiring, and we cannot wait to see where your career at Alpha Manufacturing takes you!

Precision Craftsmanship in Manufacturing and Fabrication at Alpha Manufacturing

At Alpha Manufacturing, we understand the nuances between manufacturing and fabrication, two distinct yet interconnected processes in the industrial realm. Let’s delve into the differences and highlight our expertise in delivering precision-crafted products.

Fabrication Excellence at Alpha Manufacturing

Fabrication, for us, is an art that involves constructing products by skillfully combining standardised parts through various individual processes. Consider steel fabrication, where we produce metal structures using cutting-edge techniques such as cutting, bending, and assembling. Leveraging computer-aided designs (CAD) and computer numerical control (CNC) technology, we ensure high-quality assemblies with precise dimensions.

Our design experts at Alpha Manufacturing specialise in creating fully assembled prototypes, providing our clients peace of mind. From pre-assembled balcony units for new build apartments to modular utility rooms and beyond, we excel in crafting diverse products. By embracing advanced technologies, we streamline the steel erection process on-site, ensuring cost-effective solutions through optimal material utilisation and faster assembly times.

Manufacturing Excellence at Alpha Manufacturing

Manufacturing is the seamless transformation of raw materials into finished products. It’s a holistic process that encompasses large-scale production, utilizing machinery, tools, and chemical/biological processing. Alpha Manufacturing excels in this sector, offering a start-to-finish process for virtually any sheet metal requirement.

Our expertise spans various industries, including apparel, chemicals, electronics, and more. From design to CNC machining, assembly to delivery, Alpha Manufacturing provides a comprehensive service. We take pride in our ability to oversee the entire production journey, ensuring the highest quality standards.

Bridging the Gap: How We Differ

The key differentiator between manufacturing and fabrication lies in the extent of the process involved. Fabrication focuses on assembling standardised or specialised parts, forming components for the final product. On the other hand, manufacturing is a comprehensive start-to-finish endeavor, encompassing the creation of parts and final assembly.

At Alpha Manufacturing, we seamlessly integrate fabrication into our manufacturing processes, ensuring precision craftsmanship and attention to detail. Our commitment to quality and efficiency sets us apart, making us your trusted partner for intricate projects.

Discover the Alpha Manufacturing advantage—where precision meets perfection in manufacturing and fabrication. Explore a world where every detail matters, and every product is a testament to our unwavering commitment to excellence.

Get in touch with our team to understand how we can help you by clicking here.

Forging a Greener Future: Sustainability in UK Sheet Metal Fabrication

In the heart of industrial prowess, the sheet metal fabrication industry plays a crucial role in shaping the backbone of the United Kingdom’s manufacturing sector. However, as the world grapples with environmental challenges, the industry faces a pivotal moment in redefining its practices for a sustainable future.

The Current Landscape

The sheet metal fabrication sector in the UK is a dynamic force, supplying components for a vast array of industries, from automotive to construction. While indispensable, this industry has its environmental implications. As sustainability becomes a global priority, the spotlight turns towards how sheet metal fabrication in the UK is evolving to meet the demands of a greener era.

Energy-Efficient Practices

Recognising the urgency of addressing energy consumption, we installed solar panels on the roof of our facilities. This move powers the facility using clean energy and significantly reduces the overall energy footprint.

Beyond Alpha Manufacturing, many other sectors and businesses across the UK are following suit, exploring renewable energy sources to power their operations. From solar and wind to hydroelectric power, these endeavours are not just symbolic; they represent a tangible commitment to reducing the industry’s reliance on conventional energy sources and mitigating its environmental impact.

In addition to renewable energy sources, companies are investing in energy-efficient machinery and adopting smart technologies that optimise energy consumption during the fabrication process. These efforts collectively contribute to a more sustainable and eco-friendly sheet metal fabrication industry in the UK.

Materials and Recycling

Central to sustainable transformation is re-evaluating the materials used in sheet metal fabrication. The industry is witnessing a shift towards environmentally friendly materials, emphasising recycling. From reusing scrap metal to integrating recycled materials in production, we constantly explore innovative solutions to minimise our environmental impact.

Waste Reduction

Waste reduction has emerged as a cornerstone of sustainable sheet metal fabrication. Through strategic initiatives, companies are minimising waste at every stage of the production process. Reuse, recycle, and responsible disposal methods are becoming integral to industry practices, showcasing a commitment to a circular economy.

Green Certifications and Standards

Alpha Manufacturing not only champions energy-efficient practices but takes sustainability to heart, setting a visionary goal. We have made a bold commitment to reaching carbon neutrality by the year 2037.

For us, certifications such as ISO 14001 for environmental management are not just checkboxes; they are strategic pillars in a concerted effort to foster a more sustainable and environmentally responsible future for the sheet metal fabrication industry.

As companies like us lead the charge, the industry is witnessing a shift where sustainability is not just a buzzword but an integral part of the business ethos, shaping the path towards a greener, more conscientious future.

To find out more about what we do, our environmental commitments and how we can help you, click here.