Services

/ Tool Manufacture
Supporting Projects Of All Sizes
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CNC Programming

CNC Programming

CNC programming is the creation of control programmes for Computer Numerical Control machines such as lathes, mills and other metal working tools.

At Premier Group, part of our process includes CNC programming for 2, 3, 4 & 5 axes machining, laser and inspection centres. Projects are supported of all sizes, from a single toolpath to a complete engineered project – this may include solid model creation, fixture design, stage drawings, tooling selection, multiple CNC Programmes, and onsite support for first off prove out.

With every CNC Programme set-up sheets, showing component orientation, datum positions and key dimensions are supplied. Tooling sheets are also supplied, to identify tools used, tool positions, flute lengths and gauge lengths. All of our programmes are checked for gouges and collisions, to ensure you have reliable and error free CNC Programmes.

Call us on +44 (0) 247 636 2886 if you have a project in mind.

A Dedicated Model Making Facility
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Polystyrene Pattern

Polystyrene Pattern

With a dedicated polystyrene model making facility, producing polystyrene sculptures are produced along with manufactured polystyrene patterns. Production is far quicker and more cost effective than the traditional methods and the polystyrene material is also significantly cheaper.

With this state-of-the-art facility, our CNC machined poly patterns are assembled using our team of highly skilled pattern makers.

Call us on +44 (0) 247 636 2886 if you have a project in mind.

Relieving Capacity Through Ingenuity
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Bespoke Tooling

Bespoke Tooling

We have recently designed and manufactured a bespoke Louvre tool which is being held in a press brake, customised to hold the tool. Commissioned to fabricate 10,000 sets of louvre doors on behalf of Network Rail, our Walsgrave Manufacturing facility was keen to relieve capacity by improving efficiencies.

At the outset of the project, it took 19 minutes and three men to fold 17 louvres; this was reduced to just 30 seconds. There was an incredible 70% increase in our available capacity, as well as significantly reducing the amount of handling. Therefore the cosmetic quality of parts improved greatly as well.

Call us on +44 (0) 247 636 2886 if you have a project in mind.

Supporting The Manufacture
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Castings

Castings

Our dedicated tool design supporting the manufacture of the finished part and working with a variety of partners, we can offer a full range of castings for all tooling requirements. We target the grade and choice of material to give the optimum life requirement for the finished tool.

Call us on +44 (0) 247 636 2886 if you have a project in mind.

/ QUALITY AND INSPECTION
Extensive Range of CMM equipment
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CMM Equipment

CMM Equipment

Premier utilise an extensive range of CMM equipment with the capabilities of inspecting the smallest parts to fully finished vehicles. Within the Group we have multi-tabled temperature controlled inspection areas and dedicated build tables for the detailed inspection of finished parts assemblies and fully finished bodies. Generating customer derived tailored inspection reports.

Call us on +44 (0) 247 636 2886 if you have a project in mind.

Reverse Engineering Complex Parts
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Laser Scanners

Laser Scanners

Handheld laser scanners provide a quick and effective way to inspect and reverse engineer complex parts and surfaces. They turn everyday objects into digital computer models. Soft, deformable, and complex shapes can be easily inspected – all without ever coming into contact with the part. We utilise a large range of portable laser scanning arms backed up with the latest reporting software to offer highly detailed 3D inspection reports for all parts.

Call us on +44 (0) 247 636 2886 if you have a project in mind.

Repeatability, and Reliability
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Checking Fixtures

Checking Media

All checking fixtures are designed for accuracy, repeatability, and reliability with a strong focus on operator ergonomics. Premier offers assembly and checking fixtures for body sub-assemblies and single component fixtures for all metal parts. Flush and feeler gap checking, mating part simulation and three axes true position probing. Scanning fixtures for single parts are manufactured using customer chosen net pads, master locators, and clamping arrangements.

Fixtures and Gauges available for a large variety of metal parts ranging from single Go/No-Go Handheld gauge to multiple points simultaneous pick-ups with SPC layout capabilities.

Call us on +44 (0) 247 636 2886 if you have a project in mind.

‘Right-first-time’ Approach
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Quality and Inspection

Quality Standards

Our reputation is built on the quality of the product and service provided to our clients. Our ‘right-first-time’ approach has led many to believe that we are the benchmark for the industry in Quality and Inspection.

State-of-the -art inspection equipment is employed, including CMM and laser scanning. The following Quality Standards have been achieved:

  • ISO 9000/2000
  • ISO 14001
  • Currently working towards TS16949.

Call us on +44 (0) 247 636 2886 if you have a project in mind.

/ SHEET METAL WORK
Retaining Traditional Artisan Skills
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Wheeling

Wheeling

Wheeling is the traditional artisan skill of forming 3D shapes by hand. The skill is used for wheeling one off bespoke panels that are unique in its design.

For example, it was used for for the Morgan ‘LIFEcar’ – a fuel cell-powered electric that is not only environmentally responsible but also delivers an impressive performance.During this project it took six skilled sheet metal workers over three weeks to form each panel. Some were wheeled in sections and welded together.

Call us on +44 (0) 247 636 2886 if you have a project in mind.

A Cost Effective Method to Trial a Design
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Forming

Forming

Forming or ‘chasing’ is an artisan skill of the sheet metal worker, taking a material, such as flat sheet metal and working it tight to a form. Using a chaser and hammer, it is an economical method of finishing.

For example, one of our most established customers is Johnson Controls, a world leader in the provision of world-class seat systems and components that offer safety, functionality, and comfort with proven quality. Often a one-off seat pan is formed for them, during a trial of a pan design before going into production. It is a cost effective method to trial a design without going to the considerable investment of tooling.

Call us on +44 (0) 247 636 2886 if you have a project in mind.

Retaining Traditional Artisan Skills
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Assembly Solutions

Assembly Solutions

A total manufacturing solution is available for assembly solutions, project managing your assembly with our selection of various automatic and semi automatic machines.

All our factory operatives have been fully trained on every item of assembly plant. This ensures the maintenance of a skilled and competent workforce giving greater flexibility to our resource planning and improved on time delivery performance.

Call us on +44 (0) 247 636 2886 if you have a project in mind.

A Total Manufacturing Solution
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Jointing Technologies

Joining Technologies

A total manufacturing solution is available for assembly solutions, project managing your assembly with our selection of various automatic and semi-automatic machines.

Assembly solution includes:

  • Laser Welding
  • Manual Welding including Mig, Tig, Oxy-Acetylene, and Brazing
  • Aluminium and Steel Resistance Welding
  • Self Pierce Rivets – Gantry and Pedestal
  • Adhesive Application
  • Fixing applications including Weld Nuts and Studs – Large range of tooling for the application of Impress fixings
  • Hemming – Echold Hemming and currently developing a fully robotic Hemming Cell
  • All our factory operatives have been fully trained on every item of the assembly plant. This ensures the maintenance of a skilled and competent workforce giving greater flexibility to our resource planning and improved on-time delivery performance.

Call us on +44 (0) 247 636 2886 if you have a project in mind.

 

/ PROJECT MANAGEMENT
Thoughtful Planning, Sensitive Implementation
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Change Management

Change Management

Change management is defined as ‘the application of a structured process and set of tools for leading the people side of change to achieve the desired outcome.’ It entails thoughtful planning and sensitive implementation, consultation, and involvement of all our staff. Our projects at Premier Group operate to an integrated project management process. There is an integrated change management system for every project, ensuring timely, cost effective management – on time, cost effective change management.

There is a sequence of steps that our change management team follows to apply change management to a project:

• Preparing for change (Preparation, assessment and strategy development)
• Managing change (Detailed planning and change management implementation)
• Reinforcing change™ (Data gathering, corrective action, and recognition).

Call us on +44 (0) 247 636 2886 if you have a project in mind.

An Efficient and 'Fit for Purpose' Service
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Data & Financial Control

Data & Financial Control

The data that is generated for each project is integrated within the project management system ensuring that the right data is applied to the right component and the delivery requirement of our customer. With full control of data throughout the integrated CAD system, we can guarantee our customers an efficient and ‘fit for purpose’ service.

Transparency of cost is crucial for customer confidence and in the development of long-term customer relationships. All cost implications are identified early within a project. Upon receipt of the data, we can, therefore, advise you early of any cost implication.

Call us on +44 (0) 247 636 2886 if you have a project in mind.

Integrated Time Management System
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Planning

Planning

With a well defined and integrated time management system, each of our projects aims to be completed on time and budget. At Premier Group, our system is tailored throughout all of our dedicated facilities, linking the manufacturing process to the delivery date, keeping you informed every step of the process.

Each of the steps in our process addresses a distinct area of time management in a project, namely:

• Defining Activities
• Sequencing Activities
• Resource Estimating for Activities
• Duration and Effort Estimation
• Development of the Schedule
• Schedule Control.

Call us on +44 (0) 247 636 2886 if you have a project in mind.

/ PRESS SHOP
A Flexible Press Shop
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Hydraulic Press

Hydraulic Press

At Premier Group there is the flexibility to carry out draw tool trials for stamping and engineering prior to production. Up to 500 shells per day to support BIW assembly lines can be produced.

Our Power presses range from 125 to 680 ton with a maximum bed size of 3m x 1,825m.

Call us on +44 (0) 247 636 2886 if you have a project in mind.

For Low to Medium Volume
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Mechanical Press

Mechanical Press

A small mechanical 110 tonne press for low to medium volume is retained at Premier Group. Available for all our customers, it supports the complete ‘Premier Group’ offering from small to large pressings, and compliments our other activities and disciplines, enhancing our capacity to deliver the broadest range of component types.

Call us on +44 (0) 247 636 2886 if you have a project in mind.

Rapid Prototype & Low Volume Production
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Rubber Press

Rubber Press

One of the few 5000 tonne rubber presses left in the UK is retained at Premier Group. It is utilised for the manufacture of rapid prototype and low volume production parts – a cost-effective solution for the long term manufacture of bespoke parts.

As an example, the press is employed to produce the front wings of Austin Healey’s Frog Eyed Sprint. Predominantly used in the aerospace industry, it can be utilised by most other industries.

Call us on +44 (0) 247 636 2886 if you have a project in mind.

Multi-axis For Folding Numerous Jobs
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Press Brake

Press Brake

We’ve recently installed a multi-axis Amada press brake with 4-meter bending length capabilities and a maximum force of 220 tonnes. As well as the ability to programme offline, the press brake also boasts an automatic crowning system which allows for the automatic compensation of deflection during the bending cycle and ensures that the produced bend angle is constant along the bend length.

With a multi-axis capability, it allows us to fold numerous jobs of any complexity with minimum set-ups. This increases the efficiency which in-turn allows us to take on more projects as throughput is increased.

Currently, the press brake is being used in the production of radiator housings for Modine Manufacturing Company, a variety of parts for the Morgan 3-wheeler, and fuel tanks for various vehicles.

Call us on +44 (0) 247 636 2886 if you have a project in mind.

/ LASER
The World's Fastest 2D Laser
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2D Laser

2D Laser

A large investment has been made in a state-of-the-art 2D Prima Syncrono – a radically innovative machine for the very fast and accurate cutting of sheet metal beyond 1,000 holes per minute. It represents a giant leap forward in the evolution of laser machines and provides further evidence of our commitment to a long-term investment programme.

The Syncrono utilises a compact server. This allows the fully automated ‘feed and cut’ of sheet material (negating the need for operatives to touch and potentially damage the material).

This is the world’s fastest 2D laser, with off-line programming and nesting. A good example of its capability was the manufacture of the 2012 Olympic and Paralympic torch where 100 million holes needed to be cut in 6 months.

Call us on +44 (0) 247 636 2886 if you have a project in mind.

At the Cutting Edge of Laser Welding
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laser welding

Laser Welding

At Premier Group we are at the forefront of laser welding technology. We were one of the first organisations to offer high volume 3D butt welding solutions, no-one else, to our knowledge, has successfully completed 3D laser welding for production solutions – developing the component and the jigging. Initially developed and implemented for the engineering and manufacturing of the 2012 Olympic Torch, we now have the expertise and application experience to deal with any project.

Applications have also been developed to mitigate/eliminate conventional MIG welding for component joining solutions. As an example, work is being undertaken with Modine to develop a method for attaching dual thicknesses of material by ‘through welding’ – eliminating MIG welding and improving speed, accuracy, repeatability and the aesthetic presentation. There is no need to introduce different metals, no weld stress and you re eliminating the heat effected zone.

Call us on +44 (0) 247 636 2886 if you have a project in mind.

The UK's largest laser cutting facility
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3d Laser

3D Laser

Our customers have ever increasing expectations, and we continually challenge ourselves to develop new and innovative solutions. To this end, the right tools are required to complete the tasks. With more than 10 years of experience in 5 axis laser cutting, we have invested in off-line programming generated by Cenit/Catia.

Investments have been made in brand new state-of-the-art machines, such as our 3D Prima Optimo, which is the largest 3D laser machine (bed size up to 4.7 x 2.5m) and is mainly used in car body manufacturing and in the aerospace industry. This versatile laser tool is largely employed for prototypes, spare parts and low-medium volume production.

Call us on +44 (0) 247 636 2886 if you have a project in mind.

Profiling of Magnesium Parts
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2D Laser

Magnesium Cutting

Historically the profiling of magnesium parts is completed using five-axis CNC milling stations. With the latest generation of 3D laser cutting machines, we have developed a process for the laser profiling of magnesium parts. This development has consisted of cutting parameters that utilise multiple cutting speeds in the same program for the differing material thicknesses found with magnesium part manufacture.

The development of robust gas pressures and the management of a clean and safe working environment for working with magnesium, a potentially volatile material. This has led to an improved process rate for the profiling of magnesium parts incorporating a greater level of accuracy for completed components.

Call us on +44 (0) 247 636 2886 if you have a project in mind.

/ CAD
Cost Effective, Quality Solutions
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Tool Design

Tool Design

Our founder’s core belief is to re-invest resources back into the company; to this end, we utilise 10 CAD operating systems using CATIA V5 version 19. CATIA is the world’s leading CAD/CAM/CAE software; it gives us a broad range of integrated solutions that cover all aspects of product design and manufacture, driving enterprise competitiveness, task productivity and process improvement – it is undoubtedly the ‘Rolls Royce’ of systems.

Additionally, there is a capability of translating most other CAD systems. All systems are complimented by our team of experienced tool designers.

This allows us to offer competitive solutions such as the design and manufacture of press tools. Quality and experience allow us to provide cost-effective quality solutions.

Call us on +44 (0) 247 636 2886 if you have a project in mind.

Test Work and Engineering Analysis
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Component & Press Feasibility

Component & Press Feasibility

A component and press feasibility study is an engineering study based on test work and engineering analysis. The aim is to present to you enough information to determine whether or not your project should be advanced to the final engineering and production fabrication stage. Key components in the feasibility study are the design, production schedule, a detailed process flow sheet, consideration of environmental issues, detailed capital and operating costs estimates, and an economic model of the project.

Employing Autoform Simulation Software, all of our tool designs include spring back analysis. This enables our press tools to be machined with the confidence that the design is right first time with product realisation. At Premier Group our broad depth of experience in conducting feasibility studies will optimise the path from concept through to production.

Call us on +44 (0) 247 636 2886 if you have a project in mind.

A Total Manufacturing Solution
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Design to Manufacture

Assembly Feasibility

From concept design to manufacture of low cost multifunctional flexible jigging systems. Improving assembly geometry and giving a rapid time to market.

We offer pick and mix assembly systems to cater for the uniqueness of parts and geometry change and with the extensive use of auto CAD we design and manufacture fixtures that are functional and right first time for the application required.

Call us on +44 (0) 247 636 2886 if you have a project in mind.