Subcontractor Installs Automated Cell for High-Mix, Low-Volume Production

Before this initial Brother purchase, Mr Roach conducted rigorous test cuts at the Whitehouse showroom and technical centre in Kenilworth to ensure the 30-taper machine could deliver the required production output and accuracy. Impressed by the outcome, he noted, “The performance of Brother machines is head and shoulders above what we used previously. The accuracy achieved combined with the high speed has been an absolute game-changer for us”.

In early 2026, Avant Manufacturing further enhanced its capabilities with the installation of a second 5-axis Brother Speedio, a U500Xd2-100T machining centre. This specific model is engineered to address the accelerating industry trend toward high-mix, low-volume production, which at Wisbech typically involves batch sizes ranging from one-off up to 100 components.

The machine features an ingenious arrangement that provides 100-tool capacity, achieved by mounting a 36-tool stocker on either side of the standard 28-tool turret magazine. The machine has been integrated with an Erowa Robot Compact 80 automated storage and retrieval system for 30 machine pallets, enabling the company to achieve prolonged periods of lights-out, unattended operation. The production cell is operated around the clock, seven days a week, and sometimes without any operator intervention over a 24-hour period.

Capable of serving two machines at the same time if Avant decides to integrate another Brother Speedio into the cell, the Erowa automation occupies a compact footprint, enabling both it and the machining centre to function in an area of just 3.3 x 3.8 metres on the shop floor. The robot is able to handle payloads of up to 40 kg and workpieces measuring up to 200 x 200 x 250 mm can be accommodated. The entire process is managed by the EROWA JMS 4.0 process control system, which provides a transparent overview of job priorities, CNC programs and tool management, while offering real-time machine status monitoring to ensure maximum process reliability.

Like its Brother Speedio predecessor, the 100-tool model allows multi-face machining of parts in a single clamping, which simplifies workflow and reduces cumulative errors from repeatedly reclamping parts. The machines have a rapid 0.7-second tool-to-tool change time and feature 50 m/min rapids in the X and Y axes, 56 m/min in Z, with 2.2 g acceleration. The latest Brother CNC-D00 control system provides enhanced functionality for fully interpolative 5-axis machining, while support apps offer cycle time optimisation and real-time monitoring of power consumption.

Reflecting on the system’s versatility, Mr Roach said, “Investing in the 100-tool machine has massively increased our flexibility. We are able to have 50 jobs set up at any one time for immediate implementation. Another benefit of the Brother Speedios is their compact footprint – the number of parts produced per square metre of shop floor space is through the roof.”

Furthermore, the move to the 30-taper platform has supported the company’s journey towards sustainability. Brother technology typically delivers an 80 percent reduction in electricity and air consumption compared to 40-taper machines. Mr Roach highlighted this efficiency, noting that after installation of the first U500Xd2-5AX, Avant Manufacturing saw an increase in business revenue but no increase in its electricity bill.

He concluded, “From sales to support and service, Whitehouse has been exemplary. The supplier has really helped us to elevate our business and take it to the next level. The parts we are producing on the Brother platforms are high accuracy and have a fantastic surface finish, which our clients expect.”