Automotive & motorsport
the physical injection moulding process, with 60 per cent of all the materials that come into Johnston Sweeper’s factory on a three to four-day delivery cycle. “Although we have what
looks to be a big factory, it is limited in warehousing space,” adds Hurst. “One of our key objectives is to work with our suppliers to hold the stock and we call it in regularly.” Putting into context the
volumes, Hurst emphasises that each vehicle produced on-site only requires a maximum of six filler caps. By operating a Kanban system,
Broanmain provides a weekly line- side delivery to the Dorking factory, topping up shelves. This arrangement negates the need for Johnston’s to monitor stock levels, including after-sales spare parts. Broanmain’s most recent
that required strength and ABS (acrylonitrile butadiene styrene) for the ascetics components.” Further production trials and
analysis by Johnston Sweeper’s Quality Control team affirmed the project’s viability, with Broanmain overseeing all aspects of the tool development. Hurst estimates that switching from aluminium to plastic for these caps has reduced the part cost by half.
Since then, Broanmain has
helped convert more than 30 metal parts to plastic, among them a complex suction water outlet integral to the road sweeping operation that previously cost £50 per metal part and required extensive welding and powder coating. Being just a stones throw from
Broanmain’s injection moulding facility has also proved beneficial to
development is a holster for the pendant that enables a driver of a sweeper to walk outside of the cab and operate the machine to lift and tip the body. “The switch to plastic has been a
slow development over the past decade,” ends Hurst. “Where we see the opportunity for plastic we will use it. And as we move more into all electric vehicles and zero emissions, lightweighting will become increasingly imperative.”
Broanmain Plastics
www.broanmainplastics.co.uk
Below:The tooling for this latest component - a door controller - was designed by Broanmain, produced in China and is made at the Dorking mould shop to meet short cycle delivery times
Left: Broanmain physically monitors stock levels and provides a weekly Kanban line- side delivery to the Dorking factory
Instrumentation Monthly February 2019
47
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