News: AIE signs production order with The Proving Factory

Engine designer Advanced Innovative Engineering (AIE) is partnering with the innovative Proving Factory initiative that will see the production of the first in the series of AIE's modern Wankel rotary engines.

The £22m government-backed manufacturing initiative aims to bridge the gap (or "Valley of Death") between small enterprises developing leading edge low carbon technology and large vehicle manufacturers. It is jointly located in Rotherham and in Coventry.

Tata Steel is the key partner in establishing The Proving Factory alongside industry experts, Productiv Limited, and as part of the programme, which is backed by Government funding, a component manufacturing facility is being created at Tata Steel's site at Brinsworth. The Proving Factory has been using 1,000 sq m of leased space at Newburgh Precision at Templeborough on an interim basis for its component manufacturing operation, while the facilities are completed nearby.

AIE joins other developers of technology including Bladon Jets, Flybrid, Torotrak, Drive Systems Design, Libralato and Magnomatics.

The AIE partnership is one of the first examples of the work to get products into production. Wankel rotary engines inherently operate at very high revolutions per minute (rpm), generating a lot of heat in their cores. While high temperatures are essential for offering the best operating efficiency and in turn the best fuel consumption, this heat then needs to be safely managed and dispersed. AIE engines are unique in that they use an innovative cooling design, which applies both mechanical and thermodynamic processes to reject heat effectively. The main design challenge is achieving both precision and smoothness on the surfaces and contours of core components that are subjected to high thermal, chemical and fatigue stresses, during operation.

AIE's initial orders are from an R&D end-user of unmanned surface vehicles (USVs) in the marine sector and a systems integrator developing a ruggedised hybrid motorcycle. Both of these orders are for the first in a series of ultra-compact rotary engines. There is also interest from the automotive industry and discussions are ongoing for the supply of an engine in a high-performance sports car. The first units will be produced at The Proving Factory for delivery this autumn and since the company's manufacture and assembly is completely scalable, production can be rapidly increased or decreased to reflect the market need.

The Proving Factory is supporting AIE by using the latest design computer numerical control (CNC) milling machines and tooling, together with computer-aided manufacturing (CAM) software and skilled operators, to enable high-quality machining of components.

Nathan Bailey, managing director of AIE, said: "From initial engagement with The Proving Factory through to the on-going joint manufacturing, assembly and commercial activities that have been undertaken to date, AIE has benefited hugely from the experience, expertise and enthusiasm of the team. In particular the continued manufacturing support we've received has enabled AIE to push its technology further, faster, while focusing and strengthening its core competencies both technically and commercially. We look forward to building this relationship further as we commercialise our technologies into the broader market with the support of The Proving Factory."

Richard Bruges, co-founder of The Proving Factory and chief executive of Productiv, added: "AIE's design has real potential for a range of low-carbon applications and we are excited about being its production partner on this technology. The UK is truly reclaiming its heritage as a manufacturing nation, with so many promising new technologies being designed here. Historically moving these prototypes to products has been challenging for one-off developers, with little financial backing, but The Proving Factory is increasingly proving itself as the missing conduit between the stages."

The Proving Factory website
AIE website

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News: Tata's two year timetable

Tata Steel will relocate all its UK-based research and development within two years, including moving away from the Swinden Technology Centre (STC) in Rotherham.

This week saw an agreement signed between Tata Steel and the University of Warwick which marks the next stage in the creation of a new UK research and development centre for Europe's second largest steelmaker.

The STC mainly focuses on product research and applications research for the transport, building and construction sectors but Tata considers that it is no longer a suitable home for the R&D arm and announced that it is relocating research to Warwick University last year.

The Warwick Manufacturing Group (WMG) announced in March it is establishing a £20m Advanced Steel Research Centre at the university with the backing of Government funding.

The first step will be the opening of a research facility at the university this autumn where more than 40 Tata Steel scientists will be based.

Within two years, Tata Steel will relocate all its UK-based R&D specialist equipment, including electron microscopes, to expanded facilities at the university where a range of new materials will be developed to meet customers' future demands, such as for renewable energy generation and more fuel-efficient cars and planes.

Karl Koehler, chief executive of Tata Steel's European operations, said: "This development will allow us to work with world-class scientists and researchers to create new steels for customers who are shaping the low-carbon technologies of tomorrow.

"Our new UK R&D facilities will enable us to speed up the development of new products that help our customers become more competitive."

As part of the consultation on Rotherham's local plan, Property consultants, Harris Lamb, on behalf of Tata Steel, has put forward potential residential development at the Moorgate site.

Rotherham will still be the location for the manufacture of speciality steel and for the Proving Factory - a £22m government-backed manufacturing initiative will take low-carbon vehicle technologies designed by small high-tech British companies and university research departments and prove their viability in production to increase their chances of being adopted by major motor manufacturers.

The Proving Factory will consist of two facilities: component manufacturing at the Tata Steel site at Brinsworth, and an assembly facility in the West Midlands, providing employment and regeneration.

The Indian-owned steelmaker has this week reported a write down of £500m mainly relating to the Long Products UK business in Tata Steel Europe which will now be fully impaired. A write down reduces the book value of an asset if its is overstated compared to current market values. It follows a review of goodwill, plant and property before its audited financial results are published next week.

Tata Steel website

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News: Magnomatics on show at The Proving Factory launch

Magnomatics, a Sheffield-based manufacturer of energy-efficient products based on ground-breaking magnetic gear technology, is receiving a boost through the innovative Proving Factory initiative.

Part of Tata Steel's Brinsworth site in Rotherham will house a new component manufacturing facility as part of the £22m government-backed manufacturing initiative that aims to bridge the gap (or "Valley of Death") between small enterprises developing leading edge low carbon technology and large vehicle manufacturers. It is jointly located in Rotherham and in Coventry, where the assembly facility was officially opened for business last month.

Led by industry experts, Productiv Limited, working closely with Tata Steel, technology will be developed by Bladon Jets, Flybrid, Torotrak, Drive Systems Design, Libralato and Magnomatics.

Magnomatics was founded in 2006 by a group of engineers from the University of Sheffield. Since then the team has grown to over 30 staff. The company is active in many market sectors, including automotive, renewables, marine propulsion, aerospace and oil & gas.

David Latimer, chief executive of Magnomatics, showcased the magnetic gear, which uses permanent magnets to transmit torque between an input and output shaft without mechanical contact, to dignitaries attending the recent launch of the project, including business secretary Dr. Vince Cable.

Magnomatics became an official production partner of The Proving Factory in September 2014 for its MAGSPLIT power split which is currently being evaluated by a number of global automotive customers.

Latimer (pictured, right), said: "Our relationship with The Proving Factory has continued to develop and is a vital element in the commercialisation of our technology. We were really pleased to be invited to attend the official opening of the business, to demonstrate one of our market leading products to the invited guests and particularly to business secretary Dr. Vince Cable. It really was an exciting day for everyone concerned."

Magnomatics' products use powerful permanent magnets to replace traditional mechanical meshing gears in a gear box. MAGSPLIT is particularly suited to hybrid and electric vehicles and magnetic gears have been shown to be more efficient and reliable than the "planetary" gearboxes used in hybrid engine systems.

Magnomatics website
Proving Factory website

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News: Official launch for The Proving Factory

Business Secretary, Vince Cable MP has performed the formal opening of The Proving Factory, an innovative partnership between Tata Steel and high-tech companies in the automotive supply chain.

The £22m manufacturing initiative will take low-carbon vehicle technologies designed by small high-tech British companies and university research departments and prove their viability in production to increase their chances of being adopted by major motor manufacturers. It is jointly located in Rotherham and in Coventry, where the assembly facility was officially opened for business last week.

Tata Steel is the key partner in establishing The Proving Factory alongside industry experts, Productiv Limited, and as part of the programme, which is backed by Government funding, a component manufacturing facility is being created at Tata Steel's site at Brinsworth. The Proving Factory is currently using 1,000 sq m of leased space at Newburgh Precision at Templeborough on an interim basis for its component manufacturing operation, while the facilities are completed nearby.

The Proving Factory initiative was launched by Dr Cable exactly two years ago, in February 2013, after receiving funding from the Advanced Manufacturing Supply Chain Initiative (AMSCI). It now has a 6,000 sq m site in Coventry where the engineering and systems assembly operations are located, and the 1,000 sq m component manufacturing facility in Rotherham, housing state-of-the-art machine tools. More than fifty people have been recruited so far, with this number set to increase to 250 over the next four years.

Technology is being developed by the likes of Bladon Jets, Flybrid, Torotrak, Drive Systems Design, Libralato and Magnomatics and the project aims to bridge the gap (or "Valley of Death") between small enterprises developing leading edge low carbon technology and large vehicle manufacturers.

"Proving volumes" of 10,000-20,000 units a year will be produced and support will be given in moving to higher volumes through the traditional first-tier supply chain. Nine technologies have now gone through the development stages, with two due to start production this quarter. The range of products being handled by The Proving Factory reflects the fact that there isn't just one solution to the challenge of developing new low-carbon powertrain technologies, rather a whole suite of options are needed to address different duty cycles and applications.

Business Secretary Vince Cable (pictured, left), said: "When I visited this site two years ago I was standing in an empty shed, talking about a great idea. Now with £13 million support from government that idea has been transformed into state-of-the-art machines, new jobs and a host of technologies that will help produce the next generation of low carbon vehicles.

"The government's industrial strategy is backing the automotive sector as it goes from strength to strength, giving business the confidence to invest over the long term and helping to develop cutting-edge technology that will create high-skilled jobs."

Richard Bruges, chief executive of Productiv (pictured, right), added: "The whole team, from our engineers to our technology developers, has worked tirelessly over the last two years to make The Proving Factory vision a reality. I would like to thank everyone involved for their hard work and thank the Minister and the Department for Business for their support so far.

"With tight emissions regulations levied on both the UK and the EU, vehicle manufacturers are under increasing pressure to make their products cleaner and more eco efficient than ever before. But we know that there is no one solution to this challenge. We have a team of experts in place who can make an informed decision on which technologies might form a part of a greener automotive industry and the facilities and skills to turn them into products."

Henrik Adam, chief operating officer at Tata Steel, added: "The Proving Factory, as well as supporting the development of new technologies for the automotive industry, is setting a bench mark for more efficient production processes as well as leading to the design of novel materials.

"As an organisation we pride ourselves on working closely with the automotive industry and its associated supply chain, both in the UK and further afield, to provide the support and services they need to create the vehicles the consumer wants. The Proving Factory is a brilliant example of this response to market needs and we are proud to be a part of it."

Images: The Proving Factory

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New: Newburgh Precision expands apprentice training school

Newburgh Precision Ltd, the high-tech precision engineering sub-contractor with a facility in Rotherham, has expanded its apprentice training school and invested in new equipment, doubling in size, due to the new intake of apprentices.

With apprenticeships at the heart of the business, Newburgh celebrated its 75th year in 2014 and decided to split its two sites, Rotherham and Bradwell, into two separate businesses.

Newburgh Precision at Templeborough has unrivalled expertise in machining precision components. It specialises in manufacturing "cells" that include dedicated groups of resources operated by a team of multi-skilled individuals that are committed to producing a product or products for one customer. Newburgh's customers come from the UK and around the globe, in the nuclear, defence, oil and gas, petrochemical, aerospace and power generation industries.

Part of the 85,000 sq ft Rotherham facility is currently being used by The Proving Factory, the £22m manufacturing initiative that will take low-carbon vehicle technologies designed by small high-tech British companies and university research departments and prove their viability in production to increase their chances of being adopted by major motor manufacturers.

Newburgh Precision are currently training six 2nd and 3rd year students with Newburgh Engineering in Bradwell currently having three 2nd year students. In addition Newburgh Precision are collaborating with The Proving Factory's component manufacturing operation to train eight 2nd year apprentices through its own apprentice training programme.

Due to the increased intake Newburgh Precision has added more machining resources, going from from 11 to 16 with three new centre lathes and two vertical milling machines.

Currently the apprentices have undergone initial training at the AMRC Training Centre on the Advanced Manufacturing Park (AMP) in Rotherham and have joined the business to continue their learning to NVQ level 3 and beyond. All the apprentices are taking a multi path apprentice framework including extra CNC and manual units in milling, boring and turning enabling them to have a greater understanding of basic engineering principles.

A further six Tata Steel / The Proving Factory apprentices we will be on the Newburgh Precision site from the AMRC Training Centre in July 2015 after completing their first year training. A possible new intake of Newburgh apprentices is in the pipeline in the summer of 2015.

David Greenan, ‎managing director at Newburgh Precision, said: "The Newburgh Apprentice Scheme has seen our apprentices win national awards and we are proud to have been chosen by The Proving Factory to train their component machining apprentices."

Today, the company employs 148 employees (20% of which are current apprentices) over the two facilities. Around 90% of Newburgh staff are apprentice-trained, including all management right up to the present managing director, David Greenan. Its turnover has grown to over £11m - an impressive feat during a recession.

Newburgh Precision website

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News: Newburgh provides proving ground for Proving Factory

The Proving Factory, an innovative partnership between Tata Steel and high-tech companies in the automotive supply chain, is leasing space from Newburgh Precision in Rotherham so it can gear up for production.

The £22m manufacturing initiative will take low-carbon vehicle technologies designed by small high-tech British companies and university research departments and prove their viability in production to increase their chances of being adopted by major motor manufacturers.

Tata Steel is the key partner in establishing The Proving Factory alongside industry experts, Productiv Limited, and as part of the programme, which is backed by Government funding, a component manufacturing facility is being created at Tata Steel's site at Brinsworth in Rotherham and is set to open in 2015.

The Proving Factory will use 1,000 sq m of leased space at Newburgh Precision at Templeborough on an interim basis for its component manufacturing operation, while the facilities are completed nearby. Newburgh Precision was chosen for its expertise in machining precision components and its knowledge and reputation in best working practices in areas such as health and safety, IT systems and staff recruitment.

In its 75th year, Newburgh Engineering decided to split its two sites, Rotherham and Bradwell, into two separate businesses.

Newburgh Precision, which has also been selected as a strategic supplier to the Proving Factory, utilises manufacturing cells in Rotherham, dedicated groups of resources operated by a team of multi-skilled individuals that are committed to producing a product or products for one customer.

A number of state-of-the-art machines will be delivered to The Proving Factory's interim component manufacturing facility over the next few months, including two Mazak mill turn machines, a Fanuc Robodrill and the latest Studer grinding machine. This cutting-edge technology will provide The Proving Factory with the specific range of capabilities it needs to meet the demanding specifications required for the development of low-carbon vehicle technologies.

The ten apprentices taken on to work at The Proving Factory are also set to join Newburgh's renowned training programme after undertaking initial training at the AMRC Training Centre.

David Greenan, managing director at Newburgh Precision, said: "Newburgh Precision has a healthy order book in its own right and we have been recruiting and investing in new equipment at our Rotherham facility to support this growth. This relationship with The Proving Factory will continue this development and add new technology and processes into our working practices.

"Our works manager, Nick Andrew, has been carefully selected by The Proving Factory to take the role of operations lead in this relationship, a fantastic opportunity for him and the business to work closely with this innovative initiative."

Mark Broxholme, managing director of Tata Steel's Speciality Steels business said: "We have worked hard to plan our development and growth as The Proving Factory's component manufacturing volumes increase towards our target of four million components over the next decade. This new interim site allows us to get started with component development and manufacturing as quickly as possible, while achieving the most efficient combination of required space and cost.

"We are very much looking forward to moving into our new home this month, and are positive our new site and the support of Newburgh Precision will give us the capability we need to support the delivery of the initial pre-production components and assemblies by the end of this year."

Technology is being developed by Bladon Jets, Flybrid, Torotrak, Drive Systems Design, Libralato and Magnomatics and the project aims to bridge the gap (or "Valley of Death") between small enterprises developing leading edge low carbon technology and large vehicle manufacturers. "Proving volumes" of 10,000-20,000 units a year will be produced and support will be given in moving to higher volumes through the traditional first-tier supply chain.

Proving Factory website
Newburgh Precision website

Images: Newburgh

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News: Proving Factory gears up for production

The Proving Factory, an innovative partnership between Tata Steel and high-tech companies in the automotive supply chain, has taken on interim premises, in order to start developing the technologies of tomorrow, today.

The £22m manufacturing initiative will take low-carbon vehicle technologies designed by small high-tech British companies and university research departments and prove their viability in production to increase their chances of being adopted by major motor manufacturers.

Tata Steel is the key partner in establishing The Proving Factory and as part of the programme, which is backed by Government funding, a component manufacturing facility is being created at Tata Steel's site at Brinsworth in Rotherham and is set to open in 2015.

Industry experts, Productiv Limited has invested £3m in a 6,000 sq m factory in Coventry where the assembly operation will be located, while Tata Steel has signed a contract to lease a 1,000 sq m engineering facility in South Yorkshire, to house state-of-the-art machine tools due to be installed and commissioned by the end of July for The Proving Factory's component manufacturing operation.

The Brinsworth site will still be the permanent home of The Proving Factory's component manufacturing operation and this interim site nearby has allowed component development and manufacturing to begin as quickly as possible, with the right amount of space for the size of the current operation.

Mark Broxholme, managing Director of Tata Steel's Speciality Steels business, said: "We have worked hard to plan our development and growth as The Proving Factory's component manufacturing volumes increase towards our target of four million components over the next decade. This new interim site allows us to get started with component development and manufacturing as quickly as possible, while achieving the most efficient combination of required space and cost.

"We have moved significantly closer to manufacturing readiness over the last couple of months, having now machined the first components to go into one of The Proving Factory’s technologies. We are very much looking forward to moving into our new home this month, and are positive our new site will give us the facilities we need to support the delivery of the initial pre-production components and assemblies by the end of this year."

Richard Bruges of The Proving Factory consortium and chief executive of Productiv, added: "These new facilities give The Proving Factory a home, with ample space for growth. We are well on our way to the project vision becoming reality.

"There is a lot of work to be done over the next year or so, but we have a brilliant team of dedicated automotive and production engineers already on board, and we are continuing to recruit outstanding people to help build the future of sustainable British automotive manufacturing."

Technology is being developed by Bladon Jets, Flybrid, Torotrak, Drive Systems Design, Libralato and Magnomatics and the project aims to bridge the gap (or "Valley of Death") between small enterprises developing leading edge low carbon technology and large vehicle manufacturers. "Proving volumes" of 10,000-20,000 units a year will be produced and support will be given in moving to higher volumes through the traditional first-tier supply chain.

In-house pre-production trials are expected to commence in August 2014, with production of the first advanced technologies to begin in January 2015.

Proving Factory website

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News: Progress at The Proving Factory

The Proving Factory, an innovative partnership between Tata Steel and high-tech companies in the automotive supply chain, has completed the first phase of development and established the blueprint for helping to develop the technologies of tomorrow.

Tata Steel is the key partner in establishing The Proving Factory and as part of the programme, which is backed by Government funding, a component manufacturing facility is being created at Tata Steel's site at Brinsworth in Rotherham and is set to open in 2015.

The £22m manufacturing initiative will take low-carbon vehicle technologies designed by small high-tech British companies and university research departments and prove their viability in production to increase their chances of being adopted by major motor manufacturers.

Led by industry experts, Productiv Limited, working closely with Tata Steel, technology will be developed by Bladon Jets, Flybrid, Torotrak, Drive Systems Design, Libralato and Magnomatics. Design reviews are currently taking place for each of the partners, which has allowed experts to develop concepts for product development, component manufacturing and systems assembly.

The project centres on technologies with the "potential to transform the vehicles of tomorrow" and aims to bridge the gap (or "Valley of Death") between small enterprises developing leading edge low carbon technology and large vehicle manufacturers.

Recruitment began last year with nine apprentices beginning their training at the state of the art AMRC Training Centre in Rotherham. It is envisaged that 250 direct new jobs will be created directly within The Proving Factory, whilst 1,000 more will be generated throughout the engineering and manufacturing supply chain.

The second phase of the project has now begun. This year, work will take place to refine The Proving Factory systems-assembly and component-machining strategies, complete the supply chain development and confirm and deploy a structured Design Verification Planning tool. The production facilities are then set to be completed production of the initial technologies will begin.

Productiv and Tata Steel, believe that the Proving Factory component manufacturing will have capacity of up to four million components, and an assembly capacity of up to 200,000 systems. The component manufacturing facilities will be housed in a purpose-built facility in Rotherham, equipped with around 100 state of the art production machines.

A second assembly facility is to be situated in the West Midlands and technologies being taking to the market include drive systems for hybrid cars and gear boxes that use powerful magnets to replace meshing gears.

Richard Jones, project manager at The Proving Factory, said: "Having achieved more than we had planned in 2013 we are now driving towards commercial reality. 2014 has already started in a positive way and I cannot help but think that the fact that it has been so well received already is evidence of how important the project's premise is to UK manufacturing – bridging the gap between technology developers and manufacturers."

Tata Steel will be demonstrating innovative applications of its bar products being brought to market through The Proving Factory at this year's wire fair in Dusseldorf, Germany, where two of the six technologies will be on show.

The Proving Factory website

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News: £8m to keep Tata Steel's R&D in Rotherham for now

Tata Steel is to boost its research and development programme in the UK following an £8m Regional Growth Fund investment from the UK Government.

The investment will allow researchers at Europe's second largest steelmaker to develop next-generation steels for cars, aircraft, rail networks, skyscrapers, mining equipment and power stations.


The Indian owned steelmaker said that the RGF-funded research will initially take place at Tata Steel's R&D facility in Rotherham, but added that "the company is currently considering where the research will continue over the longer term with a possible relocation to a different UK site in the future."

Reports surfaced again last year that Tata Steel intends to close the Swinden Technology Centre (STC) on Moorgate in Rotherham. The Sunday Times claimed that Tata had warned the Government that it intends to close two technology centres, in Rotherham and on Teeside adding that it would move the research to the Netherlands and India.

Tata rubbished the reports but said today that it is now in discussions with a number of business partners to transform its Teesside research centre into a not-for-profit, open-access shared facility.

The new £8m in funding will see scientists and engineers develop a range of materials to meet manufacturers' and consumers' future demands, such as for renewable energy generation and more fuel-efficient cars and planes.

The Regional Growth Fund is the Government's main source of funding for economic development and regeneration. The aims of the fund are to create jobs, encourage private investment and support areas dependent on the public sector.

Dr Karl Koehler, chief executive of Tata Steel's European operations, said: "This investment will strengthen our UK programme of cutting-edge research allowing us to develop new materials and applications to help our customers overcome their challenges, now and in the future.

"Our solutions contribute to our customers' innovative new products, such as more fuel-efficient vehicles and sustainable buildings. The Regional Growth Fund investment will support research projects which are key to us developing new customer solutions."

Tata Steel is the key partner in establishing The Proving Factory – an innovative partnership with high-tech companies in the automotive supply chain to help develop the technologies of tomorrow. As part of the programme, which is also backed by Government funding, a component manufacturing facility is being created at Tata Steel's site at Brinsworth and is set to open in 2015.

The £22m manufacturing initiative will take low-carbon vehicle technologies designed by small high-tech British companies and university research departments and prove their viability in production to increase their chances of being adopted by major motor manufacturers.

Debashish Bhattacharjee, R&D group director at Tata Steel, said: "We are strengthening our Research & Development in the UK to further develop technology and knowledge partnerships with customers, suppliers, and universities.

"We want to meet the future demands of our customers who are asking for lighter, stronger and more versatile steel products. Car manufacturers, for instance, are constantly looking to produce lighter and more fuel-efficient vehicles. Cutting-edge innovation plays a crucial role in helping us to create world-leading differentiated products and services for customers like these."

Tata Steel website

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News: Tata Steel outlines its importance to UK's rebalanced economy

Tata Steel, the Indian-owned steelmaker with significant operations in Rotherham, has set out the importance of "Foundation Industries" to the UK economy and called on the Government to help them capitalise on the economy's return to growth.

In a report commissioned by Tata Steel, PricewaterhouseCoopers (PwC) challenges many existing perceptions about Foundation Industries to emphasise the role they play in driving innovation and skills, as well as providing nearly half a million jobs and supporting millions of others.

It classifies the Foundation Industries as those which supply materials to multiple, strategic manufacturing and construction supply chains, such as steel producers, chemical companies and other mineral producers. They accounted for about 30% of the UK's exported goods in 2012. Turnover is close to £69bn per year which is 3% of the UK economy as a whole.

A key point for rebalancing the UK's economy is that many of the jobs in these industries are outside London and the South East. In 2012, nearly 31,400 businesses employing 487,000 people formed the Foundation Industries in the UK. The proportion of the total workforce employed in the Foundation Industries in 2012 was highest in Yorkshire and the Humber, where 3% of employment in UK's Foundation Industries were based.

Secondary steelmaking accounts for much of this with just over 2,000 people employed at Tata Steel in South Yorkshire where sites including Stocksbridge and Aldwarke specialise in the production of high grade and special steels for the world's leading companies in markets ranging from automotive to aerospace, civil engineering to component manufacturing, energy industries to consumer goods.

The report also highlighted how sectors such as automotive, aerospace and construction are important buyers from Foundation Industries and how they have a significant multiplier impact on the UK economy through local supply chains, which is as high as six times in terms of employment.

As well as highlighting the impact on employment and GVA, the report highlights ways in which Foundation Industries are taking steps to ensure that they can compete successfully on the global stage. Tata Steel's involvement in the Proving Factory is used as a case study.

Part of Tata Steel's site at Brinsworth in Rotherham is being converted into a component manufacturing facility for The Proving Factory, a £22m government-backed manufacturing initiative that will take low-carbon vehicle technologies designed by small high-tech British companies and university research departments and prove their viability in production to increase their chances of being adopted by major motor manufacturers.

Over the next five years, the Proving Factory is expected to invest over £10m in machine tools and assembly fixtures; manufacture over four million components and employ 270 people of whom 100 will be apprentices; at the same time as increasing efficiency of electric vehicles and supporting the low carbon economy.

Following the publishing of the report, Karl Koehler, CEO of Tata Steel's European operations, called for urgent action to nurture Britain's Foundation Industries with the appointment of a single minister to champion the sector in government and the creation of a level playing field on key issues such as energy policy.

Energy costs remain a significant element of the costs of the Foundation Industries with evidence that they are higher than those facing competitors operating in other countries. The report highlights the risk that relatively high energy costs will adversely affect the competitiveness of Foundation Industries in the UK as well as that of their potential customers. This will impact negatively on UK firms' ability to compete in both domestic and overseas markets and deter foreign investors.

Mr Koehler warned: "This report makes clear how important Foundation Industries are to the UK.

"Much of the cutting-edge innovation seen in parts of British manufacturing and construction in recent years wouldn't have been possible without home-grown Foundation Industries working hand in hand with them.

"If the Government is serious about rebalancing the economy and creating sustainable jobs in the regions, it must recognise the importance of the UK's Foundation Industries.

"We're not asking for hand-outs but we deserve a level playing field and an equal seat at the table."

Tata Steel website

Images: Tata Steel Europe / twitter

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News: Proving Factory takes on nine new apprentices

Nine apprentices, who will start work at The Proving Factory's component manufacturing facility when it opens in 2015, have started on a three-year mechanical-manufacturing engineering course at the The University of Sheffield Advanced Manufacturing Research Centre (AMRC) with Boeing's training centre in Rotherham.

The Proving Factory, a £22m government-backed manufacturing initiative will take low-carbon vehicle technologies designed by small high-tech British companies and university research departments and prove their viability in production to increase their chances of being adopted by major motor manufacturers.

The Proving Factory will consist of two facilities: component manufacturing at the Tata Steel site at Brinsworth, and an assembly facility in the West Midlands, providing employment and regeneration.

The AMRC Training Centre is nearing completion on the Advanced Manufacturing Park (AMP) and the first cohort of 150 apprentices recently began their employer-led training, concentrating on sectors such as aerospace, energy and Formula One.

The Proving Factory's new apprentices will take part in a three-year, high-value machining course, which will provide them with all the skills they need to support the set-up and production process at the component manufacturing facility on Tata Steel's Brinsworth site.

Following a year's training at the AMRC, which includes modules specifically related to The Proving Factory, the apprentices will work closely with Tata Steel in the second year at Brinsworth, and by the third year will be working in the facility. They will also play an important part in supporting pre-production commissioning, ensuring the facility will be ready for full operation in September 2015.

Jacob McNeill, apprentice at The Proving Factory, said: "The training that we are receiving is excellent and the trainers are very friendly. I am really enjoying the projects, they are very interesting.

"The workshop and the facilities are really good. I feel that I made the right decision in taking up this apprenticeship, and am confident that the skills I'm learning will stand me in good stead for supporting the exciting work of The Proving Factory."

Skills and Enterprise Minister Matthew Hancock added: "These apprentices have been given a great opportunity to train in an outstanding facility. The AMRC Training Centre will give them the chance to learn the basics required to become a skilled engineer.

"Following their initial training, the apprentices will be able to continue their learning whilst working with Tata Steel before moving on to The Proving Factory in 2015. I would like to wish the apprentices luck as they take their first step into a new and exciting career."

Led by industry experts, Productiv Limited, working closely with Tata Steel and other advanced manufacturers and technology developers, the project centres on technologies with the "potential to transform the vehicles of tomorrow."

Funded under the Government's Advanced Manufacturing Supply Chain Initiative, it aims to bridge the gap (or "Valley of Death") between small enterprises developing leading edge low carbon technology and large vehicle manufacturers.

Richard Jones, project manager of The Proving Factory at Tata Steel, said: "The Proving Factory supports the automotive industry by bringing the latest low-carbon vehicle technologies to volume production, using state-of-the-art manufacturing and assembly processes.

"The key to our success will be training the talented young people needed to fill these highly-skilled manufacturing roles. We look forward to supporting our new recruits through their courses, and to welcoming them into The Proving Factory when we start volume production in 2015."

Proving Factory website
AMRC Training website

Images: Proving Factory

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News: Proving Factory up for innovation award

The Proving Factory, a £22m government-backed manufacturing initiative with a base in Rotherham, has been shortlisted for the UK Society of Motor Manufacturers and Traders' (SMMT) annual Award for Automotive Innovation.

Part of Tata Steel's Brinsworth site in Rotherham will house the new component manufacturing facility as part of The Proving Factory that aims to bridge the gap (or "Valley of Death") between small enterprises developing leading edge low carbon technology and large vehicle manufacturers.

It will take low-carbon vehicle technologies designed by small, high-tech British companies and university research departments and prove their viability in production to increase their chances of being adopted by major motor manufacturers.

Led by industry experts, Productiv Limited, working closely with Tata Steel, technology will be developed by Bladon Jets, Flybrid, Torotrak, Drive Systems Design, Libralato and Magnomatics.

The Award showcases the UK's capabilities in automotive design and engineering by identifying exceptional innovations that have the potential to transform the industry.

Richard Jones, Proving Factory project manager at Tata Steel, said: "Our work in the Proving Factory is already beginning to show how Tata Steel, Productiv and our other partners can be a driving force in bringing low-carbon vehicle technologies to market. To have reached the shortlist of these awards is something the whole team can be proud of, and we look forward to the next round."

Richard Bruges, chief executive of Productiv, added: "The Proving Factory concept is a vital initiative in filling a gap in the automotive industry. This has already been recognised by the Department for Business, Innovation & Skills in the industrial strategy, and we are delighted this has now been recognised at industry level too, through these prestigious awards."

The winner will be announced at the SMMT Annual Dinner on November 26.

Proving Factory website

Images: Sterecycle

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News: Magnomatics joins The Proving Factory

Magnomatics, a Sheffield-based manufacturer of energy-efficient products based on ground-breaking magnetic gear technology, has been announced as the sixth technology developer to join The Proving Factory.

Part of Tata Steel's Brinsworth site in Rotherham will house the new component manufacturing facility as part of The Proving Factory, a £22m government-backed manufacturing initiative that aims to bridge the gap (or "Valley of Death") between small enterprises developing leading edge low carbon technology and large vehicle manufacturers.

Led by industry experts, Productiv Limited, working closely with Tata Steel, technology will be developed by Bladon Jets, Flybrid, Torotrak, Drive Systems Design, Libralato and now Magnomatics, who were announced as the newest member at Cenex LCV2013, the UK's premier low carbon vehicle event.

Magnomatics was founded in 2006 by a group of engineers from the University of Sheffield. Since then the team has grown to over 30 staff. The company is active in many market sectors, including automotive, renewables, marine propulsion, aerospace and oil & gas.

Magnomatics' products use powerful permanent magnets to replace traditional mechanical meshing gears in a gear box. It has joined The Proving Factory to prove the viability in production for its MAGSPLIT power split device that is suited to hybrid and electric vehicles.

Chris Kirby, managing director of Magnomatics, said: "Membership of The Proving Factory is assisting us in engineering our products for cost effective manufacture in automotive volumes. The future ability to supply in quantities of up to 20,000 units p.a. for introduction fleet evaluation is welcomed by our clients."

Richard Bruges of The Proving Factory consortium, and chief executive of Productiv, said: "We are delighted to welcome Chris and the Magnomatics team to The Proving Factory. Magnomatics is a classic example of the innovative low-carbon vehicle technologies The Proving Factory initiative seeks to support, and we look forward to developing this technology, and those of all our other developers, through pre-production in 2014 and on to proving volume production for vehicle manufacturers in 2015."

Magnomatics website
Proving Factory website

Images: Magnomatics

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News: Rotherham expertise on show at low carbon vehicle event

Project partners from Rotherham working on pioneering research will showcase their work this week at Cenex LCV2013, the UK's premier low carbon vehicle event for showcasing new technology and networking.

Rotherham will be home to The Proving Factory, a £22m government-backed manufacturing initiative that will take low-carbon vehicle technologies designed by small high-tech British companies and university research departments and prove their viability in production to increase their chances of being adopted by major motor manufacturers.

Part of Tata Steel's Brinsworth site will house the new component manufacturing facility as part of the initiative that aims to bridge the gap (or "Valley of Death") between small enterprises developing leading edge low carbon technology and large vehicle manufacturers.

The Proving Factory will be taking over the whole of Hall One at the exhibition being held at Millbrook Proving Ground in Bedfordshire. The Proving Factory's founders, Productiv and Tata Steel, and investing partners MIRA and MTC (part of the High Value Manufacturing Catapult), will be joined by the technology developers: Bladon Jets, Flybrid, Torotrak, Drive Systems Design, Libralato. Other supporting partners include Jaguar Land Rover, Schaeffler, the Advanced Manufacturing Research Centre (AMRC in Rotherham) and the Midlands Assembly Network.

The event will also see Magnomatics, a Sheffield company specialising in the development of energy efficient technologies, named as the newest addition to The Proving Factory. A high-technology spin-out company formed in 2006 from the internationally renowned research group in Electrical Machines and Drives at the University of Sheffield, Magnomatics develops and delivers novel proprietary magnetic transmissions and ultra compact and efficient motors and generators for some of the world's largest multinationals and is active in a range of industries, including automotive, renewable energy, aerospace, marine and defence.

The Niche Vehicle Network will also be represented at the event where it will be showcasing the results of a number of R&D projects. This includes the £100,000 ELCOMAP (Environmentally friendly lightweight composite materials for aerodynamic body panels) project researching the potential alternatives to composite technologies currently in use such as carbon fibre and epoxy resin systems. The technology has the potential to revolutionise the production of low volume specialist components for high performance vehicles.

Project partners include a number of firms based on the Advanced Manufacturing Park in Rotherham - Performance Engineered Solutions (PES) Ltd, TEKS UK Ltd and the University of Sheffield Advanced Manufacturing Research Centre (AMRC) with Boeing.

The Niche Vehicle Network will also be announcing the winners of its 2013 Niche Vehicle R&D Competition.

Cenex LCV website
Proving Factory website

Images: Cenex LCV

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