How continuous improvement has shaped TBI Manufacturing’s expansion strategy 

Established in 1992 as a sub-contract tube bending company, TBI Manufacturing (TBI) has since evolved to offer a wide range of in-house service and sub-contract capabilities including not only tube bending but also, sheet metal forming, fabrication, machining and assembly. Having relocated to Mildenhall in 2005 to increase capacity, the business has grown to occupy three facilities and is now a major employer in the area. 

Mark Tanner, Commercial Director, joins us to elaborate on the company’s evolution, a new facility, and an ever-evolving range of capabilities. “Here at TBI we offer a diverse range of services that enable us to offer the highest level of support to our blue-chip customer base,” Mark opens. “We boast a wide variety of products, but most can be characterized as complex tubular fabrications. This can vary from a simple grab handle that you will see on a yellow goods machine cab, to a full ‘roll over protection system’ that protects the operator should a dump truck roll over. The latter requires a stringent quality management system to be in place, which we can demonstrate as an ISO:9001 accredited business, along with coded operators. 

“Other products include large tubular chassis, door frames, seat assemblies, and handrails, which are primarily supplied into the automotive, off-highway, and defense industries. With tube manipulation historically at the heart of our business, we’re committed to continuously improving these capabilities by regularly reviewing and investing in the latest tube bending technology, adding to our already sizeable suite of machines. 2025 will see the addition of another 40mm electric CNC bending machine to increase our capacity and flexibility due to increasing demands. This will reinforce our position as industry leaders in tube manipulation and ensure we remain agile to adapt to our customers’ requirements. 

“Our in-house toolroom and machining center support the manufacture of tooling, ensuring we can offer industry-beating lead times to our customer base who may require unique bend radii,” he continues. “We have a selection of saws, drills, and presses to support additional operations if required post-bending. Once produced and inspected carefully, the formed tubes are then distributed to all sites for the subsequent processes to be carried out. 

“In most cases, these tubes form part of an assembly and the next process is for them to be welded at one of our three facilities in Mildenhall. All of which have dedicated welding cells with a variety of coded operators who are trained to meet specific customer requirements. We employ more than 50 welders across the three sites, who use our in-house designed and manufactured weld fixtures to produce high quality, complex products. These assemblies will typically include a combination of manipulated tube, laser cut and formed sheet metal, and machined components. 

“Once welded and signed off by our inspectors, most products proceed to our bespoke, fully automated powder coating facility, which was commissioned in 2019 and includes a three-stage pre-treatment and powder system to ensure consistent performance and quality. In 2023 we installed an automated shot blast facility to increase our offering for particularly aesthetic products where finish is critical. Once painted, we have a dedicated assembly and packing area where additional checks and post-painting assembly operations can be carried out.” 

On the topic of TBI’s production processes, Mark explains how site investments are ensuring the business maintains its industry-leading position. “We relocated to Mildenhall in 2005 to significantly increase shop floor space and allow us to realign our manufacturing operations,” he states. “The move also enabled us to centralize our fragmented administration departments, and today, we have three facilities. Our James Carter Road facility, where our main offices are based, is the hub for tube manipulation that feeds all other sites. It also houses our NPI department, toolroom, and main inspection area with CMM facilities. This site is primarily used to weld assemblies that do not require painting and can therefore be shipped directly to customers.

“The original site on Finchley Avenue is our main goods-in area and includes dedicated welding cells, a shotblasting facility, and our automated pre-treatment and powder coating line. This facility is primarily used for welded products that require painting or an additional assembly operation post-paint. 

“Lastly, we acquired a new, state-of-the-art welding facility in 2024, which is equipped with dedicated weld bays and will become the home of our robotic welding operations as we begin our automation journey over the coming months. The site also contains a machining center and a variety of presses to support our production work, as well as allowing us to offer additional standalone services.” 

Providing great customer experience is crucial to TBI, as Mark confirms: “We pride ourselves on our level of customer service when working with customers and this is driven by the efficient processes built into our quality management system. Any new enquiries are reviewed by a cross-functional team and a full feasibility review is carried out ensuring we can achieve the customer requirements. We regularly offer recommendations to modify product designs to allow the best use of efficient manufacturing processes or reduce the tooling cost for customers based on our extensive experience. This feedback is crucial in helping our customers to reduce their costs and risks, so we share the benefit. Our dedicated quality, operations, commercial, and new project teams keep close contact with customers, and our open and honest approach has ensured those relationships continue to flourish.” 

Considering the company’s recent investments, TBI will continue to succeed in 2025 and beyond. “With the addition of a new site and significant growth from key strategic customers, 2024 was a transformative year for TBI and 2025 offers a fantastic opportunity to build on this momentum,” Mark says. “We now have the necessary infrastructure in place to support a sustained period of growth, and we’ll continue to explore opportunities with current and prospective customers. 2025 will see a particular focus on strengthening our supply chain and streamlining processes to ensure we benefit from the efficiencies aligned with our growth plans. This growth naturally creates opportunities for employee progression and personal development will remain a high priority for the board, ensuring that we upskill and develop employees as we continue to develop as a business. 

“Given the improvements made over the last 18 months, the sky is the limit for TBI moving forward,” Mark concludes. “We will continue to develop key relationships and ensure we are viewed as a trusted partner that offers insightful feedback and high-quality services. Our people will be at the forefront of this, and we’ll continue to invest in training and development to ensure we retain and recruit top talent to drive the business to new heights. Likewise, we’ll continue to review and invest in the latest technologies to support future growth and ensure operational efficiency.”  

https://www.tbi.uk.com