Manufacturing

Lander's manufacturing capabilities

office

Key Features

With over 30,000 square metres of manufacturing floor space across 5 production facilities in the UK and US, Lander has the capacity to support our customers’ growth in multiple markets. Our facilities all have different strengths which combine to make us a strong and capable supplier of tube assemblies. 

Picture1

Lander Total Manufacturing System

As part of our commitment to be the best for our customers we have developed the Lander Total Manufacturing System ©.

The Lander TMS is our blueprint for the consistency, repeatability and quality that we expect from all of our manufacturing facilities.

The system derives from the collective experiences, knowledge and skills from over 140 years of Lander manufacturing that are harnessed to achieve future success.

The Lander TMS is made up of 7 Building Blocks encompassing all areas of manufacturing, and within each of these Building Blocks there are 3 Core Disciplines that all employees are required to understand.

These Building Blocks and Core Disciplines are powered by a clear set of Common Goals and a strong Team Culture that are designed to have an impact on the system’s success at every stage of the process.

Our Common Goals are Zero Accidents, Zero Defects, and Zero Arrears.

Our commitment is to deliver products on time, in full, safely, and with a zero-defect culture in each of our factories; the Lander TMS gives us the blueprint to achieve this.

CNC Bending machine

Tube Bending

Tube bending is at the core of our capabilities, we have in excess of 60 CNC tube bending machines across the group with the ability to bend tubes in diameters from ø4mm up to ø152mm.  

We have several state-of-the-art multi-stack CNC bending machines which allow us to produce complex compound bends where there is very little straight length of tube between bends. This is often seen in automotive applications where there are very tight package spaces for tubes to be routed through. 

end forming

End Forming / Beading

We can produce all different kind types of beaded end form on tube, from single beads for the attachment of hoses and double beads to allow for a hard stop for a hose joint. We also produce complex Quick Connector end forms for the attachment of snap fit plastic Quick Connectors and rolled end forms which have a very tight tolerance and are used to join to applications such as turbochargers. 

Picture by Shaun Fellows / Shine Pix             Dudley College photography Lander Automotive case study 2018

Welding/Brazing

Our metal joining capabilities enable us to offer our customers a variety of solutions from simple manual MIG and automated MIG welding, to manual TIG, and aluminium soldering. 

Our in-house mild steel brazing furnace means that we are able to provide our customers with brazing services to deliver high quality joining solutions on steel products where brackets are featured. Brazing helps to ensure that the joint between the tube and the brackets have a very good integrity so they will last a long time. 

Picture by Shaun Fellows / Shine Pix             Dudley College photography Lander Automotive case study 2018

In-line validation testing

Once our products have been through the manufacturing process, where applicable we leak test and gauge the product to validate it. Our standard testing system for smaller diameter tubes is air decay which is highly accurate for detecting any leaks. We also use air under-water testing as an alternative method.  

Once the part has been leak-tested we will gauge it to ensure that all components are in place and the geometry of the part is correct. Where possible, we build poka-yokes into our gauges in the form sensors to check components are present and camera vision systems. Only when the part has been validated will the system print a pass label. 

Large Gen Set pipes[14259]

Surface coating

We have surface finishing capabilities at our Malvern facility in the UK and at Rabun Gap in the USA. We have in-house powder coat and wet spray lines which allows us to finish many of the parts that we produce internally.  

In the USA we us a Zirconium pre-treatment before the painting process which has a significantly lower environment impact compared to the more widely used Zinc Phosphate. 

IMG_5334-scaled (2)

Apollo System

Created in-house by a cross-functional team, the Apollo system uses the latest IoT (Internet of Things) and PLC technology to get information from many different information sources (machine controllers, environmental, ERP and HR systems) to provide real-time feedback to operators and team leaders.  Additionally, this data is recorded in a data warehouse solution that can be interrogated by an easy-to-use web-based portal to view historical trends and data or even make ad-hoc queries without the need for IT intervention. 

Key Features

With over 30,000 square metres of manufacturing floor space across 5 production facilities in the UK and US, Lander has the capacity to support our customers’ growth in multiple markets. Our facilities all have different strengths which combine to make us a strong and capable supplier of tube assemblies. 

Lander Total Manufacturing System

As part of our commitment to be the best for our customers we have developed the Lander Total Manufacturing System ©.

The Lander TMS is our blueprint for the consistency, repeatability and quality that we expect from all of our manufacturing facilities.

The system derives from the collective experiences, knowledge and skills from over 140 years of Lander manufacturing that are harnessed to achieve future success.

The Lander TMS is made up of 7 Building Blocks encompassing all areas of manufacturing, and within each of these Building Blocks there are 3 Core Disciplines that all employees are required to understand.

These Building Blocks and Core Disciplines are powered by a clear set of Common Goals and a strong Team Culture that are designed to have an impact on the system’s success at every stage of the process.

Our Common Goals are Zero Accidents, Zero Defects, and Zero Arrears.

Our commitment is to deliver products on time, in full, safely, and with a zero-defect culture in each of our factories; the Lander TMS gives us the blueprint to achieve this.

Tube Bending

Tube bending is at the core of our capabilities, we have in excess of 60 CNC tube bending machines across the group with the ability to bend tubes in diameters from ø4mm up to ø152mm.  

We have several state-of-the-art multi-stack CNC bending machines which allow us to produce complex compound bends where there is very little straight length of tube between bends. This is often seen in automotive applications where there are very tight package spaces for tubes to be routed through. 

End Forming / Beading

We can produce all different kind types of beaded end form on tube, from single beads for the attachment of hoses and double beads to allow for a hard stop for a hose joint. We also produce complex Quick Connector end forms for the attachment of snap fit plastic Quick Connectors and rolled end forms which have a very tight tolerance and are used to join to applications such as turbochargers. 

Welding/Brazing

Our metal joining capabilities enable us to offer our customers a variety of solutions from simple manual MIG and automated MIG welding, to manual TIG, and aluminium soldering. 

Our in-house mild steel brazing furnace means that we are able to provide our customers with brazing services to deliver high quality joining solutions on steel products where brackets are featured. Brazing helps to ensure that the joint between the tube and the brackets have a very good integrity so they will last a long time. 

In-line validation testing

Once our products have been through the manufacturing process, where applicable we leak test and gauge the product to validate it. Our standard testing system for smaller diameter tubes is air decay which is highly accurate for detecting any leaks. We also use air under-water testing as an alternative method.  

Once the part has been leak-tested we will gauge it to ensure that all components are in place and the geometry of the part is correct. Where possible, we build poka-yokes into our gauges in the form sensors to check components are present and camera vision systems. Only when the part has been validated will the system print a pass label. 

Surface coating

We have surface finishing capabilities at our Malvern facility in the UK and at Rabun Gap in the USA. We have in-house powder coat and wet spray lines which allows us to finish many of the parts that we produce internally.  

In the USA we us a Zirconium pre-treatment before the painting process which has a significantly lower environment impact compared to the more widely used Zinc Phosphate. 

Apollo System

Created in-house by a cross-functional team, the Apollo system uses the latest IoT (Internet of Things) and PLC technology to get information from many different information sources (machine controllers, environmental, ERP and HR systems) to provide real-time feedback to operators and team leaders.  Additionally, this data is recorded in a data warehouse solution that can be interrogated by an easy-to-use web-based portal to view historical trends and data or even make ad-hoc queries without the need for IT intervention. 

Smart Manufacuring

Connected – processes, machines, and teams are connected to shorten the time required to analsye and react to data

Optimisedcontinual analysis of process performance in real-time to increase machine uptime and productivity

Agileflexible manufacturing systems allow us to re-configure our factory layouts to implement products in real-time

Transparentvisibility for our teams across all operations to shorten decision making times

Proactiveautomated stock replenishment, error monitoring, and safety protection

Contact us for more information