Training the next generation of engineers is at the top of the agenda for Velocity Composites
In line with its core mission to reduce operational costs for customers, Velocity Composites (Velocity) provides supply chain optimization and engineered raw material kit manufacturing designed to minimize all forms of waste in the composites supply chain. Today, the company stands as the leading supplier of composite material kits for aerospace and other high-performance manufacturers. Oliver Smalley, Chief Operating Officer, discusses how Velocity operates.
“Based on a fantastic business model, our unique selling point lies in our flexibility; we are not tied to any specific raw material or provider, allowing us to accommodate different customer needs across the whole composite supply chain. We deliver value by utilizing our market-leading processes and software, which we designed and optimized in-house. These processes and software controls optimize the entire supply chain, from long term raw material planning through to kit manufacturing and logistics, enabling us to manage all aspects of the front-end composite manufacturing process for our customers. This in turn allows our clients to focus on aerospace part manufacture, safe in the knowledge that whatever their operational plan requires, the raw material kits will be available in a lean and efficient form. As a result, we not only enhance raw material yield but also reduce process waste in all forms, which aligns with both commercial and ESG strategies, while delivering to customers a reduced total cost of manufacture. For our aerospace composite products, we apply an innovative packaging solution which matches the sequence of build for our customers, with all necessary parts for each build step in a separate packaging to preserve product integrity. In addition to the structural materials that form the finished item, Velocity also applies the same logic to the process materials that are consumed during the part manufacturing at our customers’ sites. These are all manufactured to reduce material waste, standardize the build process and reduce process waste to reduce costs to our customers whilst reducing build times and part to part variation.
“As every part we supply is different, some projects feature straightforward products, some products are more complex and the build processes for our customers are more intricate and labor-intensive. By pre-manufacturing the kits, Velocity substantially reduces customers’ labor time and material waste. In addition, its strong relationships with materials suppliers enable it to take away the onerous task of managing the supply chain with its long lead times. Simply put, customers communicate the number of products they plan to manufacture in the future, and the company delivers the corresponding kits.”
To further enhance its value to customers and drive further efficiencies, Velocity has recently developed a fully digital in-house manufacturing cell, which can be replicated across all sites. “We are cutting numerous and complex products from materials whilst maintaining full batch traceability, and our digital manufacturing cell allows us to campaign larger nests across multiple kits/customers where specifications allow,” Oliver explains. “Additionally, it allows the rapid sorting and reallocation of these long and mixed nests back into individual kits in real time without any loss of traceability. As the raw materials have a short ambient shelf life the digitization of the entire process allows us to manufacture kits utilizing optimum material batch selection and produce the kits in the minimum time so that the shelf life is both tracked and preserved. Managing their lifespan is vital to delivering in accordance with our service level agreements and providing customers with sufficient life to complete their own manufacturing processes before the part is finally cured. To deliver this level of accuracy the digital manufacturing cell employs a unique code for each individual ply, coupled with a pick-to-light system to accurately track plies and materials from the start to the end of the process. To stand out to our customers, we must continue to develop processes and technology that is not available on the open market so we can deliver excellent service and value, which is exactly what the digital manufacturing cell enables us to achieve and verify.”
Alongside this technology, Velocity is dedicated to investing in education and recruitment, a cause that is incredibly important to Oliver. “We work closely with Burnley College, which is based in Lancashire and boasts a fantastic engineering infrastructure. Having worked as an engineer prior to my current role, engineering is something I hold close to my heart and is the foundation that this business is built on. As such, I believe it is essential, especially in the UK, to ensure that valuable engineering skills are not lost so we can be at the forefront of technology-driven manufacturing. Historically, Britain has faced challenges in both developing and retaining skilled engineers, but the situation is slowly improving. Education in engineering and manufacturing helps massively in addressing this shortage, as do T-Levels since they provide both academic knowledge and hands-on experience. The team at Burnley College work hard to help students transition into the manufacturing industry. Recently, we interviewed several T-Level candidates from Burnley College for placements at Velocity, and the successful individuals will join us shortly. This partnership gives them a real taste of the working environment while allowing us to assess talent in a real environment. Additionally, I have a colleague named Ethan who entered the workforce through the T-Level route. He completed his placement at a different company, but he was so impressive that I took him on as an advanced apprentice when a position became available at Velocity,” he continues.
In terms of recent projects, Velocity has won a significant renewal and expansion contract with an Airbus supplier, which is not only a great endorsement for the company but for the British manufacturing industry as a whole. “We’ve been awarded a significant contract that requires us to service the -900 and -1000 programs for the A350 platform, including additional sub packages. We are incredibly proud of this achievement as it helps maintain employment within the UK in this important sector. There has been an ever-evolving trend in our industry where much of the work is being relocated to lower cost manufacturing overseas, posing significant challenges for UK-based operations. Our continued investment in people, processes, and technology allows us to remain competitive in a global market and support our customers in ensuring that work remains in the UK.
“Historically, in my career I have seen a cyclical pattern where work can move away and then return, often because overseas manufacturers struggle to cope with the demand and technical requirements. It is an interesting topic as both the civil aerospace and defense sectors are growing within the composites sector, and aviation is on an upward trajectory due to growth and continued rate recovery. However, this growth has not yet fully reached the SME market in the same way it has benefited larger OEMs, and I believe it is crucial for this positive trend to cascade down to SMEs within the UK and for the SMEs to be ready. This contract award is a sign that confidence is growing, and as there are opportunities emerging, we must ensure that we are prepared to retain this work within the UK,” Oliver ends.