KMF Group: Leading the Way in Manufacturing Automation

4 mins read

Sheet metal fabrication company KMF Group has recently invested in new technology and processes to continue to grow its capabilities and status as a leader in industry.

KMF has installed an array of Trumpf machines to support its automation transformation
KMF has installed an array of Trumpf machines to support its automation transformation - KMF Group

First founded as a Limited company in 1971 by Michael Higgins, Ken Warburton and Fred Leigh, KMF Group has now established itself as one of the largest sheet metal companies in the UK and Europe.

From its facilities in Newcastle-under-Lyme and Trencin, Slovakia, the company manufactures and delivers sub-contract sheet metal services to a wide range of leading original equipment manufacturers (OEMs). Its clients span from the EV charging and renewable energy industries, to the digital signage, HVAC and telecommunication sectors.

Describing itself as a ‘one-stop shop’ manufacturer for its clients, it offers services including CNC laser cutting, metal punching, finishing, welding and advanced assembly.

And KMF’s set-up seems to be working: the company now has sales of over £45 million, over 450 members of staff and 220,000 sqft of manufacturing facilities – all while retaining its privately owned status.

Despite this undeniable success and growth, though, KMF has still faced some challenges over the last year, as many manufacturing firms can likely relate to: “What looked like a year where we were going to have at least a consistent order book and hopefully a steady growth plan, it has been far different,” Adam Ellis, who joined KMF Group in 2011 as an apprentice and who is now the company’s Head of Business Development, told Machinery magazine.

“Changing order schedules, delays in projects and fluctuations in customer demands are just the tip of the iceberg. However, we have rode the storm well, and have thankfully, seemed to have come out on the other side with a good strong finish to the end of the year.

“Recent challenges, such as material shortages and the energy crisis, have involved uncertainty followed by huge spikes in demand, coupled with short lead times, but, thankfully, due to our continuous investments in automation keeping KMF at the forefront, we have met these demands from our customers.”

Technological investment has always been a major focus for the company, and, as of 2024, it has invested more than £10 million into automation specifically.

Through the use of automated machinery, KMF believes it can reduce factory lead times and improve the overall productivity of its manufacturing process.

“Automation is key to KMF, as it keeps our lead times to a minimum. Throughout CNC Punch and Laser we are fully automated. In our folding department, we have a number of machines which are automated, such as two Trumpf Robot Folding cells and two Salvagnini panel folding machines,” Adam said.

“Our in house powder coating plant is operated using Gema plant. It is fully automated, consisting of an in-line Oxslian pre-treatment, drying/stoving ovens and powder coating booth, all linked by a continuous track.”

As part of its continual investment in new technology and equipment, KMF Group has also recently invested in a Trumpf TruPunch 5000 S12 machine.

By operating its punching machines, Trumpf’s technology has allowed KMF to reduce its secondary processing. The machine can punch forms such as countersinks, tapped holes and louvres.

KMF Group

All of KMF's CNC machines are now automated, Adam said, so its operators simply input a programme number and, once the ‘nonstandard tools’ are inputted, the machines do the rest – from bringing the material out of the storage towers, punching the part, and then placing it onto a pallet to move onwards around the factory.

“The investment now means that we have five CNC punching machines, two with Laser combination plus a standalone laser cell of two fibre lasers. By continually reinvesting in such machines, KMF is able to be at forefront of technology and ensure we keep our lead times to a minimal,” he explained.

“We partner with Trumpf for a consistent reliable punched part that their punching machines produce. We know that we can rely on their machines to gives us the quality standard that we are looking for when manufacturing parts for our customers.”

The TruPunch 5000 S12 utilises Industry 4.0 digital solutions, which KMF Group said aligns with its continuous search for new ways to increase productivity via better information flow.

Even further, “KMF are looking to invest in software and digital systems, to streamline our processes further in departments such as sales and purchasing, with CRM systems and automatic matching systems for invoice and delivery notes,” Adam added.

“We are also looking at systems which will improve communications between ourselves and our customers, speeding up the order loading/acknowledgment process.”

INVESTING IN ITS WORKFORCE

For addressing the ongoing engineering skills challenge in the UK and beyond, Adam believes that automation in particular can help to overcome this, “But by having more complex kit, it then gives KMF other challenges such as maintaining and looking after more sophisticated kit, and then hiring the right people and knowledge to look after this kit.”

With this, KMF has prioritised finding and training the ‘right people’ for its operations, establishing its in-house apprenticeship training scheme in 2009. Since then, it has recruited and trained over 150 apprentices, typically taking on between 12-15 each year.

The company has an onsite training school and workshop, which means that apprentices can attend KMF five days a week, undertaking all learning, theory and practical onsite with no external influence.

“This is key to KMFs growth plans, as it was identified we had an ageing workforce and needed to bring younger skilled employees through the business to support it for many years to come," Adam said. “Apprentices now occupy positions such as shop floor operators, team leaders, quality, sales and even management.”

Looking ahead for 2025 and further, KMF has recently changed its strategy – now looking for strategic long-term partners, customers with a consistent demand, high volume and repeat parts.

“We want to grow with our customers, and we can do this through collaboration and investing in customer specific equipment, areas and dedicated teams of people,” Adam concluded.

“KMF are well placed for large scale transfers and would encourage anybody who currently manufactures in-house and is looking at large investments in equipment to investigate the potential of out-sourcing with KMF. We can start off small, and work through the portfolio, or even keep some of the product in-house and transfer the higher demand products.”

Adam Ellis, Head of Business Development at KMF Group.