DVD is one of the most important events in the defence diary for companies involved in the equipment support and sustainment for the UK’s Armed Forces.

Our stand at DVD will showcase our innovative Extralite torsion bar upgrade for the Warrior & CVR(T) Defence vehicles which met an Urgent Operational Requirement for the Ministry of Defence. The Extralite torsion bar helped achieve a significant improvement in suspension performance, and the Tinsley Bridge contribution was widely recognised by UK Government ministers, the MOD and receipt of industry innovation awards.

DVD takes place at Millbrook Proving Ground for DVD on 20th and 21st June 2012.

Millbrook was purpose-built more than 40 years ago and has evolved into one of the most comprehensive test and development facilities available to the world’s transportation industries, making it the ideal location for DVD.

Torsion bar

The Smart programme provides grant assistance to R&D projects in strategically important areas of science, engineering and technology, from which successful new products, processes and services could emerge.

The Tinsley Bridge project will focus on developing technically innovative suspension components for customers in the automotive, rail and defence industries – a sector in which the Group enjoys a reputation for innovation and technical strength.

Tinsley Bridge has recently launched several new products using a new high performance steel, Extralite – a technology which has been widely recognized by industry innovation and manufacturing awards.

Responding to the Technology Strategy Board decision, Mark Webber (Managing Director, Tinsley Bridge) commented, “The need for innovation in our sector has not reduced – in fact, given the economic situation, it is greater than ever. Innovation is a key enabler of growth, and this is central to Sheffield retaining a sustainable manufacturing capability. The Smart programme will help us develop the competitive advantage in our products to a new level.”

As part of the Smart project, Tinsley Bridge has teamed up with Sheffield Hallam University’s Materials and Engineering Research Institute. MERI is a dynamic interdisciplinary research institute dedicated to addressing industrial problems through the application of fundamental science and engineering.

Mark continued: “MERI have a highly successful track record applying cutting edge research to find innovative solutions to industry problems, and we will benefit from their experienced team and world leading research facilities. This award will allow us to get new products to market more quickly, and accelerate the pace of innovation in the future. We strongly believe that stimulating technology-enabled innovation offers the greatest scope for boosting UK jobs and productivity.”

Suspension

Speaking at the end of National Apprenticeship Week, Mr Webber, who is managing director of the Sheffield-based Tinsley Bridge Group, said engineering and manufacturing was at the heart of Sheffield’s history and the legacy that will be handed on to the next generation.

“In order to ensure we have the right skills to continue to grow and develop our industry, it is vital, especially in the current environment, that companies invest in the talent and potential that we have in the region,” he added.

Tinsley Bridge’s apprentices include 19 year old Sam Bishop praises the company’s scheme.

“When I first started I was really welcomed into the team at Tyzack, and I felt that I was seen as being able to contribute rather than simply assisting on small tasks,” said Sam.

“Working alongside the other apprentices is great, as we can help support each other through the process. We’re not just stuck out on our own though – the people here know their stuff and help you and watch over you to make sure we are doing it right and are safe, without you feeling they are constantly over your shoulder.”

Tinsley Bridge Apprentices

“I am a trained engineer and have worked within heavy industry all my working life. Discovering that I had a passion for oil painting in my mid forties was a surprise to me and my family.

“Even more of a shock was how my efforts have been received, as I have exhibited at the Great Sheffield Art Show on a number of occasions now.

“Ten years ago I was on holiday in Cornwall and walked passed an art shop that had a postcard in the window that stopped me in my tracks. It was The Singing Butler by the Scottish artist Jack Vettriano.

“The shop was closed but my wife and I went back and I ended up buying it. On returning home I purchased a small canvas and some acrylic paints as well as a book to read up about painting techniques.

“I found out Jack Vettriano was a miner who then became an artist. He was self taught, so I thought if a miner can do it a steel man can.

“Interestingly enough, the panting came out well and my wife encouraged me to persevere. A decade later I have discovered a great way to de-stress and am now deep into a consuming and fulfilling hobby.

“In the last decade, I have concentrated on copying paintings by Jack Vettriano and Mark Spain, both well-known and whose paintings sell for thousands, but now I feel confident enough to develop some subjects of my own.

“I am learning Adobe Photoshop and have just renovated a Gentry kit car (a replica of a 1953 MGTF). So I am putting together a computer canvas of a woman sat inside a French café window and have used a photograph of my car parked outside the café window in order to paint my own composition.

“I paint at home and also when visiting my caravan on the East Coast, sitting in the doorway that overlooks fields and a fishing pond. I am known there now and sometimes I find it difficult to progress with paintings as so many people come and chat. I tend to produce up to three a year and now paint in oils. I have even sold some of my copies.

“I had great satisfaction from a recent visiting Australian relative. I had showed him a book of Vettriano’s work one of which depicted Donald Campbell’s Bluebird land speed car. He said how much he liked the subject and colours. Before his nine-month stay in the UK expired I presented him with one I had painted specifically for him.

“I think perhaps my engineering training, and my time as a draughtsman, that requires accurate drawing, has helped me develop a skill for copying.

“I never let my painting become a mission or a chore. If I am not in the mood I walk away and come back when I want to. It’s a pleasure and a pride to see my finished work that mostly adorns the walls of my home and those of my family and friends.”

Published in the Yorkshire Post – 20/03/12

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NAMTEC and the AEM Innovation Network also assisted the Tinsley Bridge Group in exploring new market opportunities for their high performance and light-weight Extralite™ steel components in the wind energy sector.

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Tinsley Bridge Group was delighted to be amongst the victors at the city’s annual Business Awards, winning the Wake Smith Excellence in Manufacturing Award, in a year of record entrants. Comedian and impressionist Jon Culshaw hosted the glittering awards ceremony on behalf of Sheffield’s Chamber of Commerce. Over 1,000 people from all sectors of the business community gathered at Ponds Forge International Sports to celebrate the region’s achievements.

Mark Webber, Managing Director, of Tinsley Bridge Group, said: “Manufacturing is the backbone of Sheffield’s heritage. For an independent manufacturing company like ours that has experienced the highs and lows of this industry for over a century, we are immensely proud to be recognised in this way. This award is recognition for the amazing team we have from the shop floor to the boardroom who have worked hard to help us grow, develop and adapt.

“The Award assesses excellence in product innovation, manufacturing efficiency and people investment. Tinsley Bridge-owned Tyzack Machine Knives has also been commended for its contribution to the clean-up operation following the Deepwater Horizon oil spill. The Group’s vehicle suspension division worked with the Ministry of Defence, along with its prime contractor BAE Systems, to develop a suspension upgrade to the British Army Warrior Infantry Fighting Vehicles currently deployed on the front line in Afghanistan. The improvements to the defence vehicle suspension were completed within a short lead-time and to budget, and have already protected troops from IED strikes in Helmand.”

Wake Smith Excellence in Manufacturing Award

Mark Webber, Managing Director of Tinsley Bridge Group said: “We’ve proved over the years that we have the ability to use innovation to create margin and enter new markets. We are prepared to take risks, invest in technology and back the ideas of our employees.”

The production of blades by the Tyzack Machine Knives arm of the group was a key part of the capping of the Deepwater Horizon oil pipe following the BP oil disaster in 2010, and torsion bars made by Tinsley Bridge using Extralite™ steel, a new high-strength material, were fitted to the British Army Warrior Vehicles currently deployed in Afghanistan.

The judging panel felt that the Group’s products were “integral” in fixing the oil spill, and in its life-saving solution for the military “demonstrates the company’s strength in innovation”.

Whilst the blades capped the pipeline and prevented further billions of pounds worth of damage and environmental effects from taking place, the torsion bars have been helping to save the lives of soldiers from IED attacks.

Previous awards include:
BAE Systems Bronze Chairman’s Award 2010 for the CVR(T) Suspension Upgrade.

The oil spill in the Gulf of Mexico was the largest accidental marine oil spill in the history of the petroleum industry. When the rig exploded, the riser pipe connecting the rig to the seabed well head remained attached.

The pipe needed removing as quickly as possible so the well head could be capped, but this required expert machinery as the steel pipe was 350mm in diameter and beneath one mile of
sea water.

It was Tyzack Machine Knives’ technology which was brought in for the job.

Technical director David Owens said: “A piece of equipment called the Genesis XP was used. It’s the most powerful shear cutter in the world and the engineers working in America specified that only Tyzack shear blades are suitable for the extreme cutting the machine is designed to do.”

The Genesis XP, fitted with the Tyzack blades, and a full hydraulic power pack were lowered into the sea. Via an internet video link-up, engineers all over the world were able to watch as the Tyzack blades cut through the pipe and enabled the capping off process to proceed.

David said: “Tyzack Machine Knives is a globally-recognised brand and we’re proud that our expertise was used to bring this disaster under control. We’ve got more than 65 years of experience and plenty of specialist knowledge so we’re glad our skills could be drawn upon to help out during this crisis.”

View BP Oil Spill Case Study

This has been noted by Minister for Defence Equipment and Support, Peter Luff, who has said: “Warrior vehicles are doing a tremendous job in Afghanistan and these numerous improvements are already proving their worth in theatre. This vehicle is extremely versatile, offering good mobility and high levels of protection for its crew. It also allows troops to get out into communities safely, maintain areas and provide reassurance to the local population.”

BAE Systems approached Tinsley Bridge to see if there was a way to develop the vehicle suspension and raise the ride height of the vehicle at its increased protection weight. Limiting vehicle suspension component changes and within a very tight timescale the objective was to maintain mobility whilst significantly reducing the impact of land mines.

In a development project between the two companies, a new high-strength steel, Extralite™, was proposed to replace the standard steel suspension torsion bar. The steel was initially developed by Tinsley Bridge for use in high strength leaf springs where the steel was used mainly in ‘tension’.

Development and testing of the torsion bars was completed in less than 5 months; a time frame which included extensive field trials conducted by the Army. This urgency for the project was dictated by the requirement to improve the mobility of the armoured personnel carriers, as their ongoing deployment necessitated an almost immediate upgrade.

The vehicle now features improved cross-country mobility, ride and handling to work at its best in the challenging Afghan terrain, and the extra height also improves crew protection from mine blast. The Extralite™ steel used is now part of a patent application made by the Group.

The Warrior is a specialist tracked infantry vehicle and so can get to places that wheeled vehicles cannot, enabling the troops to deploy more effectively in difficult terrain.

Image: Trevor Sheehan/BAE Systems