This high dedication to training is part of the company's programme to develop its own in-house production skills to meet future plans and maximise the gains from the latest developments in manufacturing technology that continues to be established on the site.
Says director Wayne Thomas: "To ensure our long term success in the type of work we are undertaking, our company must have advanced processing capabilities to perform the tasks and be very cost-effective in its operation. This means as we continue to invest in the latest technology machine tools, equipment, systems and software, this also applies to the people required to manage and operate them."
Mollart Engineering has progressed to become a key supplier to demanding sectors such as the semiconductor industries, medical, defence, sub-sea, metrology, nuclear, and oil and gas following an investment of some £4 million over the last three years.
Thomas adds: "It is now our objective to enhance our existing skill base with younger people to create a highly motivated and knowledgeable production team that will span all ages and is willing to transfer skills and expertise to enable the business to develop as a high technology-based sub-contract operation."
Mollart has 13 apprentices at Resolven, 11 of them machinists, plus four at the Chessington headquarters, each undertaking three years of training. In addition, a further three from Chessington are post graduates now working on special projects. A further post graduate Howard Mitchell won the AMTRI Scholarship from the MTA in 2013.
Says managing director Guy Mollart: "The types of high technology equipment we have installed can be quite challenging and sometimes daunting for a young person to have responsibility to set and operate, but I am totally supportive of pushing them forward. As a result, we have found with careful training and guidance, and working closely with them to build their skills, they quickly appreciate how rewarding manufacturing and engineering can be."
Already well advanced second- and third-year apprentices are creating some of their own programs, selecting and setting tools and even operating high value and complex machinery such as a Mazak Integrex, a Mazak VTC800 and a Doosan DNM 4-axis machining centre. By working alongside older, more experienced skilled people, both parties are benefitting. Says Thomas: "You should see the pride in their faces when they stand back and realise what they have achieved and especially when they are complemented with a 'well done'."
A key element in Mollart's development programme is apprentice training and project engineer Liam Jeffreys. As an ex-apprentice who progressed in the automotive industry as a production line team leader and project leader machine setting, he joined Mollart seven years ago. He initially worked at Chessington for a year to develop his gundrilling and deep hole machining experience before moving back to South Wales. Three years ago he was asked to help train Mollart's first two apprentices as machinists and worked with Thomas to create a platform where apprentices could gain all the benefits from a true machinist training schedule embracing all the main areas of production.
Now part of the shopfloor at Resolven is an area designated as a training zone but which is kitted out with production machines, into which normal batch-type work is being scheduled. This work, plus test pieces, is produced on a newly installed Mazak (01905 755 755) Quick Turn Nexus 250-ll MY 4-axis turning centre, a Takisawa 3-axis lathe (available from Rockwell Machine Tools: 01527 522211), a DMG Mori Seiki (0247 651 6120) 4-axis turn-mill centre, a Haas (01603 760539) 4-axis machining centre and an inspection area with a portable 3-D measuring arm from Romer (available from Hexagon Metrology: 01952 681300) .
Mollart has also established a strong relationship with nearby Neath Port Talbot College's (NPTC) School of Engineering, one of the largest further education providers in Wales. NPTC is also involved in the selection by Mollart of suitable apprentices drawn from students with minimum GCSEs of maths, english, science and computer skills. These potential apprentices then have to progress through two interview stages which is then followed with the NPTC setting pre-enrolment tests.
The apprentices on Year 1 learn about health and safety issues and basic machine operating skills; they learn how to read and interpret a drawing; and carry out basic machine tool setting and operating tasks. At NPTC, they start a foundation apprenticeship that lasts for two years bringing them up to a semi-skilled status (Level 2). In Year 2 they progress into workholding, fixture design and build, and they begin programming and setting machines on the Resolven shopfloor. They also have the added benefit of attending courses set by certain suppliers, such as those providing tooling and coolants to the firm, and take part in team building courses. In the third year, Mollart brings everything together and really starts to develop the setting skills. They are involved with more complex machines including the Wenzel (01527 582830) CMMs in the quality department, clean-room assembly and work on SolidWorks CADCAM (available from New Technology CADCAM: 01844 295235). The third year apprentices have also attended programming courses this year at Mazak UK and are now working on challenging materials as diverse as aluminium, titanium, Inconel and stainless steels.
At NPTC they are working towards the Advanced Diploma in Engineering Level 3 and are assessed on-site and are working towards completion of the NVQ Level 3 Extended Diploma in Mechanical Manufacturing/Engineering.
Concludes Thomas: "What is interesting is the way our skilled setter/operators have responded to how these young people have taken to their tasks. In addition to providing all the help they can, some have requested to have more advanced training themselves to widen their skill base, which is a great motivator to help progress the business."
