Manufacturing has seen remarkable advancements in technology over the past decade – but striking a balance between embracing next-generation technology and retaining traditional skills can be a challenge. Jon Higson, Managing Director at Titan Manufacturing in Dorset, explores the issues.
From AI-assisted CNC machining to robotic welding, cutting-edge innovations are transforming manufacturing, promising greater efficiency and precision. The benefits can be great – but the technology comes at a financial cost, and is not without limitations, especially when in the context of small to medium-sized enterprises (SMEs).
Titan Manufacturing, based in Weymouth, Dorset, is constantly asking where to invest; when to hold back; where the benefits are and what works best for the business and customers?
Embracing advancing technology seems like the smart choice, but Jon argues that traditional skills remain vital to delivering the flexibility, quality and affordability that customers expect. So, how do businesses like Titan strike the right balance between adopting next-generation tools and preserving and supporting traditional engineering skills?
Investing in innovation: when it makes sense
CNC machines have long been central to precision engineering, allowing for the automated control of machining tools. The challenge has always been the reliance on G-code to dictate every movement and operation. For complex components, creating or modifying this code often required external CAD/CAM systems (computer-aided design/manufacturing). This programming process takes time to master and execute. It is also unforgiving; a small error in the code could lead to waste or even damage to equipment.
But the new generation of CNC machines is a game changer. Titan specialises in CNC precision engineering as part of a full-service package. The company took the plunge last year, investing £450,000 in five state-of-the-art Hurco NC machining centres at its Weymouth facility.
Jon explained that they are incredibly easy to work with. Instead of relying on code, these machines feature ‘normal language’ programming, or conversational commands. Operators can input instructions in a more intuitive way, using menus, prompts and dropdowns on the machine’s touchscreen display, with diagrams and previews of the toolpaths further helping to reduce errors.
The models chosen by Titan enable even complex components to be programmed directly at the machine. By uploading customer models, such as DXF files, directly to the machines, Titan has virtually eliminated the need for CAD/CAM or offline programming.
Working harder AND smarter
Integrating next-generation CNC machines has unlocked huge gains. As we often produce small production runs or custom parts, rapid turnaround is essential. Reducing programming time and minimising downtime between jobs has increased production speed and output volume, ultimately boosting productivity and profitability.
As well as speeding up the ‘print-to-part’ process, the ability to program and interrogate models directly on the machine makes it easier to handle last minute design changes or customisations on the fly – another big plus.
While an older-style CNC machine can only execute as programmed – even if an error in the code meant that the machine would tear itself up in the process – the new models come equipped with smart-error detection, alerting the operator if they have asked for something that is impossible, risks damage or creates unnecessary waste.
The new CNC machines can also optimise the machining processes, further increasing productivity and reducing waste. Titan’s are equipped with sensors that monitor parameters such as temperature, vibration and tool wear, enabling proactive maintenance and helping to minimise costly downtime.
However, even given these significant advancements, Jon argues that traditional machining expertise is still important. These machines are smart – but the human ability to draw on experience, understand materials and make nuanced judgements is still vital for fine-tuning and troubleshooting.
Knowing when to wait: the limits of automation
While investing in one area may seem like a no-brainer, the equation can look quite different in other cases. For example, Titan has chosen to hold off on investing in laser welding for now, as we prefer to wait and see how the technology develops.
The advantages are numerous – laser welding offers precision, speed and the ability to create high-strength welds with minimal heat distortion, reducing the need for additional finishing. However, the initial outlay for the equipment is significant, and traditional TIG and MIG welding still outperform laser welding in many scenarios.
Titan has considered a robotic laser welding arm, but this would come with the added costs of robotic integration, maintenance and staff training. There’s also the time required to programme it – something that works well for repetitive welds, but less so for small-batch, custom production. In a business like ours, the programming effort needed for robotic welding would ultimately outweigh the benefits.
Despite technological advancements, skilled human welders continue to play a vital role in this sector. Because versatility is crucial for Titan, the company relies on its experienced team of welders, who have 100+ years’ experience between them – two have more than two decades of experience apiece. Their skill enables them to work across a variety of materials, joint configurations and project requirements, making real time adjustments as required.
The quality of welds is also critical, especially in the work Titan does for the food production sector, where flawless welds are essential. Even the smallest pinhole flaw in a join can create a refuge where bacteria can build up. To achieve that level of precision, traditional welding skills remain hard to beat.
The future is hybrid: blending tech with human expertise
Things are changing but we still need to be teaching young people the traditional engineering skills as well as moving on with the latest tech. Many of the most experienced engineers, machinists and welders have spent decades perfecting their craft and are a huge asset.
However, as these skilled professionals approach retirement, there is a growing risk of losing the essential knowledge that has long been the backbone of the industry. Ensuring that this expertise is passed down to the next generation through apprenticeships, training and mentorship is critical. Rather than waiting and relying on new technology to fill the skills gap, Titan wants to retain those traditional engineering skills, adapting them to complement advancing machinery and tools rather than allowing them to be lost.
Technology that enhances traditional skills can offer a smart middle ground. Titan’s recent acquisition of the Hexagon Absolute Arm 6-Axis is a prime example of this approach. This state-of-the-art articulated measuring arm enables high-precision 3D measurement of both small and large fabrications – up to three metres in size – with an accuracy of 80 microns. By integrating this advanced tool into workflows, Titan is empowering its engineers to work with greater precision while still drawing on their technical knowledge and judgement.
While it makes sense to invest in new tools that offer efficiency gains without excessive cost, striking the right balance is key. Next-generation technology is undoubtedly reshaping the machining and fabrication sector, but it serves as an enabler, not a replacement, for traditional skills – especially for SMEs.
Human expertise remains essential to deliver the flexibility and adaptability that clients demand. So, in the race to advance, it is important we don’t leave all our hard-won human expertise behind.
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