Insight

Major Industries, the hot and cold forming tooling specialist, has recently made several significant investments in advanced machinery and infrastructure that have enabled the company to expand its capacity and efficiency, enhance its precision and reliability, as well as continue to meet its sustainability goals. 

With 40 years of experience, Major Industries is dedicated to helping its customers achieve operational excellence by providing customised die assemblies, inserts, punches, pins and auxiliary tooling. Through its in-depth knowledge of materials and heat treatment processes, combined with cutting edge machinery and rigorous testing, Major Industries can empower its customers to lower their production costs while maintaining high performance.

“Building on our expertise in heat treatment and machining, we have recently made several investments so that we can continue to meet and exceed the needs of our customers,” reports Major Industries Ltd. “We’re committed to staying ahead in the market and supporting our customers with cutting edge precision tooling tailored to their industry needs. That is why we have invested in advanced machinery and infrastructure, so that we can enhance our customers’ production capacity, efficiency and accuracy.”

Major Industries’ investments include the installation of a three axial CNC milling machine and an additional CNC turning machine to boost throughput and reduce lead times. Plus, a new five axial CNC milling machine and a CNC complex milling and turning machine have been added to handle intricate designs with exceptional accuracy. The company has also expanded into hot forming tooling and can now produce tooling for manufacturers in the wind, power and ammunition industries – specialising in fasteners and critical components.

“Investing and innovating in efficiency, quality, cost-effectiveness and sustainability is crucial for us to stay competitive and meet the evolving demands of our customers,” explains Major Industries. “By optimising production processes, and maintaining high-quality standards, we not only reduce costs and waste but also ensure that we deliver reliable, high performance tooling solutions. Embracing innovation allows us to adapt to new technologies and continuously improve our offerings, while prioritising sustainability aligned with our environmental goals and customers’ expectations. This holistic approach also ensures long-term growth, strengthens our market position and drives customer satisfaction.”

To add to these investments, Major Industries has also looked to enhance its precision and reliability, with a CNC EDM (Die-Sinking Type) for highly precise and consistent machining. The company also relies on advanced measurement technology, including 3D and 2D high-level measuring devices, as well as a height measuring device – ensuring the highest quality standards.

When it comes to sustainability, Major Industries uses lower power consumption equipment, aligned with decarbonisation goals, as well as a fully integrated MES infrastructure, with IoT connectivity, for ‘real time’ monitoring and improved workflow efficiency, managed from a centralised control room.

“At Major Industries we take pride in our comprehensive approach to vertical integration, which enables us to offer a seamless, end-to-end manufacturing solution. Our in-house capabilities span from machining and production to high-value investment in heat treatment and PVD coating equipment, ensuring that we control every stage of the process for maximum efficiency and quality,” underlines the business. “By handling everything internally, we meet our customers’ demand for a ‘one stop shop’, simplifying their supply chain and reducing the need for multiple suppliers. This integrated approach streamlines customers’ production, cuts lead times and ensures consistent quality from start to finish.”

The vertical integration also gives Major Industries full control over product quality and traceability, meaning every component is closely monitored throughout the production process – enabling the company to maintain the highest standards and provide its customers with complete transparency. “Our approach to vertical integration has earned us the trust of top automotive fastener suppliers in North America and Europe,” comments Major Industries. “By offering superior products, and unmatched reliability, we help these industry leaders stay competitive in a fast paced market. Furthermore, we have a network of local agents and representatives worldwide, ensuring prompt and personalised service wherever a customer is based.”

Even with such a diverse and loyal customer base, Major Industries is still able to provide expert design advice by reviewing tooling specifications and analysing performance in its advanced metallurgical laboratory. “Our team conducts thorough inspections, material analyses, performance evaluations, and failure mode identification, to pinpoint the root cause of any issues,” highlights the company. “Once we have a clear understanding, we implement tailored corrective actions, whether it’s refining the design, adjusting materials or improving maintenance procedures. Our goal is to not only resolve the issue but also enhance customer productivity, ensuring
long-term, effective solutions that prevent future failures.”

The company can also meet the evolving and growing demands of industries – including automotive, aerospace and renewable energy – when it comes to lightweight, high strength materials, such as titanium, advanced composites, and high grade steel, which need to be designed to withstand harsher conditions and enhance the durability of products. To add to this, there is also the increasing interest in corrosion resistant coatings, eco-friendly materials, and custom fastener designs, to improve performance, reliability and reduce environmental impact.

“The industrial fastener industries in our main territories – USA, UK and Ireland, and Germany – are undergoing significant development, driven by advancements in technology; increasing demand for sustainable products; and the need for higher performance in challenging applications,” mentions Major Industries. “High performance tooling enhances the production of fasteners by ensuring tighter tolerances, as well as improving material efficiency by minimising waste and maximising the use of high strength alloys – promoting sustainability and
cost-effectiveness.”

Major Industries adds: “Advanced tooling solutions also speed up production cycles and reduce lead times while maintaining quality. Optimised tooling ensures improved durability, enabling fasteners to perform reliably in demanding environments. High performance tooling also plays a crucial role in supporting the fastener industry’s product development and assists formers with operational efficiency.”

Thanks to its ability to provide performance tooling, Major Industries believes it is poised to be a global leader in precision tooling, driven by its diversification into industries such as wind power, ammunition, and renewable energy, alongside its established markets in automotive, aerospace and construction. “Strategic investments in cutting edge machinery, IoT enabled infrastructure, and advanced measurement tools, will enhance efficiency, precision and sustainability – solidifying our competitive edge,” concludes Major Industries. “Our focus on total cost of ownership, superior tooling performance, and eco-friendly solutions, aligns with global trends in sustainability and high performance manufacturing. By leveraging our expertise in materials, heat treatment, and failure analysis, we will further strengthen customer relationships, expand our market presence and offset challenges, such as pricing pressures and shifts in demand. With continued innovation and operational excellence, we are set to reinforce our position as a leading tooling supplier, as well as go on delivering long-term value to our customers.”