Intermediate Extrusion Moulding Course
The Sierra 57 Consult Extrusion Moulding Training Course consists of 22 modules overall, with an additional 8 specialty modules that address specific weaknesses that your workforce may have.
For Intermediates in Extrusion Moulding, we suggest that candidates take the following 5 modules, with extra 2 practical courses, & 3 extra specialty modules. These modules cover the following:
For Intermediate:
Module EX-03 The importance of process monitoring
Module EX-08 Machine control
Module EX-09 Introduction to troubleshooting the extrusion process
Module EX-13 Formulas used in Extrusion
Module EX-22 An Introduction to Polymer Materials and Processing
Intermediate Extrusion Practical:
Module EX-J Safe Purging for Extrusion Machines & Component Care
Module EX-6B Extruder Line safe start up and shut down procedure
Specialty Modules
Module EX-E An Introduction Overall Equipment Efficiency (OEE)
Module EX-21 Introduction to SMED
Module EX-11 Engineers Extrusion Principles Appreciation
EX-PD3: Intermediate Extrusion Theory Courses – Detailed Modules
EX-3 The importance of process monitoring
Duration: 1/2 days
Aims – to reinforce the importance of process monitoring with respect to:
- selection and set up of Process Monitoring
- consequences of no process monitoring.
Outcome – improved efficiency, reduced maintenance, developed process control (reduced variations), improved extrudate quality, increased process understanding by management team, improved communication by management to process team.
EX-8 Machine control
Duration: 1/2 day
Aims – to introduce the aspects of how the following criteria can impact on machine control efficiency
- Know the basic control parameters on an extrusion machine.
- Understand how barrel temperature changes effects the extrusion process.
- Understand how screw adjustment effects the extrusion process.
- Have a basic understanding of how motor load is interpreted in relation to the extrusion process.
Outcome – improve the teams understanding of machine control to reduce downtime and increase shop efficiency.
Ex-9 Introduction to troubleshooting the extrusion process
Duration: 1 day
Aims – To gain an understanding of the 3 stage screw.
- Mechanical Problems.
- Sensor Problems – Thermocouples & Transducers.
- Process Controllers
- Contamination in finished product
- Extrusion Surging
Outcome – reduce scrap, improve quality, improve the ability of the team to undertake root cause analysis.
EX-13 Formulas used in Extrusion
Duration: 1 day
Aims – To give the trainee a basic understanding of mathematical principals used in the extrusion process.
- Addition, Subtraction, Multiplication and Division
- Rounding Numbers and Significant Figures
- Formulas, Equations and Order of Operations
- Common unit conversions in the extrusion process
- Calculation of Area
- Calculation of Volume & Flow
- Calculation of Weight, Mass and Force
- Understanding Percentages
- Understanding ratios
- L:D Ratio
- Compression Ratio
- Shear Rate
- Pump Ratio
- Flow Equations.
Outcome – Attendees will be more prepared to calculate data, enabling them to match extruder requirements with appropriate machines.
EX-22 An Introduction to Polymer Materials and Processing
Duration: 1 day
Aims – To provide an understanding of the plastic materials development, manufacture and end use.
- A brief history of polymers
- How Are Plastics and Polymers Defined?
- A brief Introduction to Polymer Chemistry
- An Introduction to Polyolefins
- An Introduction to ABS and Polystyrene
- An Introduction to Engineering Polymers
- Engineering Plastics in Healthcare
- An Introduction to Speciality Polymers
- An Introduction to High Temperature Polymers
- Data Sheet Interpretation
Outcome – improve the understanding of material rheology, improve production process, achieve process stability
EX-PD4: Intermediate Extrusion Practical – Detailed Modules…
EX-6B Extruder Line safe start up and shut down procedure
Duration: 2 day
Aims – to provide an understanding of safe start up and shut down methodology.
- Identify and Check Ancillary Equipment.
- Identify Machine Controls and Check Barrel Temperatures.
- Identify and Check Plastics Material.
- Identify and Check Die Head and Tooling.
- Identify Necessary Hand Tools and PPE.
- Recognise Correct Safety Protocols.
- Perform Safe Start-up Procedure
- Perform Safe Shut-down Procedure
- Individual practical Extrusion Line assessment
Outcome – improved understanding of safe start up and shut down of Extrusion process and end practical test
Specialty Modules for Intermediate Extrusion Moulding Training
EX-11 Engineers Extrusion Principles Appreciation
Duration: 1 day
Aims – To provide engineers with an appreciation of the principles of Extrusion:
- Understand the Operation of the extruder.
- Understand the Various Components of the Extrusion machine.
- Basic’s of Screw Design.
- Shear and Direct heat Transfer and Effect on Plasticising.
Outcome – to educate attendees on the basic extrusion principles
EX-21 Introduction to SMED
Duration: 1 day
Aims – to provide the methodology to improve tool/process changeover times
- What is SMED?
- SMED benefits
- Basics of SMED
- SMED example
- Record a tool change from the start of run to end of run
- Accelerate progress
- What you should do next…
Outcome – After the course the participant can understand the function the function of the SMED process and its place in an injection moulding environment to improve efficiency.
Module EX-F – An Introduction to Material Handling
Duration: 1 Day
Target audience – Material handlers, setters, technicians, and team leaders.
Prerequisites – None
Aims – To increase the knowledge of material handlers with respect to materials and the correct way to handle them and the risks to be avoided.
- What are Plastics, and where do they come from.
- Uses of Plastics and the Diversity of the Plastics Industry.
- Classification of Plastics Materials.
- Basic Understanding Material data sheets.
- Types and uses of additives.
- Drying and Handling requirements.
- Risks and H&S requirements
Outputs – Increased knowledge leading to the safe handling of materials for drying a recycling.
Sierra 57 Consult offers award-winning, industry-recognised training. Several of our plastics training courses hold approval from the IOM3.
Recognised with ‘Best Training & Development’ at the 2022 Plastics Industry Awards and ‘Best Business Initiative’ in 2023, we are also proud to be members of the British Plastics Federation (BPF) and the Polymer Machinery Manufacturers and Distributors Association (PMMDA).
Education is a powerful way to transform lives & your business.
With a growing shortage of skilled engineers in the UK, investing in your existing workforce has never been more important. Upskilling fosters loyalty, empowers employees to reach their full potential, and can cost as little as a third of recruiting new talent.
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3 September 2026Far from being a short-term solution to fill a skills or resource gap, contract manufacturing support can become an important part of a manufacturer’s wider business strategy.
By bringing experienced personnel and specialist expertise directly into the manufacturing environment, businesses can strengthen their operations, improve flexibility and create the capacity needed to pursue new opportunities.
Contract manufacturing is more than additional resource:
✔️ Manage increased workloads and changing production demands.
✔️ Access specialist expertise without committing to permanent headcount.
✔️ Scale resources in line with changing business requirements.
✔️ Assign skilled personnel for the duration of a specific project.
✔️ Bring fresh perspectives and specialist knowledge to existing teams.
✔️ Benefit from additional expertise whilst underpinning continuity.
✔️ Support knowledge transfer and share practical experience across teams.
✔️ Build a flexible workforce that responds to changing circumstances.
✔️ Add an extra layer of operational resilience.
Consider asking yourself the following questions:
1️⃣ What problem are we trying to solve?
2️⃣ What expertise do we need on site?
3️⃣ How will external support integrate with our existing team?
4️⃣ How flexible does our support need to be?
5️⃣ How will we measure the value of the support?
Rather than viewing external manufacturing support simply as a temporary response to a problem, manufacturers can use it proactively – bringing in the right expertise at the right time to support growth, improve performance and create greater operational flexibility. [...]Read more...
11 August 2026We are delighted to welcome Andy Dixon to Sierra 57 as our new Mould Contractor/Training & Development Consultant.
With 30 years’ experience in injection moulding Andy brings a wealth of technical expertise, having built a strong reputation as a proven Process Engineer and Subject Matter Expert within the industry.
As our business continues to grow, so does the need to place highly skilled, well-rounded technical professionals into the field. In an ever-changing market, our customers require more than just expertise – they need experienced individuals who can adapt, add value and provide the specialist support needed to overcome operational challenges.
Alongside his technical knowledge, Andy also brings excellent people management skills and a passion for developing others – making him a perfect fit for our growing training, development and mould contract team.
Having recently returned from seven years with CT Automotive in China, Andy joins us with valuable global experience and a fresh perspective on manufacturing excellence.
Based in the Midlands, he will play a key role in supporting our customers with specialist moulding expertise, skills development and operational support.
We’re excited to have Andy on board and look forward to the contribution he will make to Sierra 57 and the wider plastics industry.
Please join us in welcoming Andy to the team,! [...]Read more...
5 August 2026We are delighted to announce the promotion of James Hayward to the role of Training Manager – Polymer Engineering.
Since joining the Sierra 57 team, James has consistently demonstrated an exceptional work ethic, a passion for continuous learning, and an unwavering commitment to delivering outstanding results. His dedication, professionalism, and ability to apply his technical expertise have made a significant impact across the business.
Throughout his time with the company, James has successfully delivered a wide range of polymer training initiatives, supported the development of trainees across multiple disciplines, and played a key role in strengthening customer’s polymer engineering workforce capabilities. His ability to translate complex technical knowledge into practical, engaging learning experiences has earned him the respect of both colleagues and customers alike.
James has continually exceeded expectations through his proactive approach, attention to detail, and determination to drive improvements. Whether developing new training programmes, supporting engineering projects, or mentoring team members, he has consistently delivered high-quality outcomes that align with Sierra 57’s commitment to excellence.
In his new position as Training & Development Manager – Polymer Engineering, James will lead the continued development of our technical training strategy, ensuring our customers teams have the skills, knowledge, and confidence to meet the evolving needs of the plastics industry.
This promotion reflects not only James’ outstanding achievements over the past 18 months but also the confidence we have in his ability to lead, inspire, and contribute to the future success of our customers.
Please join us in congratulating James on this well-deserved promotion. We wish him every success in his new role and look forward to seeing the continued positive impact he will make. [...]Read more...
23 June 2026Breaking the Mould is the podcast that explores the people, ideas, innovations, and challenges shaping the plastics industry today and tomorrow.
And EPISODE-2 is now available to download!
Opening Doors to the Future of Plastics features Alicia Chrysostomou and Steve Blanks from Design Innovation in Plastics (DIP)
Underpinned by creativity, sustainability, and educational engagement DIP is a competition that has been running since 1985 and is Europe’s longest-running student plastics design award and encourages university undergraduates to develop products primarily made from plastics, emphasizing creativity, usability, and environmental responsibility.
Listen today and understand just how important industry/education collaboration is to the future of plastics manufacturing, and how our next generation of industry makers are encouraged to think about this valuable resource differently.
Listen on:
Spotify: Listen here
Apple Podcasts: Listen here
Amazon Music: Listen here
Podbean: Listen here
[...]Read more...
22 June 2026Shaun McCarthy recently joined the growing Sierra 57 team as Projects Director. Hear about his transition into the specialist plastics recruitment, training and contract manufacturing sector, how his journey with the business has gone so far, and his ambitions for the future
Change can feel a bit daunting at times, but my move to Sierra 57 Consult has been a really positive one. From day one, I felt genuinely welcomed into a team that values working together, sharing knowledge, and helping each other grow.
One of the standout moments so far has to be my baptism of fire at Interplas 2026 – straight in at the deep end! It was fast-paced, full of great conversations, and had that real buzz you only get at a big industry event. A brilliant way to get stuck in and find my feet quickly.
A real highlight for me has been being able to use my experience to support and develop others across the plastics industry. It’s great to share ideas, offer a bit of guidance, and hopefully make a difference – while still learning plenty myself along the way. It’s also rewarding to play a part in helping companies recognise the value of investing in their people and seeing the impact that can have.
What’s made the biggest difference, though, is the team. Everyone’s approachable, supportive, and always happy to help, which makes settling in so much easier. They’re also hugely encouraging when it comes to the courses they run – there’s a real focus on developing people, not just within the business but across the wider industry too. It’s great to be somewhere that genuinely invests in growth. It’s also refreshing to be part of an environment where ideas are welcomed and contributions are recognised.
The variety of work has also kept things interesting – no two days feel the same. There’s always something new to get involved in, which keeps me learning and growing, both professionally and personally.
All in all, joining Sierra 57 Consult has been a fantastic step for me. I’m excited to keep building on this start, contributing where I can, and seeing what comes next. [...]Read more...
15 June 2026Breaking the Mould is the podcast that explores the people, ideas, innovations, and challenges shaping the plastics industry today and tomorrow. From injection moulding and manufacturing excellence to skills development, education, policy, governance, sustainability, and workforce development, each episode brings together voices from across the sector.
By bringing together conversations from across the full spectrum of the plastics sector, the series creates a more accessible, rounded view of the plastics industry – how it works today, where it is heading, and what it will take to build a stronger, more resilient future workforce.
Listeners can access content that connects all of these perspectives in one place – a space that brings together the technical, operational, strategic, and human layers of the plastics industry in a joined-up way.
Listen to Episode 1 – Filling to Holding: Why the Switch Matters featuring James Hayward from Sierra 57.
Spotify: https://open.spotify.com/show/033tbfpH7UErTKurpIyDYf
Amazon Music: https://music.amazon.com/podcasts/4f5e7568-c542-46b0-bc2e-2ffe297676bc
Apple Podcasts: https://podcasts.apple.com/us/podcast/breaking-the-mould/id1896884274
We shall be distributing a new, topical podcast every two weeks, so keep an eye out for updates and benefit from listening to some of industry’s leading and most influential figures.
Want to be part of it? Drop us a line: contact@sierra57consult.com
[...]Read more...
19 May 2026Szkolenie zostało opracowane z myślą o osobach pracujących w branży przetwórstwa tworzyw sztucznych i pomaga rozwijać praktyczną wiedzę z zakresu materiałów polimerowych, procesów przetwórczych oraz sprawdzonych metod produkcyjnych.
Program wspiera operatorów, techników oraz zespoły produkcyjne w lepszym zrozumieniu materiałów, procesów oraz codziennych wyzwań występujących w środowisku produkcyjnym.
Dwujęzyczna forma szkolenia pomaga poprawić komunikację w wielokulturowych zespołach oraz zwiększa dostęp do wiedzy technicznej dla szerszej grupy pracowników.
Wraz z rozwojem branży tworzyw sztucznych rośnie znaczenie praktycznych i dostępnych szkoleń technicznych, które pomagają rozwijać kompetencje pracowników produkcyjnych.
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Sierra 57 is proud to introduce its Polymer Materials Science – Basic Level training course, now available in Polish.
Designed to support individuals working across plastics manufacturing, the course provides a strong foundation in polymer materials, processing principles, material behaviour, and industry best practices – helping operators, technicians, and production teams build greater technical understanding and confidence within their roles.
By delivering the programme bilingually, Sierra 57 is helping manufacturers create more inclusive learning environments, improve communication across multicultural teams, ensuring that valuable technical knowledge is accessible to a wider workforce. This not only supports employee development and retention, but also strengthens quality, consistency, and operational performance across the industry.
As the plastics sector continues to evolve, investing in accessible, skills-based training is essential to developing knowledgeable and capable manufacturing professionals. [...]Read more...
18 May 2026How establishing recruitment and training strategies can sustain future workforces and growth plans.
In a market constrained by skills shortages, sustainable growth is no longer driven by headcount alone. It depends on how organisations attract the right people, develop their capabilities, and retain them over the long term. Recruitment and training are no longer separate functions – they are two pieces of the same jigsaw that, when aligned, underpin success and drive growth.
Attracting the right talent
Attracting the right people starts with clarity. Businesses that understand who they need and why are far more successful in recruiting the right people. Clear role definition, realistic expectations, and transparent employer branding allows recruitment to move beyond filling vacancies and towards building future capability. Candidates increasingly look for purpose, development, and stability – not just a job title.
Developing capability through training
Recruitment is only the beginning. Structured training ensures skills keep pace with change – whether those changes are driven by technological, regulatory, or sustainability demands. Investing in development increases productivity, supports succession planning, and demonstrates a long‑term commitment to employees. When people see a pathway to grow, engagement and performance shall follow.
Retaining people for long-term growth
Retention is the final piece of the jigsaw. High staff turnover can stall momentum and inflate costs associated with cyclical recruitment and training. Strong onboarding processes, continuous learning, and clear career pathways help organisations retain internal knowledge and experience. Recruitment and training strategies when established can allow businesses to proactively address potential skills gaps before they become a risk.
The Bigger Picture
Future‑proof workforces are developed when recruitment and training strategies align with business goals. Attracting potential, developing skills, and retaining talent creates resilience – supporting not just today’s business needs, but tomorrow’s growth plans.
Sustainable success is about building workforces that last.
To find out more about how Sierra 57 can support your recruitment and training deliverables, drop us a line at: contact@sierra57consult.com [...]Read more...
7 May 2026In injection moulding, waste is rarely accidental – it is often designed in.
Scrap rates, short shots, excess regrind, energy inefficiencies, and unplanned downtime all erode margins quietly but relentlessly. At a time when material costs, energy prices, and customer pressure are rising, the most resilient manufacturers are those who design waste out from the very beginning.
Waste can start long before the machine runs 💯
Many sources of waste are locked in early:
❌ Part and tool design that’s hard to process consistently
❌ Poor material selection or drying practices
❌ Not optimising process windows
❌ Operator reliance on ‘knowledge’ rather than data
Once production starts, teams often end up firefighting 🔥
The result? Higher scrap rates, longer cycle times, inconsistent quality – and shrinking margins.
𝐓𝐫𝐚𝐢𝐧𝐢𝐧𝐠 𝐢𝐬 𝐚 𝐛𝐨𝐭𝐭𝐨𝐦‑𝐥𝐢𝐧𝐞 𝐬𝐭𝐫𝐚𝐭𝐞𝐠𝐲, 𝐧𝐨𝐭 𝐚 𝐜𝐨𝐬𝐭
One of the fastest ways to design out waste is through targeted training across the injection moulding process.
Well‑trained teams:
✔️ Set machines correctly the first time
✔️ Understand the why behind process limits
✔️ Identify root causes instead of masking symptoms
✔️ Reduce variation, scrap, and rework
✔️ Optimise cycles without risking quality
𝐈𝐭 𝐢𝐬𝐧’𝐭 𝐚𝐛𝐨𝐮𝐭 𝐭𝐡𝐞𝐨𝐫𝐲 – 𝐢𝐭’𝐬 𝐚𝐛𝐨𝐮𝐭 𝐦𝐚𝐤𝐢𝐧𝐠 𝐛𝐞𝐭𝐭𝐞𝐫 𝐝𝐞𝐜𝐢𝐬𝐢𝐨𝐧𝐬 𝐨𝐧 𝐭𝐡𝐞 𝐬𝐡𝐨𝐩 𝐟𝐥𝐨𝐨𝐫 𝐞𝐯𝐞𝐫𝐲 𝐝𝐚𝐲 𝐚𝐧𝐝 𝐜𝐨𝐧𝐧𝐞𝐜𝐭𝐢𝐧𝐠 𝐬𝐤𝐢𝐥𝐥𝐬 𝐭𝐨 𝐩𝐫𝐨𝐟𝐢𝐭 💵
When operators, setters, technicians, and engineers share a common understanding of: material behaviour, process stability, tooling influence and scientific moulding principles 𝐰𝐚𝐬𝐭𝐞 𝐛𝐞𝐜𝐨𝐦𝐞𝐬 𝐯𝐢𝐬𝐢𝐛𝐥𝐞 𝐚𝐧𝐝 𝐩𝐫𝐞𝐯𝐞𝐧𝐭𝐚𝐛𝐥𝐞.
Training aligns teams around data, not guesswork, and that alignment translates directly into:
💯 Lower material usage
💯 Reduced downtime
💯 Improved first‑time‑right quality
💯 Stronger margins
𝐃𝐞𝐬𝐢𝐠𝐧𝐢𝐧𝐠 𝐨𝐮𝐭 𝐰𝐚𝐬𝐭𝐞 𝐢𝐬 𝐚 𝐜𝐨𝐦𝐩𝐞𝐭𝐢𝐭𝐢𝐯𝐞 𝐚𝐝𝐯𝐚𝐧𝐭𝐚𝐠𝐞
The most successful moulders don’t accept waste as ‘part of the process’ they invest in capability, empowering people to prevent problems rather than react to them.
Contact us and discuss how designing out waste through training isn’t just good manufacturing practice – it’s how you protect your bottom line for the long term: contact@sierra57training.com [...]Read more...
21 April 2026In the fast-paced world of plastic injection moulding, precision is everything.
From cycle times to surface finish, every variable plays a role in determining whether a component meets specification or ends up as scrap. At the heart of this process lies materials science – the mechanics that governs how polymers behave under heat, pressure, and flow.
Yet, despite its importance, materials science is often overlooked in day-to-day production environments. Operators may rely on established settings or past experiences, but without understanding the underlying principles, even small changes in material batches or environmental conditions can lead to costly defects.
At its core, materials science provides insight into how polymers respond during processing. Concepts such as Polymer Rheology explain how molten plastic moves through a mould, influencing fill patterns and the risk of defects such as short shots or flash. Similarly, an understanding of Thermodynamics is essential for controlling cooling rates, which directly impact cycle time and part stability.
(Sierra 57’s Polymer Materials Science course is designed for material handlers, trainee setters, IMM operators, apprentices, quality personnel, procurement, estimators and middle management.)
For semi-crystalline materials, knowledge of Polymer Crystallinity is particularly important. Cooling too quickly or unevenly can result in internal stresses, warping, or dimensional inaccuracies. With the right training, these risks can be anticipated and mitigated before they affect production.
The benefits of this knowledge extend beyond quality. A workforce trained in materials science is better equipped to optimise processing conditions, reduce waste, and respond quickly to issues. Instead of relying on trial and error, teams can make informed decisions based on how materials are expected to behave – leading to more consistent output and improved efficiency.
Moreover, as the industry evolves with new materials, sustainability requirements, and tighter tolerances, this expertise becomes even more critical. Engineers and operators alike must be able to adapt, applying scientific principles to new challenges and opportunities.
Ultimately, materials science is not just theoretical – it is a practical tool that underpins every successful moulding operation. Investing in training ensures that teams are not only running machines but truly understanding the processes behind them. The result is a stronger, more capable workforce, and a more competitive, efficient business.
To find out more about Sierra 57’s comprehensive training programme, or to enrol in one of our forthcoming Polymer Material Science courses, drop us a line at: contact@sierra57consult.com [...]Read more...
31 March 2026We’re pleased to welcome a Ben Maguire to the Sierra 57 team, as we continue to grow our offering across technical recruitment, mould contracting, and mould training.
Joining us as an experienced Injection Moulding Mould Setter / Technician, Ben brings a wealth of hands-on knowledge and industry expertise that will play a key role in supporting our continued growth into 2026.
As Sierra 57 strengthen our position across the plastics industry, this addition enhances our ability to deliver high-quality recruitment solutions, practical mould training, and on-site mould setting support to our customers.
Ben’s experience and technical capability will be instrumental in helping us bridge the gap between skills development and operational delivery – supporting businesses with both people and performance.
We’re excited to have Ben on board and look forward to the value he will bring to our clients and partners.
Mark Lawson, CEO, Sierra 57 Consult, welcomes Ben to the team:
“To support increasing customer demand and our strategic growth plans for 2026, we are focused on securing three additional Polymer Engineering professionals. We’re pleased to introduce the first of these appointments – Ben Maguire.
Ben joins us as an experienced Injection Moulding Mould Setter / Technician, bringing strong hands-on expertise that will complement our specialist hybrid offering across technical recruitment, mould contracting, and mould training.
He demonstrates excellent attention to detail, a clear ambition to further develop, and aspirations to progress into a Process Engineer role. Alongside his technical capability, Ben is a trustworthy and knowledgeable professional who will be a valuable advisor to both candidates and clients alike.
Outside of work, Ben brings just as much energy – he’s a keen runner (taking on the London Half Marathon next month), a dedicated supporter of Liverpool FC and Telford AFC (we’ll let that one slide, Ben… though Telford might be having the better run of it!), and a proud family man to three girls.
We’re delighted to have you on board, Ben, and look forward to working with you as part of the Sierra 57 team.” [...]Read more...
30 March 2026Training is not just a nice-to-have; it is a strategic imperative that should be woven into every business’s growth plan to ensure skills and competencies align with evolving industry requirements 💯
This is just the stance that TEX PLASTICS has taken, ensuring that their staff, regardless of experience, has access to industry training to ensure that they are able to grow with the business – highlighted in this terrific testimonial from Richard Bromley, Process Manager at TEX PLASTICS.
“𝐀𝐬 𝐞𝐱𝐩𝐞𝐜𝐭𝐞𝐝, 𝐚𝐧𝐨𝐭𝐡𝐞𝐫 𝐬𝐮𝐜𝐜𝐞𝐬𝐬𝐟𝐮𝐥 𝐭𝐫𝐚𝐢𝐧𝐢𝐧𝐠 𝐩𝐫𝐨𝐠𝐫𝐚𝐦 𝐝𝐞𝐥𝐢𝐯𝐞𝐫𝐞𝐝 𝐛𝐲 𝐍𝐞𝐯, 𝐚𝐥𝐰𝐚𝐲𝐬 𝐚 𝐩𝐥𝐞𝐚𝐬𝐮𝐫𝐞 𝐭𝐨 𝐬𝐞𝐞 𝐡𝐢𝐦 𝐨𝐧 𝐬𝐢𝐭𝐞 𝐚𝐧𝐝 𝐢𝐬 𝐰𝐞𝐥𝐜𝐨𝐦𝐞𝐝 𝐰𝐢𝐭𝐡 𝐨𝐩𝐞𝐧 𝐚𝐫𝐦𝐬 𝐛𝐲 𝐚𝐥𝐥 𝐦𝐞𝐦𝐛𝐞𝐫𝐬 𝐨𝐟 𝐭𝐡𝐞 𝐭𝐞𝐚𝐦.
𝐓𝐡𝐞 𝐭𝐫𝐚𝐢𝐧𝐢𝐧𝐠 𝐩𝐫𝐨𝐠𝐫𝐚𝐦 𝐢𝐬 𝐚 𝐩𝐫𝐨𝐯𝐞𝐧 𝐬𝐭𝐫𝐚𝐭𝐞𝐠𝐢𝐜 𝐩𝐚𝐫𝐭𝐧𝐞𝐫𝐬𝐡𝐢𝐩 𝐭𝐡𝐚𝐭 𝐞𝐧𝐚𝐛𝐥𝐞𝐬 𝐮𝐬 𝐭𝐨 𝐝𝐞𝐯𝐞𝐥𝐨𝐩 𝐛𝐨𝐭𝐡 𝐞𝐱𝐩𝐞𝐫𝐢𝐞𝐧𝐜𝐞𝐝 𝐭𝐞𝐜𝐡𝐧𝐢𝐜𝐢𝐚𝐧𝐬 𝐚𝐧𝐝 𝐜𝐨𝐦𝐩𝐥𝐞𝐭𝐞 𝐧𝐨𝐯𝐢𝐜𝐞𝐬 𝐚𝐧𝐝 𝐠𝐢𝐯𝐞 𝐩𝐞𝐨𝐩𝐥𝐞 𝐭𝐡𝐞 𝐜𝐨𝐧𝐟𝐢𝐝𝐞𝐧𝐜𝐞, 𝐨𝐟 𝐚𝐥𝐥 𝐚𝐛𝐢𝐥𝐢𝐭𝐢𝐞𝐬, 𝐭𝐨 𝐭𝐚𝐤𝐞 𝐭𝐡𝐞 𝐧𝐞𝐱𝐭 𝐬𝐭𝐞𝐩𝐬 𝐢𝐧 𝐭𝐡𝐞𝐢𝐫 𝐜𝐚𝐫𝐞𝐞𝐫 𝐝𝐞𝐯𝐞𝐥𝐨𝐩𝐦𝐞𝐧𝐭 𝐰𝐢𝐭𝐡 𝐓𝐞𝐱 𝐏𝐥𝐚𝐬𝐭𝐢𝐜𝐬.”
If you would like to discuss your company’s training requirements with us, drop us a line at: 📧 contact@sierra57consult.com we have a number of programmes to suit all experience capabilities, from entry level through to expert 🧑🎓 [...]Read more...
11 March 2026Much has been said about the skills gap in UK manufacturing. Large numbers of retirement-age employees are leaving the industry, taking vital knowledge and experience with them, while next-generation intake remains relatively low, limiting opportunities for critical knowledge transfer.
There is also a growing skills crisis within industry. Employees increasingly require upskilling and reskilling as the sectors around them evolve. Employers are facing a train-or-not-train conundrum, largely centred on cost. But when push comes to shove, what is the real cost of not upskilling staff and failing to create clear internal pathways for them?
Industry is moving incredibly quickly. Technology, processes, materials and legislation are evolving faster than many organisations can keep pace with. However, there is a solution: knowledge transfer strategies.
These can be developed internally or delivered through external partners, but the key to any initiative aimed at empowering and upskilling employees is relevance.
In the UK, around one third (33%) of manufacturers say their biggest barrier to growth is skills and workforce gaps. While those gaps persist, productivity falters, efficiency declines, and costs rise. The solution lies in growing skills internally. As the manufacturing landscape becomes more competitive – both domestically and internationally – training must become a strategic priority for plastics manufacturers.
How is the industry changing?
Regulatory pressures and policy reforms aimed at reducing plastics waste and increasing recycling
Economic pressures and global competition, including cheap imports undermining UK markets and high domestic energy costs
Consumer demand for recycled and sustainable materials such as plant-based polymers and biopolymers
Emerging technologies accelerating innovation aligned with smart manufacturing, connectivity, Industry 4.0 and automation
How can training help manufacturers respond?
A well-trained and informed workforce can reduce production waste (scrap) through improved process monitoring and optimisation
High energy consumption can be mitigated through better maintenance practices and more efficient processing
Biopolymer and sustainable material literacy can support informed decision-making around material selection and product development
Training enables employees to develop the digital and technical competencies required to operate, monitor and maintain advanced manufacturing technologies
A shift in priorities over the past decade has seen the focus move from increasing sales to improving productivity, innovation, digitalisation and resilience.
Training underpins all four, driving efficiency, product quality, operational reliability, and the effective use of technology.
Sierra 57’s training programmes are designed to develop skills across the injection moulding process, from entry level through to advanced. We recognise that training is not a one-off event, but a continuous journey of knowledge development.
We look forward to supporting manufacturers and their teams as they embark on their skills development journey.
To find out more about our training, please visit: Home – Sierra 57 Plastic Injection Moulding Training Courses
or email us at: contact@sierra57training.com [...]Read more...
4 March 2026The day-to-day knowledge held by the Sierra 57 team working directly with machines, tooling, and manufacturing partners provides rare, real-time visibility into the challenges that shape manufacturing outcomes
This expertise is more than operational know-how that demystifies complex processes – it bridges the gap between theory and practice
Here, James Hayward, Principal Consultant – Mould Training & Development, explores the important topic of training, and the transfer of theoretical learning, to practical tasks.
It’s been a solid start to 2026. At Sierra 57 Consult, we’ve already delivered 1,216 hours of CPD training to 42 trainees across January and February. While the numbers are encouraging, the real story is in how that training actually happens.
In my experience, you can’t have a high-performing mould shop without a balance of two things: a proper understanding of the “why” and a practical grasp of the “how.”
Nailing the Theory
We start in the classroom because that’s where we get the theory nailed down. Whether it’s machine principles or polymer behaviour, you need to understand the science before you start turning dials. This is where the “lightbulb moments” happen, when a setter realises why a part is behaving a certain way. It’s about building a foundation of knowledge that takes the guesswork out of the job.
Practical Application on Your Kit
Once the theory is sorted, we get straight out onto the shop floor. We don’t train on generic “test rigs” we work on your own tools and your own machines. Solving a specific processing issue or an imbalance on a tool the team uses every day is where the real value lies. It empowers your staff to take ownership, troubleshoot effectively, and build the skills to handle those same challenges long after we’ve left the site.
Working Around Your Schedule
We know that a mould shop never really stops, which is why we don’t expect you to work around us. At Sierra 57 Consult Ltd we are completely flexible to your shift patterns. Whether your team is on earlies, lates, or nights, we’re there when they are. It’s about making training fit into the reality of a 24/7 production environment, not the other way around.
A Positive Step for the Industry
Training has been instrumental in my own career, and it’s rewarding to see businesses seeing the return on investment through better efficiency and more confident teams. I’m proud to be part of that progression as we move through 2026.
If you need a training partner who is happy to get stuck in on a night shift or work through a specific tooling problem with your team, let’s have a chat. [...]Read more...
4 March 2026In the fast-moving world of plastic injection moulding, precision and efficiency are critical. From cycle time optimisation and material performance to tooling management and automation integration, even small improvements can deliver major commercial advantages for manufacturers.
As injection moulding machinery becomes more advanced and production demands continue to grow, many manufacturers are facing a widening skills gap on the shop floor. Without the right training, operators and setters can struggle to fully utilise modern equipment and maintain consistent production performance.
Industry-Focused Injection Moulding Training
To address this challenge, Sierra 57 Consult is working directly with leading machinery OEMs and plastic manufacturers to deliver specialist injection moulding training programmes designed specifically for the UK plastics industry.
These programmes go beyond theory, providing practical training that equips setters, technicians, operators, supervisors, even managers with:
Greater technical confidence
Practical machine-level understanding
Improved process optimisation skills
Techniques to reduce downtime and improve productivity
Sierra 57’s training programmes are designed to help manufacturers maximise machine performance, strengthen process control and drive long-term operational efficiency.
Injection Moulding Training Locations
Working in collaboration with major industry partners including FANUC UK Ltd, Brother Industries (UK) Ltd and Advanced Plastics Ltd, Sierra 57 is delivering three specialist training programmes across the UK:
FANUC UK Ltd – Ansty Park, Coventry
Brother Industries (UK) Ltd – Vauxhall Industrial Estate, Wrexham
Advanced Plastics Ltd – Bergen Way, Hull
These programmes provide hands-on training environments, allowing participants to work directly with industry equipment while developing real-world skills used in modern injection moulding operations.
Continuing the Programme in 2026
Following the successful delivery of the 2025 training programme, Sierra 57 will continue to expand its industry-specific injection moulding training throughout the UK.
The programmes are designed to help plastics manufacturers:
Improve process stability
Increase production efficiency
Strengthen operator capability
Build long-term operational resilience
Learn More About Our Training Calendar
To find out more about upcoming plastic injection moulding training courses, or to discuss how these programmes can support your team, please contact: contact@sierra57training.com [...]Read more...
25 February 2026The day-to-day experience of the team at Sierra 57 Consult, working directly with machines, tooling and manufacturing partners, provides rare real-time visibility into the factors that shape injection moulding performance.
This practical expertise goes far beyond operational know-how. It helps bridge the gap between engineering theory and real-world production, demystifying complex manufacturing processes and helping technicians understand how design decisions impact long-term results on the shop floor.
Here, James Hayward explores a topic that frequently sparks debate in the plastics industry: process control in injection moulding, specifically the role of hot runner vs cold runner systems.
“At Sierra 57, we spend a significant amount of time – both in the classroom and on the shop floor – discussing what we often call ‘The Great Runner Debate.’
But this discussion goes far beyond the cost of the steel. The real issue is how much control you truly have over your injection moulding process – from part consistency and material waste to process optimisation and long-term production stability. Let’s explore in more detail…”
Cold Runner Systems: A ‘Locked-In’ Process
With cold runner systems, particularly in multi-cavity or family mould tools, the injection moulding process is fundamentally governed by runner geometry.
If flow balance is not correctly engineered into the tooling design, there is very little a technician can realistically adjust at the press to compensate. Unlike many other process variables, runner imbalance cannot simply be tuned out through machine settings or optimisation techniques.
This is why tool design is critical.
If the runner system is not balanced in the steel from the outset, achieving a stable and repeatable moulding process becomes extremely difficult. In many cases, the success or failure of a cold runner mould is decided long before the tool ever reaches the machine.
Hot Runner Systems: Flexibility vs the ‘Band-Aid’ Trap
Hot runner systems provide a level of process flexibility that cold runners cannot offer. However, this flexibility can sometimes create new challenges.
Too often, individual hot runner temperature zones are adjusted to compensate for poor tooling design or fundamentally unbalanced flow paths. When this happens, a powerful system designed for precision control becomes a short-term workaround rather than a long-term solution.
Another common misconception is that the hot runner controller is simply auxiliary equipment that keeps the plastic molten.
In reality, the hot runner system is a critical component of the injection moulding process, influencing:
Melt quality
Flow balance
Shot-to-shot repeatability
Overall process capability
If hot runner zones are not established using scientific moulding principles and controlled with the same rigour as barrel temperatures, the process will struggle to achieve true capability.
Used correctly, hot runner systems enhance process stability and control. Used incorrectly, they often become little more than a Band-Aid applied to deeper design and process issues.
The Sierra 57 Perspective
At Sierra 57 Consult, our position is simple: Flexibility is a tool – not a cure for bad physics.
Whether you are running a simple cold runner mould or a complex 32-drop hot runner system, the objective remains the same: Achieve a balanced fill through intelligent tooling design – not by “cranking up the heat” on Zone 4.
A Question for the Industry
From your experience in injection moulding operations, what do you see more often?
Tools designed correctly and balanced from day one
Technicians using the hot runner controller to force an unbalanced tool to run
We’d be interested to hear your thoughts… [...]Read more...
16 February 2026All-electric – All-performance, was the order of the day, as ENGEL opened its doors, and welcomed partners from across the plastic injection moulding industry to get an in-depth view of their all-electric injection moulding machines, at their facility in Warwick, UK.
Widely regarded for their maximum output, maximum efficiency, and minimal footprint, visitors were treated to live demonstrations of both the e-mac and e-win injection moulding machines – the e-mac is the most compact all-electric machine in its class, while the e-win combines proven ENGEL technology with consistent standardisation, offering an attractive overall package.
The event also gave participants an insight into how ENGEL’s digital solutions are perfectly aligned with the life cycle of their products.
Mark Lawson, CEO, Sierra 57 Consult attended one of the four, half-day sessions that was well attended by the industry, enjoying the excellent demonstrations of ENGEL’s state-of-the-art and precision engineering applications.
The agenda was thoughtfully structured and well delivered, with a lunch period bridging the morning and afternoon sessions to maximise networking opportunities for visitors. Four presentations also enabled visitors to fully appreciate the ENGEL portfolio and ethos, including: Digital solutions & ENGEL AI, ENGEL all electric, and ENGEL UK overview and introduction.
While he was there, Mark also caught up with Senior Engineer Robin Brown, also in attendance, whose current position Katie Francis, Projects & Accounts Manager at Sierra 57 had helped to secure at Northampton based firm Plastivaloire. Mark said that it was great to catch up with Robin and hear that he has settled in well.
To find out more about ENGEL’s machine range you can visit: ▷ Injection moulding solutions from a single source – ENGEL [...]Read more...
9 February 2026If there is one event guaranteed to draw a crowd from across the manufacturing and engineering sectors, it is the annual FANUC UK Open House.
This year’s event took place from 27–29 January and centred on The Future of Precision Engineering – a nod to FANUC’s ROBOMACHINE portfolio and the growing need for manufacturers to deploy the right machinery and processes to remain innovative and relevant in an increasingly demanding manufacturing landscape.
Alongside the right tools, businesses also need the right people, supported by ongoing training to ensure they can keep pace with evolving industry trends. Sierra 57’s attendance – acting as a primary sponsor, exhibitor, and panel discussion contributor – was focused on educating and informing visitors on how effective recruitment, training, and retention strategies can be implemented, regardless of business size.
Sierra 57 regularly delivers training at customer premises, enabling businesses to upskill and empower employees without compromising throughput. More recently, we have collaborated with FANUC UK to deliver injection moulding-focused training courses at FANUC’s Ansty Park facility, combining Sierra 57’s expertise with FANUC’s industry-leading injection moulding machinery. As such, our participation at the event was a good fit.
Too often, training is viewed as an expense or a ‘nice to have,’ rather than a strategic necessity built around having the right skills at the right time. This point was well articulated by Sierra 57 CEO Mark Lawson during the day-three panel discussion, Education and Training in Manufacturing.
Audience engagement was very good, with numerous questions from the floor covering topics such as equality, the next generation of talent, apprenticeship support, investing in and empowering employees through ongoing training programmes, maintaining competitiveness, future UK growth, and promoting polymer and automation education.
A similarly high level of engagement was evident on the exhibition floor, where Sierra 57 spoke with no fewer than 52 businesses about upskilling staff, improving retention, and empowering employees to enhance shop-floor morale.
There was also a clear appetite for training from within, with 38 businesses registering interest in Sierra 57’s polymer training programme – further evidence of an industry keen to nurture and retain talent.
The event was well-delivered and provided Sierra 57 with the perfect opportunity to discuss the need for training, and we look forward to participating in future events.
To find out more about the services that the Sierra 57 team can deliver, please visit:
https://sierra57consult.co.uk – recruitment
https://sierra57training.co.uk – training
Alternatively, please drop us an email at: contact@sierra57consult.com
To find out more about the FANUC/Sierra 57 training courses, delivered at Ansty Park, Coventry, please visit: TRAIN WITH SIERRA 57 – FANUC Academy [...]Read more...
9 February 2026The annual Southern Manufacturing & Electronics show took place from 3–5 February 2026 at the Farnborough International Exhibition Centre. Sierra 57 attended the Farnborough-based event alongside partners PS Partnerships and PlastikCity, united under their umbrella brand, Plastic Matters.
The alliance was formed to support businesses operating across the plastics industry, providing expertise in recruitment and training, procurement and industry insights, as well as regulatory and plastics consultancy. All three brands pool their resources through a single point of contact, offering a joined-up approach to industry support.
Southern Manufacturing serves a diverse range of industries, including aerospace and defence, automotive, electronics assembly and production, industrial machinery, packaging, energy, marine, and medical and pharma/biotech – sectors that all, to varying degrees, rely on plastics and polymers.
Growing demand for sustainable materials and processes is reshaping the plastics industry, forcing businesses to balance competitiveness with consumer expectations and increasingly stringent manufacturing legislation. Achieving this balance requires upskilling and training, access to the right machinery and support, and robust regulatory, quality management, and consultancy expertise – all areas in which Plastic Matters can help businesses navigate change.
Southern Manufacturing is always a well-attended event, and 2026 was no exception. Strong footfall and high levels of engagement at the Plastic Matters stand reflected the evolving landscape of UK manufacturing.
Across the three-day event, Sierra 57 generated 18 recruitment enquiries and 33 training enquiries – clear evidence of current industry priorities. Businesses are not only seeking to attract the right people, but also to train and retain them so they can adapt to ongoing industry change. Well-trained employees are proven to produce better products and contribute more effectively to productivity and efficiency, and Sierra 57 is well placed to support businesses in sourcing and securing the right talent.
Such was the success of the event that Sierra 57, along with Plastic Matters, has already signed up for Southern Manufacturing 2027, securing the same stand that delivered such positive results this year.
The pace of change within the plastics industry shows no sign of slowing. As demand for more sustainable materials grows, alongside the rise of plant-based and bio-polymers, businesses must ensure their workforce remains informed, skilled, and relevant. It is here that the expertise of Sierra 57 becomes increasingly invaluable.
To find out more about the services that the Sierra 57 team can deliver, please visit:
https://sierra57consult.co.uk – recruitment
https://sierra57training.co.uk – training
Alternatively, please drop us an email at: contact@sierra57consult.com
To find out more about the work of Plastic Matters, please visit: Plastic Matters [...]Read more...
6 October 2025We’re excited to welcome Michal Sekula to the Sierra 57 Consult team as Polymer Engineering Consultant!
With strong expertise in polymer processing, process management and optimisation, Michal thrives in tackling new challenges and adapting to diverse industrial environments, passionate about passing on his expertise to the future of the polymer industry.
Please join us in welcoming Michal to the team – we’re thrilled to have him on board and look forward to the expertise and insight he’ll bring to both Sierra 57 Consult and our clients. [...]Read more...
5 June 2025Another fantastic Polymer Materials Science course has taken place at FANUC Europe expertly delivered by Neville Dudley from Sierra 57 Consult Ltd
The session was attended by 10 eager-to-learn participants, all keen to deepen their understanding of polymer materials and their reactions during processing. With Neville’s in depth of knowledge and passion for this subject it makes the course accessible and engaging for all levels.
This course, accredited by the Institute of Materials, Minerals & Mining (IOM3), is part of Sierra 57 Consult’s ongoing collaboration with FANUC Europe to provide high-quality training in polymer materials science.
Our next course on the 4th July at the Fanuc Academy is filling up fast, contact us to secure your space! [...]Read more...
4 June 2025Recognition for the Sierra 57 Consult Technical Recruitment Division
We are proud to recognised with the award for Best Plastics & Precision Engineering Recruitment Specialists in the 2025 HR and Employment Awards.
The award acknowledges our commitment to developing long term business relationships built upon our understanding of customer needs & pain points, first class professional communication, technical expertise and our ability to provide ‘outside of the box’ people solutions.
Thank you to our clients who trust us to source specialist talent and advise on business workforce strategies in such a competitive industry, as well as the thousands of candidates we support in securing new positions.
If you are seeking a specialist recruitment partner that understands the complexities and specifics of our industry then please get in touch, we welcome the opportunity to support your business in their people requirements. [...]Read more...
8 May 2025A Warm welcome to 3 great Polymer industry professionals who have joined Sierra 57’s Training Division this month, supporting our expansion plans for delivering more technical specialist onsite plastics modular training courses, educating and upskilling the masses for driving to close the skills gap.
Chris Bussey is our new Engineering Manager, a specialist within plastic injection moulding maintenance & automation, supported with 40 years hands-on experience. Chris is working closely with our R&D team for designing & delivering basic to advanced level training courses in electro-mechanical, hydraulic, pneumatic and robot applications within IM disciplines, as well us supporting injection moulding maintenance contract projects at customers sites.
Andy Skelson is our contracted designated Training Manager for our new onsite modular courses within Blow Moulding, Extrusion Blow Moulding & Injection Stretch Blow Moulding disciplines.
Andy offers our training division a wealth of experience within this discipline, is highly knowledgeable and an absolute training & delivery professional. A massive advocate of people development and helping others to progress further, Andy is highly regarded and respected within his field craft, and he complements our training team perfectly.
Andy is also available for supporting contractor projects for customers requiring advisory guidance on production & process operations for optimising business efficiencies.
John Allsop is our contracting designated Training Manager for our newly formed Plastics Extrusion Moulding training wing, having worked with our R&D team since January for formulating 22 x new Extrusion Moulding courses, basic to advanced levels for upskilling the workforce within this discipline.
John brings a myriad of expertise and applications, some 40 years knowledge and exposure, is a very personable & amiable character and is a champion for empowering & aiding the workforce for closing the skills gap for extrusion processing businesses. [...]Read more...
25 April 2025Combining hands-on training with expert recruitment to meet evolving industry demands.
Whilst the Training Division of the business continues to evolve and make a difference in upskilling the industry, Q1 of 2025 was also a very productive period for our Technical & Engineering Recruitment Division.
Working closely with our clients in the industry to fully understand their business, their requirements and their pain points, in order to best support their recruitment needs
Making use of our plastics industry network, resourcing tools and specific industry marketing platforms to source candidates with the required technical skillset and personal characteristics across a full range of disciplines including mould setters / technicians, process engineering, toolmaking, quality, maintenance, project management, sales & commercial, senior management, HSE, continuous improvement and logistics
Supporting work seekers to open up doors for them to secure new positions and opportunities within the industry [...]Read more...
25 April 2025Training, Training…and more Training
A busy April start for the S57 Trainers with planned onsite polymer materials and plastic injection moulding education for both upskilling and refreshing technical skills, correct terminology and competence boosting the manufacturing workforce.
Modular training courses of train on site, learn and apply new or refreshed skills, with space between the courses allow the trainees to retain and embed new knowledge, become more confident before starting the next course module phase.
Coaching and mentoring in between courses enforces knowledge retention and “right first time” applications for best practice operations, process optimisation & machine conditioning, driving for better “think out of the box” CI improvements, scrap reduction and improved cycle times and tool change turnarounds.
Are you aware that Sierra 57’s Trainers deliver courses across any shift pattern for ensuring your Trainees’ optimal learning curve is in sync with the shift they are accustomed to working on.
This makes clear sense to have your trainees mentally engaged with new knowledge whilst acknowledging their welfare when returning to their normal work shift.
Whether it’s an earlies, late, nights or weekend shift pattern, we shall work around your staff working patterns, we offer absolute flexibility to maximise your production operations & productivity. [...]Read more...
10 April 2025Sierra 57 Consult’s collaborative training initiative with FANUC Europe has been prominently featured in the latest edition of Automation, Control & Engineering Magazine (ACE). The article showcases how this partnership is setting new standards for technical training within the plastics manufacturing sector. By combining Sierra 57’s specialist recruitment and training expertise with FANUC’s cutting-edge automation technology, the programme addresses the critical skills gap facing the industry. The feature highlights real-world benefits of upskilling existing staff and preparing the next generation of engineers to meet the evolving demands of smart manufacturing and Industry 4.0.
You can read the full article in the ACE Magazine’s latest issue here: https://joom.ag/SZjd [...]Read more...
27 March 2025Sierra 57’s 2025 training series, hosted at FANUC UK, is here!
Polymer Material Science, CPD accreditation to IOM3
Plastic Injection Mould Processing, CPD accreditation to IOM3
Injection Mould Machine Appreciation & Robotics Appreciation
In today’s competitive manufacturing landscape, plastic injection moulding is crucial in producing high-quality, cost-effective products across industries such as automotive, medical devices, packaging, and consumer goods. Achieving efficiency, precision, and consistency requires skilled personnel who understand the intricacies of the process. Investing in specialist training for injection moulding operatives benefits both the industry and businesses.
“Trained plastic injection moulding personnel are invaluable assets to the industry, directly contributing to efficiency, quality, innovation, and safety. Sierra 57 helps our customers prioritise specialist training to secure long-term success in the evolving manufacturing landscape.” – Mark Lawson, Sierra 57 [...]Read more...
6 March 2025Successful February Training Wrap-Up: Elevating Skills and Knowledge at Counterplas Ltd and WHS Plastics Ltd with Expert-led IOM3 Standard Courses
An end to a busy February training, onsite training courses delivered to support personal training, development and upskilling injection moulding career & education knowledge to Counterplas Ltd and WHS Plastics LTD Pickering plant.
Neville Dudley and Tom Creasey delivering hi-content modular courses to Institute of Materials, Minerals & Mining (IOM3) standards.
Trainee feedback remains high and positive, ensuring increased morale, heightened interest for wanting to progress further, and promotes staff retention. [...]Read more...
3 March 2025A great series of courses being run this week at the Coventry academy at FANUC Europe.
✅ Wednesday: Polymer Materials Science – FS8 course, accredited to Institute of Materials, Minerals & Mining (IOM3) – delivered by Neville Dudley
✅ Thursday: Introduction to Injection Moulding Processing – delivered by Neville Dudley
✅ Friday: Introduction to automation & robots – delivered by Hara Konstantelia
If you would like to engage in any of the above specialist courses planned in for every month of 2025 at the Fanuc Academy, get hands on with the robots and take a deep-dive into polymer material properties & respective applications, contact the following to enquire of available spaces: [...]Read more...
3 March 2025This week, the GTMA – Manufacturing Resource Centre hosted another remarkable Meet the Toolmaker event, which brought together a diverse range of exhibitors and industry visitors. The event provided a dynamic platform for the UK’s leading specialists in precision engineering, toolmaking, automation, and people development to showcase their expertise and enthusiasm. It was a gathering brimming with positive energy, with all attendees demonstrating an unwavering commitment to innovation and collaboration across all industrial sectors.
The event highlighted the strength and resilience of the UK’s manufacturing sector, particularly within the precision engineering and toolmaking space. From cutting-edge automation solutions to bespoke tooling innovations, the event highlighted the vast array of services and technologies that these specialists offer. Whether it’s enhancing production capabilities or providing tailored solutions for complex manufacturing challenges, the industry continues to drive forward with expertise and ingenuity.
Among the event’s key figures were our specialist consultants, Ivor Griffiths and Mark Lawson, who were in attendance to meet with both existing clients and new customers. They engaged with industry professionals from a variety of sectors, discussing the latest trends and innovations in injection moulding and tooling. Their extensive knowledge and hands-on experience helped bridge the gap between customer needs and advanced technological solutions.
In particular, the event served as an excellent opportunity for networking, with many key industry figures and thought leaders in attendance. Whether it was discussing the latest advancements in toolmaking technology or sharing insights into best practices for automation, the atmosphere was one of collaboration and shared purpose. The positive atmosphere was palpable, and attendees left the event with a renewed sense of optimism about the future of UK manufacturing. [...]Read more...
5 February 2025A warm welcome to James Hayward, the latest addition to the Sierra 57 Consult Mould Training & Engineering Division as we continue to expand the team to meet the increasing demand for our onsite mould training and mould contracting support services.
A knowledgeable mould processing professional with demonstrable experience as Technical Manager for a leading medical device injection moulding manufacturer, James is passionate about passing on his expertise to the future of the polymer industry.
James joins the team as Senior Mould Training & Development Consultant and this week jumps straight into shadow training with Training Director Neville Dudley.
Delighted to have you onboard James at an exciting time of continued growth for the business. [...]Read more...
3 February 2025Injection Moulding Setters play a critical role in the manufacturing industry, particularly in sectors such as automotive, consumer goods, and packaging, where precision and efficiency are vital. In the UK, the salary of an injection moulding setter varies depending on factors like experience, location, and the complexity of the work involved.
On average, an Injection Moulding Setter in the UK can expect to earn between £28,000 and £35,000 per year. Highly skilled setters with expertise in more advanced systems, as well as those working in demanding sectors, may earn upwards of £40,000, especially in management or supervisory roles.
Geography plays a significant role in determining salary levels. For example, setters working in London and the South East, where the cost of living is higher, tend to earn more compared to their counterparts in other parts of the UK. In contrast, regions like the North West and Midlands may offer slightly lower salaries, though the cost of living is generally more affordable in these areas.
The role of an Injection Moulding Setter is highly technical, requiring proficiency in machine setup, troubleshooting, maintenance, and ensuring the quality of the final product. Those with additional skills in robotic automation, process optimisation, and lean manufacturing can command higher wages due to the added value they bring to the production process.
In addition to base salaries, many employers offer benefits such as overtime pay, pension contributions, and opportunities for career progression. As the demand for skilled professionals in the manufacturing and automation sectors continues to grow, injection moulding setters are expected to enjoy a stable job market with ample opportunities for advancement and salary increases over time. [...]Read more...
3 February 2025An Overview of the Role of an Injection Moulding Setter
The role of an Injection Moulding Setter is vital in the manufacturing industry, ensuring that injection moulding processes run efficiently and produce high-quality products. This job combines technical expertise, attention to detail, and problem-solving skills. For those with an interest in engineering and hands-on work, it can be a rewarding and stable career choice.
What is Injection Moulding?
To understand the role of a Setter, it is essential to first grasp the basics of injection moulding. This manufacturing process involves melting plastic and injecting it into a mould to create a specific shape or part. The process is widely used in industries such as automotive, electronics, and consumer goods production. The Setter is responsible for setting up and monitoring the machinery that carries out this process, ensuring that each product meets the required standards.
Responsibilities of an Injection Moulding Setter
The primary responsibility of an Injection Moulding Setter is to ensure the injection moulding machines are properly set up and maintained throughout the production cycle. This includes:
Setting Up the Machines
At the start of each shift, the Setter is tasked with preparing the machines for production. This involves selecting the appropriate mould, ensuring it is correctly aligned, and configuring the machine settings, including temperature, pressure, and cycle times. The accuracy of these settings is crucial to achieving the desired product quality.
Monitoring Production
Once the machines are set up and operational, the Setter must continuously monitor the production process. This involves checking for any issues such as irregularities in the moulding process, machine malfunctions, or product defects. If any problems arise, it is the Setter’s responsibility to troubleshoot and adjust the settings to maintain production quality.
Quality Control
A key aspect of the Setter’s role is ensuring the final products meet quality standards. This involves inspecting the moulded parts for defects, measuring them to ensure they conform to specifications, and ensuring they are free from any imperfections. If necessary, the Setter will adjust machine settings to improve the quality of the final product.
Maintenance of Equipment
Regular maintenance of the injection moulding machines is essential for avoiding downtime and ensuring optimal performance. The Setter is responsible for carrying out routine checks, cleaning the machines, and addressing any signs of wear or mechanical issues. Preventative maintenance is critical for ensuring the longevity of the equipment and the efficiency of production.
Key Skills Required
To be successful in the role of an Injection Moulding Setter, individuals must possess a variety of technical and practical skills:
Technical Knowledge: A strong understanding of injection moulding machinery, its components, and its operational processes is crucial.
Attention to Detail: Small variations in machine settings or material quality can have significant impacts on the final product. The ability to spot potential issues is key.
Problem-Solving Abilities: The ability to diagnose and rectify issues that arise during the production process is an important skill for any Setter.
Manual Dexterity: Since the job involves working closely with machinery, a certain level of physical skill and precision is required.
Suitability of the Role
The role of an Injection Moulding Setter is well-suited to individuals with a keen interest in machinery, a problem-solving mindset, and the ability to work under pressure. It is a dynamic and demanding role that requires both independent work and collaboration with other team members to ensure smooth production processes
Advantages of the Role
There are several advantages to pursuing a career as an Injection Moulding Setter:
Job Security: Manufacturing processes, particularly injection moulding, are in high demand across various industries, offering long-term job stability.
Practical and Engaging Work: The role involves hands-on work, providing a sense of satisfaction as one actively contributes to the creation of tangible products.
Career Advancement Opportunities: With experience, setters can progress to higher positions such as production supervisors or technical specialists, opening doors for career growth.
Challenges to Consider
While the role offers many benefits, it also comes with its challenges. It requires a high level of focus and attention to detail, as even small issues can lead to significant problems in production. The Setter must also be prepared to troubleshoot and resolve technical difficulties swiftly to minimise downtime. However, for those who enjoy overcoming challenges, this can be one of the most rewarding aspects of the job. In conclusion, the role of an Injection Moulding Setter is a crucial position within the manufacturing sector. It offers a combination of technical work, quality control, and problem-solving, making it an ideal career for individuals with a passion for engineering and manufacturing. With the right skills and experience, there is significant potential for career advancement in this field. The Injection Moulding & Robotics Appreciation course at Fanuc Academy offers hands-on training, blending automation and moulding processes, to help participants enhance efficiency, quality, and productivity using advanced robotic technology – contact us for more information & to book onto the course. https://fanuc-academy.uk/injection-moulding-robotics-appreciation/ [...]Read more...
16 December 2024At the end of another busy year at Sierra 57 we have taken time to stop, look back and reflect on what has been achieved. In 2021 we realised that developing skills in the moulding industry was of vital importance for effective workplace performance.
It was evident that countless moulders work hard day in day out pushing buttons but not totally understanding how injection moulding machines work. So, we took a step back and developed training courses to review the basics to build a foundation of knowledge to develop the skills required.
This enabled companies to maximise the potential of their teams by investing in their personal development. We have been able, through training, to help individuals to learn new skills, adapt to change and grow in confidence.
In three years, we have delivered 558 courses to 1,485 students with a 98% pass rate. With courses approved for CPD by the IOM3, 221 students have achieved CPD recognition for their training with 4,456 hours of training completed.
In 2024 our training team delivered 202 courses on our customers sites to 467 trainees. Seventy-four students have successfully completed 1,920 hours of CPD training with others working towards completion in 2025, made possible by the modular format of our training.
Our training team’s dedication to sharing their knowledge and experience has been welcomed by students and customers. It has been well received and recognised for the impact it has had within the plants we have worked.
Q4
In Q4, due to the requirement for training in 2025, we have added two trainers to the team, Vince Green and Tom Creasey who will be sharing their knowledge with trainees in 2025 as they deliver the training modules.
If you would like more information on the unique way Sierra 57 Consult delivers training to fit around your business needs to upskill your workforce contact info@sierra57consult .com.
By Richard Brown – Projects Director [...]Read more...
9 December 2024Greater Manchester’s SGH Moulds acquired by the Jalex Futures group in the first full acquisition by the investment firm.
The Buckinghamshire fund Jalex Futures Ltd, has acquired the Bolton based plastic injection moulding firm as part of a series of minority and majority investments since its formation in 2023.
SGH Moulds Ltd is a plastic injection moulding fir SGH Moulds Ltd m that provides a full range of services including tool design and manufacturer, and plastic injection moulding on presses up to 360 tonne.
With five manufacturing, design, tooling, post production assembly and injection moulding sites across Bolton, SGH Moulds is an established full service manufacturer in the North West. Founded in 1978, SGH Moulds started life as a family firm by father and son Kevan and Stephen Howarth, and later joined by sister Lynn Farrell.
It has grown from strength to strength and is now a supplier to numerous international businesses and household names in sectors such as automotive, medical and industrial.
“The acquisition of SGH has been a seven-month process from first meeting to completion. We’re delighted to welcome SGH into our portfolio which includes five other minority stakes in firms ranging from SaaS providers to a restaurant chain. British manufacturing is an exciting industry and we believe SGH is a wonderful platform for future growth” says Jalex Futures CEO, Peter Thompson.
“I’m also pleased to simultaneously announce the appointment of new Managing Director Martin Jones, a thirty-year veteran of the industry. Whilst both Stephen and Lynn are committed to supporting the business for years to come, Martin’s appointment allows them to start enjoying a well-deserved retirement. Working closely with Plastics industry resourcing specialist Sierra 57 Consult, they aided in selecting Martin Jones for this exciting role.”
Outgoing MD Stephen Howarth commented “I’m delighted to see SGH Moulds continue with fresh management, ideas and capital. I want to thank our staff, clients and suppliers for decades of support and commitment in making SGH the business it is today.”
Thompson started Jalex Futures Ltd in October 2023 after the sale of the business he founded, CanTrack Global Ltd in 2021 to the British private equity backed Radius Group. “My own exit showed me the challenges in selling an SME, going through one of the most important processes in your life with limited understanding of how it works. Often too small for PE, a tiny percentage of businesses ever sell and typically a trade sale or private buyer if they do.
I chose to focus on high growth businesses in a range of industries for minority investments, and target retiring business owners of established businesses for acquisitions. Succession planning is incredibly challenging for several reasons in SME’s and Jalex Futures understands the mindset, challenges and needs of those businesses exceptionally well.
I tend to think that younger founders whose challenges lay outside of retirement often have better options than to sell, and this forms part of the advice we provide companies from our experience. The challenge is often one of losing enjoyment from running the business, and this is often around how the owner is involving themselves in it.
Retiring owners have different challenges, there might be a lack of willingness or ability for family to take on the business. Often, it’s a practical need to get their inheritance planning in order, something the recent budget has brought into focus by bringing businesses into the scope of IHT. Planning for and exiting prior to retirement or passing, turns an illiquid asset into capital at the best value whilst the owner is present in the business.
[...]Read more...
2 December 2024A great 3 day event weekend with industry friends & customers in London, albeit some horrendous weather, it was a momentous few days.
🅱️ is for Brilliant Plastics Industry Awards event in London, very well organised by Jackie Hughes and team…. Well done Jackie 👏👏
💟 Huge thanks to our attending guests for helping us work the room fundraising for Midlands Air Ambulance Charity and Pam Batson supporting a very popular & busy casino evening sponsored by ARBURG LIMITED .Looking forward to finding what the final total raised is.
💟 well done to all finalists and winners in attendance,- really pleased in particular our friends PlastikCity, TH Plastics Ltd, Andy Jones, Richard Orme and Carl Futcher
🌐 Saturday: the must attend Winter Wonderland in Hyde Park,- bad weather forced us to take shelter in the Beer & Bratwurst tent. Damn shame 😏🤷♂️
🏉 Sunday: Joining FANUC Europe and their guests for 🏴 Vs 🇯🇵 match at Twickenham,- many thanks to Andy Armstrong and Oliver Selby for the invite 👌
Great to be around some marvellous people. Humbled 👌 [...]Read more...
25 November 2024New recruitment for the Sierra 57 team
✅ Vince Green joins us as Technical Manager – Training & Development. An experienced mould tooling & engineering professional, Vince has jumped straight in to our shadow-training induction at one of our customers, refreshing his injection moulding processing expertise and learning our methods for training, delivery of content and the application for best engaging with the trainee audience.👏 a warm welcome to the team Vince.
✅ Justin Davies joins the team as Business Director on a p/time basis to add value to our commercial team whilst exploring new business inroads for our training, mould contracting and recruitment divisions. Having served an extensive period within injection mould manufacturing,
Justin will be an asset to our teams. Having beaten his battle with Cancer this year, we’re pleased to see him back on form and sharing his knowledge and expertise with us.
👏 welcome Justin
Finally with Fanuc Europe
Finally a mighty fine 3-day expo at FANUC Europe HQ was enjoyed by our team of specialists, a good level of interest from visitors of the new Sierra 57 & Fanuc Academy training collaboration for plastic injection moulding & robot training….details to be announced next month, available training dates from Jan 2025 onwards.
👏 Big thanks to Andy Armstrong, Katherine Nowill and Lydia-Pearl Morrissey for working closely with us on the prep for this event. Outstanding work people 👊🏻 [...]Read more...
8 November 2024Tom Creasey has settled in well within our Training Division, undergoing Mould Training development and passing his Basic Core Moulding Discipline certificate, part of his CPD progression accredited to IOM3 Polymer standards. Sitting the course with trainees from WHS Plastics, our Trainer Mark Lee also demonstrates to Tom the essential methods for delivering education both practical & theoretical to ensure course trainees receive the best Q&A time for either learning new content & skills or merely refreshing moulding skills that are dormant because of lack of use, bringing their knowledge to the surface and helping them to retain core principles.
No trainee is the same, they have their own way of learning & embedding new education, this is why Sierra 57 technical moulding courses are delivered to a maximum of 3 per course, providing ample time to ensure all trainees learn within their own comfortable timeframe.
Well done Tom, passing part of your development journey and empowering & encouraging you to drive for intermediate & advanced levels of Polymer materials & plastics injection moulding expertise.
** Certificate presented by S57C’s General Manager Ivor Griffiths.
Author – Mark Lawson [...]Read more...
8 November 2024Sierra 57 were again delivering onsite plastic injection moulding training at WHS Plastics at the Pickering plant, part of the monthly training programme strategically designed with their Management to ensure the upskilling, people development and staff retention.
**Core basic moulding disciplines were delivered
Module 4, Fundamental Principles of Injection Moulding
Module 7, Clamp force and shot weight calculation
Module 9, Moulding faults, causes and remedies
Module 10, The Importance of Quality
Module 11, Simple tooling care and maintenance
Courses accredited to IOM3 Polymer standards, these courses contribute to their CPD hours and upon passing a minimum 70% post training score, they qualify for certificates.
Training was delivered by Mark Lee whilst also shadowing our new Mould Trainer Tom Creasey
.
Author – Mark Lawson [...]Read more...
9 October 2024✅ Sierra 57 Consult continue to work closely with WHS Plastics Pickering plant in delivering hi-content injection moulding training to help both educate and develop the very busy men & women doing a fine job in meeting productivity KPI’s and deliverables.
⚙️Having developed a monthly training programme with Operations Manager Dave Briston and Technical Manager John Gill, the last 12 months has produced good technical Polymer results and an uplift in personal morale with improved attention to detail applications across the shop floor. Mark Richardson, WHS Pickering Plant Director and Mark Lawson, S57C continue the collaboration for identifying best strategies for encouraging and empowering their important staff.
📣Congratulations to the staff trainees for your superb pass results and enthusiastic feedback of our Training.
Polymer Training delivered:
Module 5 – The importance of Process Monitoring
Module 6 – Machine Design & Construction
Module 8 – Machine Control
Module C – Basic Tool Design
Author: Mark Lawson [...]Read more...
24 September 2024Neville Dudley recently delivered training of the 2 day Module F – Team Leader & Manager Injection Moulding Appreciation Course, a good hi-content overview of basic operating fundamentals within mould machine, ancillaries, process, material and the understanding & expectations of the Operators who daily work on their bespoke mould equipment.
Whilst this course is pertinent for all Leaders to have a good understanding of injection moulding operations, it is perfectly designed for them to have a good understanding of the daily operations of their technical staff, for both encouraging & empowering their staff, but also to have a better working cohesion with their staff when conducting their staff’s performance reviews throughout the year. Morale is greatly improved on the shop floor when the Technical mould staff appreciate their superiors have a good understanding of their daily working regime and fulfilment.
Author: Mark Lawson [...]Read more...
9 September 2024Neville Dudley delivered hi-content Polymer materials Training courses across 2 days to MOCAP in Sheffield recently, – a global leading manufacturer of quality Plastic Injection Mould, Blow mould & Rubber moulding caps & closures.
Positive comments received from Scott Ashton , European Operations Manager: “it was great to have Neville down on plant for last 2 days Aug24, his attention to detail delivery across the intermediate levels of Materials modules really broadened the knowledge base of our Trainee Sam, who found it extremely informative and took away some good positives and areas it will help us improve across the business. Having Sierra 57 on site and flexible to work around our shift patterns and business operations provides us with the flexibility for less impact on production whilst empowering our staff with the upskilling & development we need to meet the needs of the business’ technical expertise. I highly recommend Neville Dudley and Mark Lee as trainers to all moulding businesses, – very knowledgeable polymer professionals”
#14 – Materials Level 3, Morphology & Chrystallinity
#15 – Materials Level 4, TG and Design Influences
If you are keen to understand how our materials training can assist your staff’s Polymer awareness and advancement, look at below website link to understand what content the materials modules entail
https://www.sierra57training.com/plastic-materials-training/
Author – Mark Lawson [...]Read more...
30 August 2024Sierra 57 Consult’s mould trainers have been working closely with White Horse Plastics to upskill, develop & advance their Moulding staff’s expertise and knowledge, whilst aiding in retaining their newly developed skillsets…and both people morale and productivity has been recognised throughout the business efficiencies and optimum output.
Testimonial by Frank Crawley, Director at White Horse Plastics:
“Sierra 57 Consult, a great team of talented people supporting the injection moulding industry, White Horse Plastics have engaged them to deliver well-constructed training programmes and will continue to do so. Trainer Mark Lee delivered the programmes with exceptional professionalism and received great feedback from our Setters at all levels”
WHP are a leading precision injection moulding manufacturer specialising in the manufacturing of components for the Medical, Consumer & Engineering sectors.
Some of the USP’s:
Trusted supplier to the automotive industry for over forty years
Experienced manufacturer of medical components
Specialists in biopolymer moulding
Robust quality processes
End to end manufacturing service from DFM to despatch
Engineers that frequently work at Cpk values > 2.0
Accreditations ISO 13485, ISO 9001, IATF 16949 & ISO 14001
Author – Mark Lawson [...]Read more...
12 August 2024Sierra 57 Consult (S57C) are well positioned to support a business’s strategic growth, succession planning and upskilling of a workforce as a strategic partner from one of its four business arms. These being Technical & Engineering Recruitment, Polymer Process & Materials Training, Engineering Consultancy and Contract Process Engineers.
Every business faces challenges, whether that is from staff retirement, transient personnel or unexpected processing demands. To mitigate these demands a strategic plan is important as it enables positive response to these challenges, reactivity or remaining passive are not the way forward and S57C can work alongside you to help develop your workforce and fill your skill gaps.
RECRUITMENT SERVICES
The focus of the team is to support businesses and people to succeed, whether that is finding new roles, upskilling their team or filling a short-term gap in the organisation. This has been achieved by building long lasting relationships with both businesses and candidates.
S57C have a distinctive approach to recruitment as they work in collaboration with the client and potential candidates using their knowledge, expertise and experience of the sector to ensure success for both business and candidate. With a far-reaching network they can offer a bespoke and structured approach to plug those difficult to fill vacancies.
At S57C, all businesses and candidates receive excellent communication during the recruitment process, providing support and constructive advice. They tailor each recruitment assignment to meet the objectives of the client and candidate to ensure a good fit.
POLYMER PROCESS & MATERIALS TRAINING
In 2021 S57C, recognising that the sector faced a major challenge due to significant skills gaps and an ageing workforce; established a training division. This was undertaken by listening to the voice of the customer to determine what their ideal training provider would look like. From the feedback they learnt that the main challenge was releasing staff for an extended period away from the workplace and lack of follow up after training. S57C came up with a training model that delivered bite size modular training on the client’s site that builds up to Continuous Professional Development (CPD) accredited by the IOM3 and follow up mentoring/development to reinforce skills learnt. S57C recognise that Training and Development go hand in hand, training being the process that you use to teach employees the skills they need for their current job. While training focuses on specific areas of knowledge that employees need to fulfil their day-to-day tasks. Development is focused on the career progression of the employee with the activities based on each individual’s career goals and areas of improvement that help them take the next step in their profession.
Research has shown that an employee’s skills generally have a “half-life” of about 5 years, with more technical skills needing improvement after just 2.5 years. It was also found that nearly 30% of skills are lost annually because they aren’t performed regularly or reinforced through training/development. This means that employees continuously need to complete training/development that improves their business, technical and soft skills.
In 2022 S57C won the Plastic Industry Awards Training and Development category for the way they met the needs of TEX Plastics (Barnstable) delivering their high-quality training modules which bridged the skill gaps providing an immediate solution and creating mentors within the business to encourage others.
This was followed up in 2023 with S57C winning the Plastic Industry Awards Best Business Initiative category for its approach to providing an online Training Need Analysis Portal. This identifies an individual skill gaps to ensure the correct training is delivered maximising the ROI on training.
The S57C approach has been very successful with training statistics that speak for themselves since inception:
405 courses delivered
1,108 people trained
98% pass rate
174 IOM3 accredited CPD certificates issued
3,904 IOM3 accredited CPD hours completed
ENGINEERING CONSULTANCY
S57C can also provide, via their Engineering Consultants, expertise and guidance on engineering projects and advise customers how best to meet their design for manufacture and processing needs. We are able to discuss the technical needs and then project manage the implementation of technical solutions in accordance with industry best practice. Our aim is to:
Understand the needs of the project and scope out the deliverables
Conduct research, interviews and analyse the data to resolve the issue
Detect the issues and propose ways to resolve them
Identifying the advantages and disadvantages and providing solutions
Developing and implementing new procedures and training to support the introduction of these.
CONTRACT PROCESS ENGINEERS
When there is a short-term need for expertise S57C can provide a solution by offering a Contract Process Engineer to work on site with your team. They have the knowledge to deliver fit for purpose solutions to process engineering issues and New Product Introduction (NPI). Our consultants have good all-round experience covering IML, Medical, Automotive and contract moulding sectors.
SUMMARY
S57C can offer a blend of services from recruitment to training. The combination of structured bespoke bite-size industry led training, consultancy and contract services are aimed at all operational levels with a focus on enhancing skills, knowledge, productivity and Overall Equipment Effectiveness (OEE).
This suite of solutions help to tackle skill shortages whether via recruitment, upskilling via training, onsite consultancy or a processing engineer on site for short term project or tool trailing.
https://www.sierra57consult.co.uk/
https://www.sierra57training.com/
Contact: info@sierra57consult.co.uk
Tel: 01684 217 680
Author – Mark Lee [...]Read more...
31 July 2024Injection Moulding Process
As most of us are aware the injection moulding process, as with most other polymer conversion processes, have four main inputs:
Machine
Mould or Die.
Process inputs.
Material.
With other materials manufacturing industries such as metallurgy and ceramics industries, greater emphasis is placed upon the understanding of and training surrounding the material in question. The UK Polymer Conversion industry has been slow to recognise the importance of training against the very material that we ask our setters, technicians and process engineers to work with and process on a daily basis.
Understanding how polymer materials work
Understanding how polymer works, it’s Non-Newtonian characteristics and flow behaviour impact significantly on every aspect of the process from cycle time to product quality and in service performance. To help combat the current skills shortage and fill the knowledge gap Sierra 57 Consult has developed a range of modular Polymer Materials based training programmes aimed at all levels of understanding and accredited by The Institute of Materials (IoM3):
Basic Materials Concepts.
Polymers and Additives.
Crystallinity and Morphology.
Tg and Design Influences.
Fluid Dynamics.
These progressive, modular courses are half or full day in duration and are aimed at all personnel both technical and non-technical wishing to improve their current understanding of Polymer materials.
Please register your interest to attend one or more of these popular modular programmes by contacting hi@sierra57training.com
Author – Richard Brown [...]Read more...
31 July 2024We are thrilled to announce that our efforts in delivering advanced Polymer materials and Injection Moulding training courses are yielding significant results. This year, we have seen a remarkable turnaround in RFQs (Request for Quotation) stemming from connections made at @medtech2023. Our training modules are now firmly recognised by several leading Medical Device Trade Moulders and OEMs across the UK and Ireland, reinforcing our position as an industry leader in plastics education and training.
Revolutionising Training with Bite-Sized Modules
Understanding the diverse learning needs of our clients, Sierra 57 has developed a unique approach to training. Our courses are segmented into bite-sized modules, allowing staff to learn at their own pace. This method ensures that the new education is not only well received but also retained effectively, making a tangible impact on operational efficiency and product quality.
Our training programs are also accredited by the prestigious @IOM3 (Institute of Materials, Minerals, and Mining), a testament to the quality and relevance of our curriculum. Each course is delivered by time-served Polymer Processing Experts who bring a wealth of practical experience and industry knowledge to the table. Their expertise ensures that our clients receive the most current and applicable training available in the industry today.
Supporting ISO13485 Compliance
For companies aiming to attain or maintain ISO13485 certification, our training programs provide essential support. We understand the critical importance of regulatory compliance in the medical device sector. Our courses are designed to align with ISO13485 standards, ensuring that your staff are equipped with the knowledge and skills necessary to uphold these stringent requirements and improve efficiencies within your manufacturing organisation.
Empowering Staff and Driving Innovation
Our training programs are not just about meeting regulatory standards; they are about fostering innovation and promoting professional growth within your organisation. By empowering your staff with advanced knowledge and skills, we help drive new product introductions (NPI) and enhance overall operational efficiency.
Client Testimonials
Our clients have consistently praised the impact of our training programs. A leading OEM in the UK stated, “Sierra 57’s training modules have transformed our approach to polymer processing. The bite-sized format made it easy for our team to digest and apply the new knowledge, leading to immediate improvements in our production line.”
Join the Ranks of Industry Leaders
As we continue to expand our reach and impact, we invite other medical device manufacturers and trade moulders to experience the benefits of our advanced training programs. Whether you are already ISO13485 certified or working towards it, our tailored training solutions can help you achieve your goals. Training and development within our industry is vital for growth in UK Manufacturing.
To learn more about how Sierra 57 can enhance your staff training and support your new product introductions, please contact us at contact@sierra57consult.com. Our team is ready to help you elevate your operational capabilities and stay ahead in the competitive medical device industry.
Author – Mark Lawson [...]Read more...
26 June 2024We are happy to share the recognition of the recent training success provided by Sierra 57 to their exceptional team of Mould Setters and Process Engineers at the Owen Mumford medical device manufacturing plant in Chipping Norton. 🚀
Over an intensive 5-day period, our mould experts delivered comprehensive troubleshooting and materials training, accredited to IOM3 standards, empowering the team with advanced skills and knowledge. The dedication and enthusiasm displayed by the Owen Mumford team were truly inspiring!
Key Highlights from the Training:
🔹 Hands-On Troubleshooting: Practical sessions that equipped the team with real-world problem-solving skills.
🔹 Materials Expertise: In-depth understanding of material properties and their impact on production processes.
🔹 Collaborative Learning: Interactive workshops that fostered teamwork and knowledge sharing.
The feedback from the participants has been overwhelmingly positive, highlighting the immediate improvements in efficiency and problem-solving capabilities. This training is a testament to the power of investing in your team’s development and the tangible benefits it brings to operational excellence, optimising productivity & processing efficiencies .
A huge thank you to Owen Mumford for their commitment to continuous improvement and to the Sierra 57 team for delivering solid high-content training courses. Together, we are driving innovation and excellence in the industry! 🌟
Author – Mark Lawson [...]Read more...
30 October 2023 We are sponsoring the British Plastics Federation Dinner tomorrow night. It’s their 90th Anniversary
Sierra 57 Consult Ltd are proud to sponsor the British Plastics Federation Annual Dinner on Thursday 12th October 2023, being held at the Royal Lancaster London Hotel, Lancaster Terrace, London W2 2TY
We will be of course attending, with key people & friends of Sierra 57 Consult Ltd; looking forward to an eventful networking evening with wine & dance.
There will be over 400 guests from across the plastics industry for an evening of entertainment and networking.
You can still register to attend this important event on the Plastics Industry calendar. https://lnkd.in/eRx_-gFT
Sierra 57 Consult Ltd look forward to seeing you there
#bpfdinner
#plasticsindustry
#technicalrecruitment [...]Read more...
13 October 2023A great Evening for Sierra 57 Consult Ltd @ BPF 90th Annual Dinner
We at Sierra 57 Consult Ltd would like to thank British Plastics Federation for a magical evening, attending the BPF Annual Dinner. This year celebrating its 90th anniversary.
The event look place last night (Thursday 12th) & was, as promised, a great networking opportunity with dinner & wine flowing. Ed Balls provided an enthralling after dinner talk, with anecdotes from Parliament & Strictly. It was superb!
Sierra 57 Consult Ltd were sponsors, & took a table of close associates & partied late (as always)! We had a fantastic time.
To those we met – it was good to see you all & catch up with the movers & shakers in the Plastics Industry.
If you didn’t manage to catch up with us at the event to chat about what our award-winning Sierra 57 Consult Training or our expert Technical Recruitment can do for your business, be sure to get in touch.
We look forward to speaking to you.
Thanks again British Plastics Federation for a great evening
https://www.bpf.co.uk/article/bpf-annual-dinner-2023-3415.aspx [...]Read more...
8 September 2023Congratulations to Adam Nowalinski Zeke Murthi and Jake King from Pentagon Plastics Group Ltd for successfully passing the following training at Graham House:
Module 12 – Materials level 1 – Basic Material Concepts
Module 13 – Materials level 2 – Polymers and Additives
For more information of S57 Plastics Industry Awards winning injection moulding courses, contact us or visit our website https://lnkd.in/ezr98aPG
#injectionmouldingtraining #polymertraining #plasticsmanufacturing
https://www.pentagonplastics.co.uk/
Unit 4,
Blatchford Road,
Horsham,
West Sussex,
RH13 5QR [...]Read more...
8 September 2023Congrats to the Polypipe team for successfully completing:
PD1: Injection Moulding for Beginners.
PD5: Basic Understanding of Plastics Materials.
Your hard work is paying off- just imagine what you’ll do next!
https://www.polypipe.com/
Broomhouse Lane
Edlington
DN12 1ES
#plasticsmanufacturing #injectionmouldingtraining #manufacturing [...]Read more...
6 September 2023Sierra 57 Consult, a specialist precision engineering recruitment and consultancy agency based in Worcestershire, UK, announces its latest achievement – winning the prestigious title of Best Precision Engineering Recruitment Agency 2023 – UK. This recognition not only highlights the exceptional commitment of Sierra 57 Consult but also underscores the profound benefits it brings to its valued customers.
With a strong focus on customer satisfaction and dedicated service, Sierra 57 Consult offers expert technical recruitment, onsite mould training, and tooling validation project management, and is committed to meeting the evolving challenges of the plastics industry.
Ivor Griffiths, the General Manager of the Recruitment Division at Sierra 57 Consult, shares his insights, “Working closely with our industry associates, we strive to offer a broad reach that covers various industry sectors. Our mission is to support our clients in the plastics manufacturing industry by sourcing the most skilled candidates and assisting them in retaining top talent within their organisations.”
When it comes to Sierra 57 Consult’s team, the emphasis is on finding the best fit. Ivor highlights, “The most important thing for us when searching for new staff is for candidates to have the right positive, professional attitude and the drive to learn and develop their own knowledge bank.” This focus enables Sierra 57 Consult to deliver unparalleled service to its clients, catering to their unique requirements. The company has a wealth of combined experience but provides comprehensive training to ensure everyone is aligned and offers clear growth opportunities within the organisation.
At Sierra 57 Consult, effective communication is the cornerstone of success. Maintaining the highest standards of communication with clients and candidates alike ensures a thoroughly professional service and keeps everyone updated throughout the process.
In 2022, Sierra 57 Consult’s Plastic injection moulding training arm which won the 2022 Plastics Industry Award for ‘Best Training and Development Initiative’, delivered 181 courses to 455 individuals, achieving an impressive 96% pass rate. These courses are accredited by the IoM3 for Continuous Professional Development, reflecting Sierra 57 Consult’s commitment to providing valuable ongoing learning opportunities.
As Sierra 57 Consult garners well-deserved recognition as the Best Precision Engineering Recruitment Agency, it continues to prioritise customer satisfaction and exceptional service. This achievement reaffirms its position as a trusted industry leader, poised to exceed expectations and deliver outstanding results for its customers in the years to come.
To read the full article https://www.sme-news.co.uk/issues/uk-enterprise-awards-2023/167/ [...]Read more...
31 August 2023Congratulations to the Team at River Manufacturing for successfully completing:
Module B: Zero Parameter Set-Up Injection End.
Their trainer, Adam Nowalinski, is a skilled and experienced, time-served injection moulder who whilst delivering training in English, can also use his native Polish language to help Polish speaking staff understand English technical moulding terminology, interpretation and technology.
https://www.rivermanufacturing.co.uk/
61-63 Windmill Road, Sunbury on Thames, Middlesex, TW16 7DT
#plasticsmanufacturing #injectionmouldingtraining #injectionmoulding [...]Read more...
30 August 2023Congratulations to the 6 Haitian Injection Moulding Machinery trainees who successfully completed ‘Module N: Materials Handling’ at their impressive new purpose built training facility!
S57 is honoured to have facilitated the first training course at the PMM showroom, delivered expertly by our trainer Neville Dudley – a veteran of 40 years in the plastics industry.
#EngineeringExcellence #TrainingForSuccess #Injectionmoulding
Premier Moulding Machinery (PMM)
Ladymead Business Park
Quainton
Aylesbury
Buckinghamshire
United Kingdom
HP22 4AN
https://haitian.co.uk/ [...]Read more...
25 August 2023Motherson SMR Group Training
Good job everyone at Motherson Group who attended training with Sierra 57’s trainer Neville Dudley.
This is what they have been hard at work studying:
Module H: Basic Mathematics.
Module 5: The Importance of Process Monitoring.
Module 6: Machine Design & Construction.
Module 7: Clamp Force & Shot Weight Calculations.
Module 8: Machine Control.
Module C: Basic Tool Design.
Training not only helps improve the quality of work, it also helps increase staff motivation and improve productivity. [...]Read more...
20 August 2023Leadership requires continual growth and learning.
Cubis Systems leader demonstrates commitment to both with the successful completion of Module F: Team Leaders IM Appreciation.
For more information on S57 specialist injection moulding courses: https://lnkd.in/eqDJejKD
https://www.cubis-systems.com/uk/
4 Silverwood Industrial Estate
Lurgan Co.
Armagh
BT66 6LN [...]Read more...
12 August 2023Injection Moulding Training @ Sierra 57 HQ
Materials Modules being delivered at the Malvern Sierra 57 Training Centre this week:
⚙ Module 12 – Materials level 1 – Basic Material Concepts
⚙ Module 13 – Materials level 2 – Polymers and Additives
⚙ Module 14 – Materials level 3 – Morphology and Crystallinity
Great to see trainees attending from Plastic Supplies Dudley Ltd, A K Industries Ltd and Talisman Plastics .
Education unlocks attendees’ true potential! Neville Dudley and all our trainers tailor the courses to the speed of each trainee’s own learning pace, so they are able to learn, retain, and expand their knowledge base like never before. #educationispower [...]Read more...
6 August 2023We’d like to congratulate Talisman Plastics ‘s Simon F.-Thomas Goodwin and Robert Ambroziak on successfully completing the following training:
Simon F. & Thomas Goodwin:
PD 5: Basic Understanding of Plastics Materials
Module 14, Materials level 3 – Morphology and Crystallinity
Robert Ambroziak:
Optional Module H – Basic Mathematics
Module 1, Health and Safety in the Workplace
Module 2, Fundamental Principles of Pressure and Speed
Module 3, Mould Protection
Module 4, Fundamental Principles of Injection Moulding
Module 10, The Importance of Quality
Module 11, Simple tooling care and maintenance
Module PD 1: Injection Moulding for Beginners (32 hours CPD)
If you are interested in finding out more about our bite-sized, on-site, IOM3 (Institute of Materials, Minerals & Mining) approved specialist mould training [...]Read more...
30 July 2023OGM: Plastic Injection Moulding Manufacturer investing in their staff training to ensure the highest standards of production and employee satisfaction. The team successfully completed:
Module E: Safe Tool Mounting
Module H: Basic Mathematics
Module 12: Materials Level 1
Module 13: Materials Level 2
Learn from the best! Training delivered by Mark Lee who has over 30 years of injection moulding experience and is an expert trainer. S57 courses fully accredited by IOM3 (Institute of Materials, Minerals & Mining).
#injectionmoulding #polymerindustry #imjectionmouldingtraining
Home
[...]Read more...
25 July 2023Congratulations to Synthotec Limited‘s Tiby, pictured with Ops Director Wayne Williams and Ivor Griffiths for successfully completing the following training:
Module A – Zero Parameter set up- clamp end.
Module B – Zero Parameter set up- Injection end.
Achieving – Module PD 4: Intermediate Injection Moulding Practical (32 hours CPD).
???? Investing in your team is investing in your success ???? [...]Read more...
10 July 2023How does your workforce fare against your competitors? Are you investing in your people for upskilling & development? Are you a business looking to grow and drive forward?
Why is there a lack of well qualified injection moulding technicians? Has this been a result of a reduction in companies training people in the past due to recessions and the COVID pandemic? You could argue that it is also partly caused by historic changes to the apprenticeship scheme by the Government. We also have an aging workforce where we are haemorrhaging Polymer / Moulding skills out of the industry.
Do you know what the level of skills are in your business? Are you ready for future business?
Sierra 57 Consult can help you assess the knowledge in your business by way of a skills audit and recommend an upskilling & career development route.
We are seeing a real push across the UK to start training and upskilling more individuals currently as businesses look to close their skill gaps following a skills audit.
If you are amongst those that believe there aren’t enough good Moulding Technicians, please don’t complain about it…..start enquiring about the best methods bespoke to your business for training your people, promoting your business and retaining the right personnel that want to succeed for greater aspirations, which in turn promotes your company and “right first time” products.
Contact Sierra 57 Consult’s Mould Training division, speak with the Polymer team who can help you on your training journey, and design an affordable and efficient road map for your workforce.
“Protect your workforce, invest in their ambition, close the skillsgap”
[...]Read more...
5 June 2023Businesses are recognising that their future economic prosperity and the ability to maintain and enhance a competitive advantage over their international competitors can be derived through the prioritisation of strategic investments in human capital and, in general skills.
Indeed, much research highlights that the attraction and retention of talent should be the top priorities of a business. Attracting the right employees is as critical as retaining existing employees with retention being an important aspect.
We all need to maintain a constant focus on investment in our human capital to ensure we are equipped with high-quality people with the required skills. This is crucial to sustaining long-term productivity and economic competitiveness.
World-class technical skills lie at the heart of all successful polymer companies, and this is where Sierra 57 Consult are focussing on as we help our customers grow. We recognise that you need to constantly concentrate on the expertise of the team to remain at the cutting edge of innovation and manufacturing excellence and thereby support sustainable growth and development.
The focus of Sierra 57Consult is to support the evolution of polymer processors via recruitment, training and mould contracting, networking to create strong and lasting relationships whilst working as a partner to our customers helping to empower them by enabling the ongoing upskilling learning and development of their employees.
We recognise that many companies are struggling to recruit candidates with the skills they require but have not considered training to up-skill their current workforce to fill the skills gaps.
Key advantages to upskilling your team with training are:
Save and increase revenue in the long term.
Improving performance and efficiency.
Attract new business with the additional skills.
Keep up to date with the industry standards.
Keep employees motivated and productive in their job.
At Sierra 57 Consult we have a team of exceptional trainers, with experience at the ‘coal face’, ready to identify and deliver the training required on site in your facility.
We are currently working with employers who are investing money, time and energy into employee training, development, and growth – tactics that employment experts have long pointed to as being crucial for strong team morale, long-term employee retention and successful word-of-mouth-driven recruitment.
It is important to offer all employees the opportunity for workforce development by improving their skills. It is to easy to let training take a backseat to other expenditures but the most effective way to reduce scrap, cycle times, set up times and downtime is to provide the necessary skills to the workforce. This will have the greatest effect long term on the business.
Sierra 57 Training Approach
How do Sierra 57 Consult approach this? One of our expert trainer/consultants will come to your facility and train a group of your team members together. This is a cost effective way to include teams from multiple departments and it eliminates the need for travel and extended time away from work.
This is an ideal method of training because you’re able to use your own machines and we can customise training to your specific needs. Working with you we can also create a training implementation plan to ensure long-term business success.
The benefits of in-plant training are mainly:
Train a number of employees simultaneously.
Eliminate travel costs.
Reduce time away from work.
Use your own machinery and equipment.
Customised training for your specific needs.
Get everyone speaking the same language.
In-plant training means we train at your facility to provide the training identified, we can offer one-on-one training and mentoring if required. Following the training/coaching your team will walk away speaking the same processing language, which often improves organizational efficiency and communication. [...]Read more...
26 April 2023There has been a growing skills gap in the worldwide plastics industry for many years. As technology moves on, this has become even more of an issue. There is no quick fix, but a good start can be made by investing in training and offering more apprenticeships to bring new people into the sector.
Career Paths and Organisational Goals
To ensure the long-term success of a company, staff must be made aware of the available career paths. To support that, managers must be able to recognise how those roles are critical to meeting organisational goals. Investing in employees so they can advance their careers is common sense; employers who invest in their teams are able to hire, retain and develop the most productive and motivated employees.
Why Employees Leave
Some companies might say that staff attrition is to be expected and this makes them reluctant to invest in training. In many cases they blame the economy, modern cultural trends, the retirement of baby boomers and poor retention linked to millennials being perceived as notorious job hoppers.
However, in many cases, the reasons for people leaving a company are related to the development strategy of a given business and a lack of internal training. Capable and ambitious employees are constantly looking to expand their expertise and improve their skills, to stay up to date to help advance their career. If an employer does not offer learning and development opportunities, they risk demotivating and ultimately losing their talented staff members.
Selling the Benefits of Training
It is the lack of training and learning opportunities which leads to frustrated employees looking elsewhere for professional career progression and job satisfaction. Correspondingly, happier and more contented employees who are supported through training are more likely to be loyal to their employer.
If you are interested in introducing a training plan, it needs to sell the benefits to both the staff and the business. Team members can sometimes show resistance to training if it is presented as mandatory. However, when it is linked to an employee’s professional and personal objectives, while being relevant to the organisational strategy, it is far more likely to be accepted.
Training Needs Assessment
A good starting point is a skills audit using a Training Needs Assessment. This can identify gaps in the organisation and ensure that any training delivers the correct level of training, while meeting the requirements of the organisation.
Ongoing Training
Most importantly, training must be presented as a project, rather than the traditional one-off activity. Additionally, trainees must be given the time and resources to implement knowledge gained. The most effective training can show significant return on investment when correctly implemented, with a world-class workforce helping to drive profitability.
It was the renowned American motivational speaker, Zig Ziglar, who said, “What’s worse than training your workers and losing them? Not training them and keeping them!” The challenge we all face is to invest in our employees by offering ongoing training and development opportunities. By doing so, we can retain our talented staff members and help drive organisational success. [...]Read more...
21 April 2023A question often asked is whether employee training is a smart investment. It’s accepted that employee training can be a significant investment, yet it will return increased productivity and sales to a business.
Creating a better working experience through training encourages employees to develop and can also help a business save on expenses/strategy budgets by reducing staff turnover and, subsequently, recruitment costs by onboarding a new employee.
Cultivating and encouraging a positive work culture is a positive way to nurture staff and benefit your business. When it comes to employee motivation, one method to achieve this is through investment in training. Employee training can improve self-worth among staff, inspire their engagement and reinforce their value to the business.
Offering training shows that you appreciate your employees by allowing them to develop in their day-to-day work. Improving employee experience in this manner is critical to retention.
Empowering employees with the opportunity and knowledge to aid their growth benefits the employee and the business. Overall, it will inspire the employee to stay with the business.
Building pathways to develop skills builds excitement and anticipation for results, increasing employee self-worth.
Training planned and rolled out effectively can help employees see potential career progression enabling a business to explain exactly how their efforts contribute to the business.
So, returning to the original question, ‘Is Employee Training a Smart Investment?’
Let me summarise the answers:
Yes, it’s a Smart Business Decision.
Training is an ongoing process for most successful companies.
If you’re not training your employees, who is?
Are they learning their skills from unqualified sources?
A good training plan helps you to invest your training budget more effectively.
If your employees are being trained piecemeal, are they getting a consistent message for processing used unilaterally in your company?
Skilled employees need less supervision.
Skilled employees require less management to complete their job, leaving more time for management to address other issues.
It can reduce employee turnover.
Employees that receive regular training have more confidence and self-worth and are therefore less likely to seek employment elsewhere.
Sierra 57 can help you identify the areas where training is required by using a Training Needs Assessment of your team. We can then offer a structured development/training plan setting up markers for career progression as expectations are met.
It’s important to introduce regular employee training once the journey has started, designating time for training so that staff development becomes part of the routine. Normalising training ensures it remains a business priority to ensure success.
Completing employee training takes time; not everyone can learn simultaneously. That is why Sierra 57 keeps class sizes small and offers one-on-one mentoring as part of the training journey. It’s important that you do not overload employees with unrealistic expectations and work within their capacity. This approach encourages retention and feeds empathy for your employees and their needs.
Having a room in your budget for employee training motivates your team and should be communicated to them. Trained employees are engaged employees, so by investing in your staff, you invest in the workplace and the future of the business.
Boost engagement and empower your team through training. Speak to Sierra 57 Consult to see how we can help you train, coach and police your staff skills progression. [...]Read more...
19 April 2023(Report by Richard Brown, Sierra 57 Director)
It’s been reported that four in five businesses are struggling to fill vacancies because of a lack of skilled workers — the highest number in 17 years.
Six-fold increase in reports of skills shortages in 10 years
The number of employers reporting skills shortages has increased six-fold over the past decade, according to the annual survey of more than 2,000 UK employers, conducted recently by the Manpower Group, one of the UK’s largest statistics & data gathering companies.
At Sierra 57 Consult we are witnessing a similar trend with vacancies at an all-time high with businesses looking to fill the gaps within their businesses. Talent shortages are always a concern for employers, and we are hearing that they are acutely aware of the increasing scarcity of key skills they require. So, they are trying to hold on to their business-critical talent but all too often companies talk about their culture, opportunities and in-house mobility, though the truth at times S57C is finding is very different when candidates approach them looking for their next career opportunity.
Most businesses lack the skills and resources to train in-house successfully
There is a battle for talent going on, but it needs to be recognised that many businesses are very poor at skills training in all of its many aspects. This leads to the question if no one trains anyone, where do they think their future skilled employees are coming from in the Post-Brexit world.
Historically reducing costs by eliminating in-house training and development to boost the bottom line may work for a year or two, but doing this means you end up with a widespread lack of skills as we are currently witnessing. “Just in time hiring” to fill skill gaps does not work as a solution when there is a vacuum in available skills. It’s not rocket science, the solution is in businesses’ own hands, but of course it’s easier to blame someone else – the government, education, Brexit, etc.
Some of the trade skill shortages we are seeing today are largely thanks to an egalitarian Tony Blair’s view that everyone should be able to do a degree, which necessitated changing really useful technical colleges, polytechnics, etc. to universities and we are now paying the price of this. However, Companies such as Dyson and those that sponsor UTC schools have taken it upon themselves to try to fill the gaps.
The solution: Specialist in-house training by experienced and qualified Moulding consultants
At Sierra 57 in 2021 Mark Lawson – Managing Director approached the problem of candidates and skill shortages by thinking outside of the conventional box. Approaching their customers, he floated the concept of a Training/Consulting division of the business to provide in-house training to upskill current staff and thereby fill the apparent skill gaps. The response was decisive and from Mark Lawson’s training vision was born the Sierra 57 Consult Training Division.
Accredited CPD courses
In 2022 Sierra 57 Training gained accreditation for Continuous Professional Development (CPD) for their courses from the Institute of Materials, Minerals and Mining (IOM3). With enlightened customers embracing the training model S57C Training delivered 181 courses to 455 individuals. There were also 46 CPD certificate’s awarded representing 1,344 CPD training hours.
Effective, precise & succinct technical content training modules
At Sierra 57 we don’t believe in lengthy trainings courses away from the business, we have broken this down into Modules of a ½ or 1 day duration delivered onsite using the customers machines, tools and materials. In this manner trainees learn at a pace that suits them in small class sizes. Our expert trainers transfer their skills to the trainee after carefully assessing their needs via a Training Skills Assessment. In this manner we help trainees achieve their true potential by ensuring sustained improvement of skills and behaviour to drive increased performance.
Equally in order to promote a trainee’s learning curve, new education learning and promote mental application / mental wellness, S57C trainers will deliver mould module education across any client shift pattern, offering total flexibility to both customer & trainee.
So what are the recognised benefits to having a training plan:
Increased skills leading to fewer mistakes.
Identifies employees’ strengths & weakness.
Morale and employee self-confidence improves.
More employees are better equipped to solve problems.
Product quality & consistency improve.
Damage to equipment reduces & less financial impact on Capex budget.
Committing to training shows your employees they are worth your investment, that you care about their success & career aspirations.
Training helps to create a new culture. Sierra 57 Consults hands-on training is an excellent vehicle to fast-track your lower-level personnel into higher level job functions. This allows you to easily back-fill the lower-level positions and start the training journey again.
So the conclusion is that Employee Training is a smart investment, you are training to gain an advantage. [...]Read more...
31 March 2023In the ever-evolving business landscape, the harmony between customer and supplier organisations is vital for sustained success.
Graham Ward, Group Managing Director of Synthotec Limited explains, “Those companies with converging developments where both strategy and competence align often have the greatest synergies, providing an environment for further sustained development. Whilst diverging organisations find themselves drifting ever further apart.”
A Collaborative Effort
Sierra 57’s Management team have been supporting Synthotec Limited for over 12 years, and both organisations can point to supportive and two way development over the years. Today Sierra 57 Consult has developed a suite of industry specific training programs to sit alongside their targeted recruitment services, which ensure that new staff enter employment with a company well aware of their skill level and the areas that can be enhanced.
Synthotec has also offered time and availability to Sierra 57’s Consultants to ensure that their recruitment team can enhance their knowledge of both the plastics industry processes and the specific needs of Synthotec; their technical challenges and their continued commitment to continuous improvement.
Knowledge Sharing
The latest training program delivered by Sierra 57 on site at Synthotec, is further evidence of how the skills needs can be identified through careful questioning and analysis. Synthotec has a proud record of developing the skills of its whole team, and the recent training courses delivered to Lee and Tiby will be another step in their individual skill development, and will also be another small evolution of the continued development for both organisations.
Mark Lawson, MD @ Sierra 57 Consult adds “understanding the customers’ needs, expectations, deliverables, pain points and their culture aids us massively to advise and recommend high value services that both complement & promote staff empowerment, confidence, development, nurturing and bolsters their staff retention, job satisfaction and provides them with a clear path of how their staff can progress and aspire within the business. Happy and content employees add value to productivity, attention to detail applications, improved H&S and SOP’s, and provide peace of mind to respective Managers / Directors / Company Owners for forging ahead with company directives & strategies. Harmony in the workplace matters; staff matter. Recruitment, training, staff retention matter.”
https://www.plastikmedia.co.uk/sierra-57-and-synthotec-collaboration/ [...]Read more...
29 March 2023Sierra 57 Consult, a leading provider of mould training, recently visited the impressive Arburg HQ in Leamington Spa to explore opportunities for further collaboration. The mission of the visit was to meet with top-level directors and discuss ways to take their engineering relations to the next level.
Arburg’s Impressive Facilities
According to Mark Lawson, the Director of Sierra 57 Consult, “Arburg UK facilities are an excellent showroom and arena for showcasing their equipment and specialist precision plastic moulding/automation engineering brilliance. It is a premier injection moulding machine supplier, supported and driven by highly trained & knowledgeable people, who in turn undergo ongoing intensive specialist training and product guidance by the parent HQ in Germany.”
Deeper Knowledge of Arburg’s Injection Mould Machine Product Portfolio
Sierra 57 Consult is thrilled to deepen its knowledge of Arburg’s excellent injection mould machine tool product portfolio, free formers, integrated automation solutions, and control systems. This will enable them to continue delivering first-class IOM3 training and provide process and tool problem-solving solutions to their clients who have Arburg machines on site.
40 Bite-Sized Technical Injection Moulding Courses
As part of the partnership, Sierra 57 trainers will provide a range of 40 bite-sized technical injection moulding courses at Arburg’s cutting-edge facilities. Learners will have the opportunity to hone their skills on the top-of-the-line Arburg Allrounder machines, offering customers who cannot release a mould machine from their busy production runs for technical onsite training, to capitalise and upskill their knowledge bank within technical moulding, tooling and mould materials, obtaining IOM3 certification once passing and completing respective courses.
The Importance of Training
Mark Lawson emphasizes the importance of training when it comes to operating mould machines with confidence, knowledge of their functions, and a keen focus on safety. “As we celebrate our success at the 2022 Plastic Industry Awards, it’s clear that training is paramount. Our commitment to excellence demands nothing less, and with the right skills and knowledge, everyone can operate these machines like a pro.”
Commitment to Excellence
In summary, Sierra 57 Consult is excited to deepen its partnership with Arburg through mould training. The partnership will enable them to deliver top-notch IOM3 training and problem-solving solutions to their clients who have Arburg machines on site. The commitment to excellence demands the right skills and knowledge, and Sierra 57 Consult is committed to providing just that.
(Pictured Nicolas Stein, Arburg Sales Director; Mark Lawson S57 MD; Colin Tirel Arburg MD; Neville Dudley S57 Trainer)
Mark is grateful to Nicolas and Colin for accommodating the meeting. S57 have been invited to attend UK Arburg’s 100th Anniversary Open Day in May, as one of Arburg’s key industry partners, amongst key customer guests and showcasing their latest hybrid mould machine series, the 460H.
Exciting times for both businesses striving forward, pushing boundaries and moving in line with 4.0 Smart Automation and World Class precision engineering. [...]Read more...
24 March 2023In-Company Training from Sierra 57 Consult
Business success comes from having a cohesive team that understand their roles and responsibilities. Fully trained staff are confident to resolve problems effectively and efficiently. They reduce downtime, improve quality and increase output thereby contributing to the bottom line of the business.
The Sierra 57 Consult Ltd Onsite Training was developed in response to customer needs to upskill and further develop existing staff members, promoting staff confidence, personal career recognition and better applications in their everyday machining operations.
Why train?
Improve employee skills, increase their confidence, enable them to take on more challenging responsibilities.
Save the expense and time associated with replacing staff that have left by upskilling and retaining internal talent
Training staff leads to higher morale, reduces internal errors and increases efficiency
The likelihood of employees looking elsewhere for employment is reduced when they feel that their company cares about them
Provide opportunities for career advancement for those that show aptitude in the role.
Why Invest in your team?
Trained employees make educated decisions to resolve problems quicker and efficiently
Trained employees produce less scrap leading to lower costs
Trained employees set up better processes and solve problems faster
Trained employees set up robust processes reducing downtime, keep the machine running longer and decrease tooling and machine damage.
Production of quality parts consistently means happy customers and repeat business.
Does training Improve quality and productivity?
Better process and material understanding leads to efficient processes
Efficient processes lead to reduce cycle times
Introduction of Standard Operating Procedures reduces the impact of process variation
Training provides a good technical understanding and consistent communication with the team speaking the same technical terms/language.
What impact does the absence of trained staff have on a business?
Absence of technical understanding leads to human error, increased scrap rates and inefficient processes
Can lead to tool and equipment damage through poor utilisation and maintenance
Can impact on employee morale and job satisfaction
Sierra 57 Consult Ltd take Training seriously. We can help you Recruit / Train / Retain your workforce. Please see our Training website to see how we can help you Sierra 57 Training
https://www.linkedin.com/pulse/injection-moulding-training-plastics-materials-sierra-57-consult/?trackingId=NQgj31KcxUKN%2Fk1EpeMxxw%3D%3D [...]Read more...
24 March 2023Breaking Barriers and Building a Stronger Manufacturing Industry Through Diversity
The Importance of Diversity in the Manufacturing Industry
As a technical recruitment company, Sierra 57 Consult understands the critical role that diversity plays in the manufacturing industry. Sierra 57 Consult welcomes and celebrates the unique perspectives, experiences, and skill sets that women bring to the table. Increasing diversity in manufacturing isn’t just the right thing to do; it’s also essential for companies to thrive. With a diverse workforce, companies can tap into a broader range of ideas, leading to more innovative solutions and a more profitable bottom line.
Why Women Are Critical to the Future of Manufacturing
However, the manufacturing industry is currently facing a skills and labour shortage, making it more crucial than ever to welcome and embrace diverse talent, particularly women, to create a more robust and sustainable workforce. Women currently represent less than 30% of the manufacturing sector workforce, and it is critical to explore the reasons behind the gender imbalance. One of the major potential reasons for the low participation of women in the industry is the ‘industry image problem,’ with many young women still perceiving the industry as being heavy manual labour with hostile working conditions dominated by males.
Addressing the Gender Imbalance in Manufacturing
The lack of diversity in the manufacturing industry can be attributed to various factors, including biased recruitment practices. The way roles are promoted can create a bias, and if companies only use internal resources to advertise job roles, they reinforce the current workforce dynamic, which may not be diverse. Therefore, it is essential for companies to use external agencies for recruitment to ensure that bias is removed from the process.
Sierra 57 Consult’s Commitment to Inclusion and Equity in Manufacturing
Sierra 57 Consult is committed to creating a more inclusive and equitable industry for everyone. The company works to identify and recruit talented women in manufacturing, providing them with the resources and support they need to succeed. Sierra 57 Consult provides its clients with a diverse pool of candidates, helping them to create teams that reflect the communities they serve.
Tackling Barriers to Women’s Success in Manufacturing
There are still many challenges women face in the manufacturing industry, including a lack of role models, the need to work far harder than their male counterparts, and concerns around how their roles in the workplace and home are interconnected. However, efforts can be made to tackle these barriers, such as developing policies on flexible working arrangements and implementing EDI (equality, diversity, and inclusion) mandates in organizations.
Indeed, as experienced by Katie Francis, recruitment manager at Sierra 57 since 2018: “As a new mum recently returning from maternity leave, having been given the opportunity for flexible working hours around childcare and my family has been invaluable, along with the company adopting hybrid working it allows me to be more flexible when the inevitable nursery closures or sickness happens. I believe attitudes towards flexible working has changed for the better but in order to increase and sustain a more diverse workforce this needs to become the new normal for working parents (not just mums) and move away from traditional gender roles”
Celebrating International Women’s Day: Breaking Barriers in Manufacturing with Sierra 57 Consult.
This International Women’s Day, Sierra 57 Consult celebrates the women who are breaking down barriers in manufacturing and paving the way for future generations. We pledge to continue our work in creating a more inclusive and equitable industry, both as an employer and as a recruitment specialist. Together, we can create a brighter future for manufacturing and the world.
The following websites kindly published this blog:
https://www.bpf.co.uk/article/breaking-barriers-and-building-a-stronger-manufacturing-industry-3296.aspx
https://www.gtma.co.uk/breaking-barriers-and-building-a-stronger-manufacturing-industry-through-diversity/
https://www.gtma.co.uk/category/blog/
https://manufacturing-update.co.uk/2023/03/08/sierra-57-consult-breaking-barriers-and-building-a-stronger-manufacturing-industry-through-diversity-engineering-manufacturingindustry/
https://automation-update.co.uk/2023/03/08/sierra-57-consult-breaking-barriers-and-building-a-stronger-manufacturing-industry-through-diversity-engineering-manufacturingindustry/
https://engineering-update.co.uk/2023/03/08/sierra-57-consult-breaking-barriers-and-building-a-stronger-manufacturing-industry-through-diversity-engineering-manufacturingindustry/ [...]Read more...
6 February 2023Our man Glenn Barnett has shared some of his insights into Onsite Training, & why it works so well.
Sierra 57 Consult launched their range of Onsite Plastics Training Courses in 2022; we come to your workplace, training your workforce on the machines that they will be using daily. Our training courses are so good that we won Best Training & Development Programme in the Plastics Industry Awards 2022, as well as being finalists in the Best Business Initiative.
Glenn Barnett is one of Sierra 57 Consult Ltd Onsite Trainers & helped us to become the best training programme available.
12 Reasons Why Onsite Training Works
1. Professional trainers ensures you remain on target
Experienced trainers can teach you the proper protocol and methodologies. This way, you’re less likely to pick up bad habits or make mistakes. Professional trainers also acts as a safety net, so that you have someone to consult if you experience any problems.
2. On-Site training saves money
Training can be expensive, especially in technical industries. On-Site training reduces these costs and provides on-site access to training resources. This means that you can learn quickly and efficiently.
3. It is easily applicable
People interpret information in different ways, so manuals can be risky if they’re the only means of supplying information. Training modules prevent this by giving employees the chance to practise their skills. Information is more readily available as you can talk to your supervisors.
4. It can help you better memorise what you’ve learned
When gaining knowledge through practical experience, you’re more likely to recall this information accurately in the future. This is because you can visualise what’s required of you whilst facing a similar hands-on setting. An increase in retention means that employers can benefit from your high productivity levels and can feel more confident in assigning you more skill-based tasks at an early stage.
5. It saves time
On-Site training allows individuals to acquire information as and when it’s required. Simply put, on-site training involves micro-learning, so learning takes place in small increments and as required. It teaches employees short-term-focused strategies that are integral to their job role. This means that employees benefit from target-specific learning that teaches them important skills more quickly.
6. On-Site training promotes teamwork
As an employee undergoing on-site training, you get to work alongside peers and management from the beginning. This close contact makes you feel more at ease when entering the workplace. You’re more likely to build trust with those you work with you over time, so on-site training promotes a team ethic from the offset.
7. It reduces employee turnover
Employee turnover refers to the rate at which individuals leave employment. This rate is likely to be higher when employees cannot meet expectations or feel incompetent in the workplace. On-Site training reduces this as you learn skills from the outset, this also decreases the chance of someone quitting because they don’t fit in or feel alone on the job.
8. It involves paid training
Since you’re essentially contributing to business functions whilst you acquire new skills, companies compensate your time by paying you as you learn. This means that you don’t have to search for part-time work or use your savings to fund living expenses whilst training for your new position. However, check with your employer or hiring manager first before assuming they cover training costs.
9. It gives you the chance to develop new skills
Some people enjoy jobs that challenge them and allow them to grow as a person. On-Site training supports this by allowing you to develop your skill set through engaging activities. You’re more likely to take an interest in learning if you’re able to get involved and develop new skills.
10. It increases productivity levels
As an employee undergoing training, there’s no need to waste time passing knowledge tests or completing a certain amount of training hours at an alternative location. On-Site training allows you to get to work straight away, which can increase business productivity levels instantly.
11. On-Site training is more flexible
Classroom learning is very linear and rarely accounts for any unusual circumstances, like classroom learning delivered in a monotone format, such as textbooks or presentations. Alternatively, on-site training ensures that you acquire information relevant to your role and business. This can also help prevent you from receiving information or details that are irrelevant to your job roles. There are several ways to diversify on-the-job training to increase retention and adapt to individual learning styles.
12. Gauging understanding and engagement
It is easier for trainers to interact and remove any misunderstanding and provide clarification throughout the training journey if on site. If a trainee has not fully grasped an idea and wants to ask a question, it may be more difficult to get the trainer’s attention when trained in a virtual or off-site environment.
Can We Help You…?
If you would like to know more about our industry-recognised training courses, then please see our website: https://www.sierra57training.com/
Or call Richard Brown on 01684 217 618 for a discussion about how we can help you & your workforce. [...]Read more...