Acorn Aluminium has strengthened its operations by focusing on the in-house manufacture of plenum boxes and louvres. This strategic shift has led to improved factory-controlled manufacturing, faster installation times, enhanced visibility, and greater control and accountability.
Factory-controlled manufacture
Managing the entire manufacturing process has eliminated reliance on external fabricators, ensuring complete control over schedules and reducing the risk of project delays. All components are produced, assembled, and quality-checked under one roof, cutting out waiting times for third-party deliveries and significantly improving turnaround times.
This approach means Acorn Aluminium can respond to design changes without missing a beat. Adjustments that might have caused weeks of delays when relying on external suppliers are now handled internally, keeping projects on track. Real-time quality inspections also prevent minor issues from becoming major setbacks, ensuring each component meets exact specifications before leaving the facility.
Streamlining logistics is another key benefit. With no need for multiple shipments between different sites, the risk of damage in transit is reduced, and costs are lowered. This tighter control over inventory and scheduling has made Acorn Aluminium more agile, allowing them to meet demanding project deadlines consistently.
Craig Key, Operations Manager at Acorn Aluminium, explains: “Previously, coordinating parts on-site or through external fabricators posed challenges, and delays from external suppliers often disrupted our schedules. By creating a dedicated working area for these products, we’ve eliminated these bottlenecks, streamlined manufacturing, and gained full oversight of production.”
“We now bring these components in, drop them in place, fix them, and wrap them back and send them out,” adds Craig.
“We have complete clarity on what’s in stock and what’s on site. This level of control allows us to respond quickly to project demands, ensuring our clients experience minimal disruption.”
Increased visibility
Increased visibility throughout the production cycle has been achieved through innovative labelling and tracking systems. These systems provide real-time insights into component status, ensuring efficient coordination across departments.
“Previously, we used marker pens for frame references, which was time-consuming and prone to errors. Our new labelling system with clear job references, colour codes, and descriptions means anyone can quickly retrieve necessary information,” Craig notes.
This enhanced visibility supports smoother workflows and ensures that production processes remain efficient as demand scales.
The acquisition of advanced machinery, including the Elumatec SBZ140 CNC machining centre and an automated saw, has significantly boosted productivity and precision. These investments have streamlined operations, reduced manual tasks, and ensured consistent quality.
“After completing the Queen’s Medical Centre project, we saw the need to expand our machining capacity. The new CNC is faster, more accurate, and automates tasks previously done manually,” Craig says.
The CNC reduces cycle times significantly, while the automated saw, integrated with design software, eliminates manual input errors. “By sending data files directly from the computer to the saw, we’ve reduced human error and sped up the cutting process,” Craig adds.
Strengthening traceability for future growth
Looking ahead, Acorn Aluminium is introducing barcode traceability to further enhance quality assurance. “Barcodes for every component will give us full traceability from raw material to finished product,” Craig explains.
This system will bolster accountability and ensure that each component’s journey through production is fully documented, paving the way for sustained operational excellence.
The move to in-house manufacture of plenum boxes and louvres at Acorn Aluminium highlights a commitment to delivering high-quality projects with efficiency and precision.
By focusing on factory-controlled processes, reducing installation times, increasing visibility, and enhancing accountability, Acorn Aluminium has set a strong foundation for future success.
“These machines have already made a clear impact, and we’re excited about the potential still to be unlocked,” Craig concludes. “With continuous collaboration between our design, operations, and production teams, we’re confident in further optimising our processes.”
Through these strategic advancements, Acorn Aluminium is well-positioned to meet the evolving demands of large-scale projects while driving future growth and innovation.
For more about Acorn Aluminium, please call 0115 928 2166, email [email protected], or visit www.acornaluminium.com.