Advancing Quality and Capability: Weld Procedure Trials at Warren

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At Warren, we pride ourselves on continually improving our processes and meeting the evolving demands of our customers. Over the past few weeks, we’ve been undertaking a significant initiative to qualify our weld procedures. With customers now requiring greater scrutiny and standards, we recognised the need to elevate our practices.

We conducted six weld procedure tests across a range of materials:

  • Two tests on high-strength steel
  • Two tests on aluminium
  • Two tests on mild steel

The tests were carried out by our skilled team members – Russell, Mike, and Gavin, under the supervision of our responsible welding coordinator, Ben. These weren’t easy tests. The procedures were intentionally designed to be challenging to ensure a wide range of coverage for future applications. Despite the pressure, the team rose to the occasion, showcasing expertise and resilience.

Long-term benefits of qualified weld procedures

The procedures we’ve developed during these trials are now qualified and will serve as the foundation for welding work at Warren for years to come. While some gaps remain, these are less critical and will be addressed in the new year with additional preparation and practice.

Here’s how these new procedures will enhance our capabilities:

  • High-strength steel procedures: these enable us to manufacture a frame capable of holding a Pearl 15 jet engine. They also position us to attain the DIN 2303 Q2 certification, expanding our work in the defence sector. With this certification, we anticipate a steady stream of work through 2030 and beyond, providing the business with long-term stability.
  • Aluminium procedures: these ensure we remain equipped to handle critical projects such as the SeaTow 500 winches, EN 1090 aluminium welding for clients like Tech Grocer, and other aluminium projects, including Daycraft. They also prepare us for future large-scale jobs, like a potential new aluminium project for Tait.
  • Mild steel procedures: by filling gaps in our existing library, these procedures allow us to specify requirements upfront, ensuring clarity and efficiency before jobs hit the shop floor. This proactive approach will save time and resources while improving overall quality.

Streamlining and accessibility

With these procedures now qualified, the next step is to document and integrate them into our workflow. They will be easily accessible on job cards and through Warren Web, ensuring our team can quickly find the information they need to maintain consistency and quality.

A team effort worth celebrating

This milestone wouldn’t have been possible without the dedication and skill of Russell, Mike, Gavin and Ben. Their hard work and commitment to excellence have set us up for success, and we’re deeply grateful for their efforts.

As we look to the future, these weld procedures not only solidify our position in the industry but also open doors to exciting new opportunities. Thank you to everyone involved for making this a success. Here’s to a stronger, more capable Warren!

Building a skilled workforce: how Warren is supporting the next generation

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A skilled workforce is the cornerstone of every successful business. Yet, navigating how best to collaborate with education providers to develop future-ready skills can be a challenge. We’ve partnered with the University Technology College Norfolk (UTCN) and The Education Landscape to create a unique and impactful resource for 3D printing.

Innovation through collaboration
In collaboration with UTCN, we provided the college with a cutting-edge 3D printer to enhance their educational resources. We also worked alongside Andrew, a dedicated student at UTCN, to bring the college’s existing 3D printers back to full functionality. By ensuring these tools are operational, we’re enabling students to use them for future projects.

This collaboration is more than just about technology – it’s about building bridges between education and industry, ensuring students are equipped with the skills they need to thrive in their careers and tackle real-world challenges.

Why supporting education matters
For businesses like Warren, engaging with education isn’t just an investment in the future workforce – it’s a chance to inspire the next generation of thinkers, makers, and innovators. Supporting teachers and students with practical resources and mentorship helps to close the skills gap, keeping industries like ours at the forefront of technology and creativity.

Get involved: download the free guide
Feeling inspired to make a difference? Head to educationlandscape.org.uk to download the FREE Guide and Index.

Find out more here and in the video below.

 

A Milestone in Our Journey Towards Innovation and Sustainability

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At Warren, we are thrilled to share the latest development in our ongoing commitment to innovation and sustainability. We recently had the honour of welcoming Chris Starkie from Norfolk County Council (NCC) to officially open our new laser cell. This event marks a significant milestone in our company’s history and showcases the collaborative efforts that drive progress in our industry.

A major investment in cutting-edge technology

The new laser cell represents Warren’s largest single investment to date, totaling £1.5 million. The project has been a long-term vision brought to reality, and it is only through the generous support of Norfolk County Council’s grant of £100,000 that we were able to achieve this ambitious goal.

Partnership with Norfolk County Council

Our collaboration with NCC has been instrumental in the realisation of this project. As part of our application for the grant, we worked closely with NCC on a comprehensive decarbonisation plan. This plan not only justified our investment but also aligned with our commitment to sustainable practices.

Creating jobs and opportunities

The benefits of this investment extend beyond technological advancements. We are proud to announce that the establishment of the new laser cell has already enabled us to employ seven new staff members. Among these are four apprentices, who represent the future of our industry. By providing these young professionals with the opportunity to learn and grow within our company, we are investing in the next generation of engineering talent.

Supporting the transition to Net Zero

This project is part-funded by Norfolk County Council through the Business Transition to Net Zero Scheme. This initiative is designed to support businesses in their efforts to reduce carbon emissions and transition to more sustainable operations. At Warren, we are committed to playing our part in this vital global effort.

You can learn more about the Business Transition to Net Zero Scheme and how it supports businesses like ours in achieving sustainability goals. For more information, please visit this link.

Thank you to Chris Starkie and Norfolk County Council for their invaluable support.

Our Boys in Brazil

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Nick Claydon, our Technical Department Supervisor and Rob Jones, our Mechatronics Degree Apprentice, embarked on a mission to install a state-of-the-art Kawahara TXS Blanking system in the heart of Brazil. Their objective was to revolutionise in-mould label (IML) production and equip operators with the tools they need for success.

As Nick and Rob set foot in Brazil, they brought with them not just machinery, but their expertise. Their goal was clear: to empower operators and elevate production standards – and judging by the smiles on everyone’s faces, it’s safe to say they succeeded. The operators were thrilled with the new system, recognising its pivotal role in enhancing their IML production capabilities.

But this success story goes beyond mere machinery installation. It’s a testament to Blankmaster’s commitment to excellence and their unwavering pursuit of innovation. In choosing Kawahara, Blankmaster reaffirmed their dedication to quality and efficiency in IML production – a decision that has paid dividends in South America and beyond.

With four Kawahara machines now operational in South America, Blankmaster’s footprint in the region continues to expand. But the question remains: where to next? As Gary Compton ponders this exciting prospect, one thing is clear: the sky’s the limit for Blankmaster and their journey with Kawahara.

Meanwhile, ANC Machinery, the proud manufacturer behind the Kawahara brand, stands as a beacon of innovation in the blanking machinery industry. Specialising in machinery for processing die-cut sheets of cartons, cards, labels, and IML, ANC Machinery’s commitment to excellence shines through in every product bearing the Kawahara name.

As Blankmaster’s success story unfolds in South America, it serves as a testament to the power of partnership, innovation, and unwavering dedication to excellence. With each new installation, each new triumph, Blankmaster and Kawahara pave the way for a brighter future in IML production—a future limited only by imagination and ambition.

Empowering the Next Generation: A Day of Mentorship at West Suffolk College

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West Suffolk College reached out to our organisation for assistance in nurturing the talents of their Level 2 welding learners. Recognising the opportunity to contribute to the development of future engineers, Gavin Bidwell, one of our skilled welders, eagerly stepped forward to share his wealth of experience and expertise on Wednesday, 6th March.

As Gavin walked through the doors of West Suffolk College, he carried with him a passion for passing on knowledge to future engineers.

The ripple effects of this day extend far beyond the walls of West Suffolk College. By investing in the next generation of talent, we not only enrich individual lives but also strengthen the our industry as a whole.

As we reflect on this inspiring day of mentorship, let it serve as a reminder of the profound impact we can have when we extend a helping hand to those following in our footsteps. Together, we can cultivate a brighter future for the world of engineering – one weld at a time.

Positive Feedback

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In recent months, Warren encountered a significant challenge in manufacturing the V95T hopper and framework for our esteemed customer, Bucher. While this product has been in production for some time, this marked the first occasion we undertook its manufacture in-house, presenting our team with new obstacles to overcome in order to meet delivery requirements.

The hopper attached to the V95t aero project

Just days prior to the scheduled delivery of the initial assembly, we received word that, due to circumstances beyond our control, we would need to produce a second hopper and framework using a different material, and within a significantly tighter timeframe to assist Bucher in resolving a critical situation. This project impacted every facet of our operation, necessitating seamless communication, unwavering teamwork, and unwavering dedication to meet the challenge.

Throughout the process, the lead buyer at Bucher maintained close communication, providing support and guidance every step of the way. Upon completion, the leadership team at Bucher expressed their utmost satisfaction with the outcome. They shared their appreciation with the following statement:

“Just wanted to thank you all for your combined efforts and endeavours throughout both stages of the V95t aero Project. It is testament to all of your hard work that you managed to achieve delivery of the final items for the 2nd build, namely the Hopper, Subframe & Engine Frame Panels, by today (only 4 days beyond the challenging target date you were given).”

We extend our heartfelt gratitude to everyone involved in rallying together to deliver this remarkable project. With this success under our belt, we eagerly look forward to tackling the next challenge that lies ahead. Onward and upward!

The Laser Cell Floor: Paving the Way for Innovation

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Exciting developments are on the horizon as we gear up for the installation of our new laser in February/March. As we embark on this journey towards enhanced capabilities and cutting-edge technology, we want to keep you all in the loop about the remarkable preparations taking place behind the scenes. Today, let’s delve into the meticulous groundwork that has gone into strengthening the foundation for our upcoming laser cell.

Groundwork and tower automation: a huge task

Preparing for the installation of our new laser involved reinforcing the ground works to support the tower automation, a crucial component with load points of up to 40 tonnes. This meant that our dedicated ground workers were hard at work over the Christmas period, diligently digging a hole nearly one metre deep. Thank you to those of you who took proactive measures to cover the machines, recognising that the process was not without its share of noise and dust.

Concrete progress: layer by layer

The efforts put into place during the Christmas break bore fruit upon our return. The first layer of concrete was expertly poured into the carefully excavated space, setting the stage for a robust foundation. A week later, the second layer was added, solidifying the groundwork laid by our team. This critical phase of the project required precision, patience, and collaboration, and we are pleased to report that everything is progressing seamlessly.

A note of appreciation

We extend our heartfelt appreciation for the team’s understanding during this period of intense groundwork. Their cooperation has been instrumental in ensuring the success of these preparations. We understand that the noise and dust might have presented some challenges, and their positive attitude and flexibility have not gone unnoticed.

Stay tuned for more updates as we eagerly anticipate the arrival of our cutting-edge laser in the coming months.

Aluminium for Thetford Academy

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Thetford Academy asked us to supply essential material for a special school project. With Year 8 students set to embark on an exciting endeavour, the Academy urgently required small aluminium pieces to create innovative bottle openers and stylish key fobs. The Academy recently showcased the finished articles at their recent Open Evening and they kindly provided some photos of the finished articles.

 

 

 

Sneak Peek into the Testing of 10 Mini Whirly Reelers!

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We have an update to share with all our WhirlyReeler enthusiasts. Recently, one of our esteemed clients granted us permission to capture video footage of the testing phase for their ten new ‘mini’ WhirlyReelers. It provided us with an opportunity to observe these compact devices in action and showcase their capabilities.

Through these collaborations, we aim to continually explore innovation and deliver advanced solutions to our valued customers.