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Mini Gears / Components Worldwide is a global subcontract manufacturer for all types of metal components at very competitive prices. Established over 40 years ago and proudly remaining a privately owned family company, we can either make complete or source your metal machined components using our vast knowledge of engineering experience.

As we are constantly travelling the world, both selling to our customers and visiting our global supplier base, we fully understand the changing needs of our customers and this approach has

helped us grow our company to one of the UK’s largest and most respected suppliers of transmission and machined components.

Mini Gears, our UK manufacturing site, specializes in gears up to 600mm diameter, racks up to 3 metres long, transmission parts and specialized machining on the latest 5 axis CNC one hit turning / milling machines.

Components Worldwide is our overseas sourcing division set up to benefit our customers who require substantial cost reductions on high volume requirements of gears, machined parts, castings, machined forgings, stampings and fabrications.

INTRODUCTION TO MINI GEARS & COMPONENTS WORLDWIDE

The Owners & Directors

at Mini Gears

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Machined Castings Transmission Components

Bronze Gears Gear Racks

& Pinion Gears Spline Shafts

Precision Parts

Gears, Racks and Machined Parts We manufacture gears, racks and machined parts for almost every type of industry that requires power transmission. Typical markets include valve flow control, stairlifts, diesel engines, marine leisure products, printing machinery, crane hoists, autosport, aircraft seating, vacuum pumps plus many other applications. We have over 100 machines dedicated to making a vast range of machined components including gears up to 600mm diameter and gear racks up to 3 metres long, all types of machined parts, castings and small sub assemblies. • Spur Gears • Helical Gears • Spline Shafts • Machined Components • Gear Racks • Worms • Worm Wheels • Chain Sprockets • Timing Pulleys • Specialist Gear Boxes

T H E P R O D U C T S W E M A K E I N T H E U K F A C T O R Y

Machined Components All types of gears Worms & Worm Wheels

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M A N U F A C T U R I N G I N T H E U K

Quality products using the latest CNC equipment and production methods Innovation has always been a great part of the culture since the company was founded in 1966. With continual investment and over 40 years of machining excellence, components are produced on the latest hi-tech CNC machine tools. We have a large range of CNC machines including powerful multitasking twin chucked machine tools for ‘one-hit’ machining, semi-manned turning centres, larger CNC lathes to turn blanks up to 600mm, CNC gear cutting, hobbing and shaping machines. In addition we have capacity for milling, broaching, gear shaving, slotting of keyways and bore honing, plus many auxiliary operations. We can cut standard commercial gears or high precision, as used in such applications as diesel engines and high speed pumps. Award Winning Company Continual investment, working with our customers and always looking for new ways of doing things with a friendly go-ahead

approach has resulted in a number of major awards for machining excellence, supply chain partnerships and innovation.

CNC Gear cutting The latest investment, 3 new 5 axis

machining / turning centres that

complete operations in ‘one hit’

Medium volume semi manned CNC turning centre

A range of shafts being produced

Turning & Milling Drilling & Milling Gear Racks

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A machined drive clutch for applications such as

fork lift truck braking

systems

Raw material is placed into the chuck on the machine

Profile 7 off parts in one plate and machine

deburred on both sides

The plate is then loaded onto

the fixtures (one in each chuck). Machine the outside

profile of 7 parts on each plate (14 in total as there is one plate on each chuck)

Finished component on machine

Component is turned, milled, drilled and gear cut in one

cycle, without having to remove the component from

the chuck

Washers and nuts removed and all 14 parts come off

the machine as individual,

finished and deburred components

A fully machined stainless steel investment casting used in the assembly of

a stairlift

‘One hit’ machining division with 3 Mazak

5 axis CNC

machining centres

5 Axis CNC ‘one hit’ machining Mini Gears now has 3 Mazak Integrex 5 axis CNC ‘done in one hit’ machining centres which has opened up new specialist markets to us where high accuracy between multiple operations is critical. Complex machined parts and gears are expertly manufactured in a single set up from a solid bar or raw material including steel, stainless steel, bronze, aluminium, castings, forgings and even heat treated steel. In one set up components are turned, milled, drilled and, where applicable, gear cut and come off the machine as a finished part. This eliminates multiple set ups, fixtures, tools, handling and waiting time which add to manufacturing costs. Also, by eliminating multiple set ups the accuracy of the component is greatly improved. If you require your part to be engraved with specific information, for example part number or date of manufacture this can also be performed in the same programme thus saving time from previous manual etching. In the finishing operations, to maintain accuracy and surface finish, the operator sets a limit of wear on the cutter and the Renishaw probe, fitted on all 3 machines, will stop the machining as soon as the cutter needs changing. The probe also checks the component to drawing tolerances thus the inspection operation is also part of the ‘one hit’ process.

S P E C I A L I S T M A N U F A C T U R E - O N E H I T M A C H I N I N G

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Large Gear Racks - up to 3 metres long Mini Gears’ speciality is the manufacture of gear racks for all types of industries including stairlifts, lifts and lifting equipment, drilling machines, valves, switchgear units, linear motion, plus many other diverse applications. With innovative engineers dedicated to improving the performance of our customers’ products, our specialist way of cutting racks now sees us producing over 700,000 metres (2.25 million feet) of gear rack per annum. Our rack division is extensive and has a range of machinery to cut, mill and drill gear racks which can be supplied up to 3 metres long with a pitch of up to 6DP (4 mod) maximum. All gear racks are finish cut on our specialist machines to a commercial tolerance. Small Gear Racks – up to 350mm long

We also have a dedicated rack machine for small pitch racking from 1mod (24DP) up to 2.5 mod (10DP). We can cut racks up to 350mm and the maximum material section is 25mm square.

S P E C I A L I S T M A N U F A C T U R E - G E A R R A C K S

Large Racks up to 3 metres long

A range of machinery for cutting, milling & drilling racks

CNC Rack Milling & Drilling

Gear Rack & Pinion Gears Rack Cutting

Extensive Rack Division

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Gear Grinding up to 300mm diameter at our UK facility

The gear grinding operation is a final finishing process that removes any small deviation on a gear tooth and is widely regarded as the most accurate way of finishing a high precision gear.

This process is widely used in industries such as automotive, marine, pump manufacture, printing equipment plus many other uses where noise, accuracy and high performance are critical to the finished product.

Small / Medium volume batches with low tooling cost

The Höfler gear grinding machine is one of the most accurate machines available on the market and under the correct set up grades up to DIN 5 can be achieved on a production basis.

What makes the machine unique is that the grinding wheel can be trimmed / dressed on the CNC controlled machine to achieve a huge range of gear pitches without having to order specific

grinding wheels associated with high volume production machines.

Also special gear forms can be programmed and tested which is very helpful with new designs or enhancing the performance in such industries as Autosport.

We can produce all types of spur and helical gears including splines up to 400mm diameter. We are limited to 300mm diameter in-house CNC gear inspection.

Ground gears are graphed on a Klingelnburg CNC Gear Tester to verify the correct grade

S P E C I A L I S T M A N U F A C T U R E - G E A R G R I N D I N G

The newly installed Höfler Helix 400K CNC Grinding Machine

A large range of gears and shafts can be ground on the Höfler

Spur & helical gears can be ground up to 400mm dia (and checked up to 300mm

on our CNC testing machine)

A large helical gear being ground for a heavy duty compressor

All gear programmes are fully CNC controlled and fully repeatable

Set up times on this machine are vastly reduced compared to high

production machines

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Gear Shaving

We have recently added this finishing process to our range of services for those customers requiring gears with a much higher accuracy than standard gear hobbing, in such applications as high

speed pumps and power take-off units.

Gear shaving gives an enhanced surface finish. The process removes tiny particles of metal from the lead of the tooth, increasing the gear’s load capacity and reduces noise.

Sub-assembly

As well as manufacturing a vast range of components we now also offer a service for assembly work. Many of our customers prefer a part to be delivered part assembled which can include fitting bearings onto shafts or gears, whole gearbox assembly, the fixing of fasteners that are used to clamp down gear racks in the stairlift industry, plus a varied range of other sub-assemblies for all types of industry.

The benefit to our customers is that they can fit the sub-assembly straight into their own line production, saving a lot of inventory and drastically reducing total assembly time.

Please ring our Technical Sales Team with any projects you may have.

S P E C I A L I S T M A N U F A C T U R E Q U A L I T Y

Quality is planned into every job

We have a dedicated team of Technical and Administrative staff who will work with you to ensure we meet your exact requirements. The factory has recently undergone a full re-furbish and has completely altered its production methods to include lean

manufacturing and ‘5S’ philosophy to ensure standard operations, visual controls and flow production.

Our quality procedures include:

• Planning meeting to establish all requirements for materials, tooling, jigs and fixtures.

• Quality Plan to aid the job through the

production process – indicated on route card to ensure each process is done correctly.

• Dedicated Setting Sheet per job and by

machine to reduce set up times. • ISIR (Initial Sample Inspection Report) for all

new jobs to ensure tooling and planning information is correct.

• ‘5S’ – Housekeeping procedures for a

systemized, disciplined and organized workplace. All tooling and gauges identified and stored in a specific place.

• Dedicated inspection department with CNC

checking machines.

A small gearbox assembly for the medical industry

We assemble almost one million fasteners per

annum to gear racks for the stairlift industry

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Visiting the largest private

gear company in China who

has been a major supplier since 2002

A specialist machining shop in Pune, South India

A warm welcome from one of our main gear suppliers

in China

The directors and sourcing

team of Components

Worldwide establishing a

new supply agreement in

Pune, South India

A visit to a specialist gear factory in Rajkot

Travelling in both

North & South India to meet new suppliers and

audit existing ones

A visit to our aluminium casting supplier in China

Members of the team in China including Jason Chen,

Director (1st on left)

Components Worldwide - China office can now act as

a direct exporter from China

O U T S O U R C I N G - C O M P O N E N T S W O R L D W I D E

Are you looking overseas to reduce your purchasing costs? Components Worldwide is our overseas sourcing division set up in 2002 to benefit our customers who require substantial cost reductions on high volume requirements of gears, machined parts, castings, machined forgings, stampings and fabrications. All our team are highly educated individuals employed by us and we source and manufacture on a global basis, whichever best suits our customers’ demands. In addition to our large manufacturing facility in the UK we have an office in China and a sourcing base in India. How does this benefit you? An enquiry for metal based machined parts can be made or sourced in one of our locations, depending on customer specification including quantity and lead time. Products are either bought in as a finished item or just at the raw material stage to be finished at our UK factory and, from our customers’ point of view this is literally ‘The best of both worlds.’ Our professional team make regular trips to our overseas bases and suppliers to ensure that they are meeting the high standards we have set and audits are carried out to verify product quality.

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Outsourcing – Increased Product Range Components Worldwide, launched as a trading name of Mini Gears in 2006, was the result of our customers matching our core competences in precision engineering with the products that they wanted us to source for them. The name ‘Components Worldwide’ encompasses the increased product range and global supply base and, in addition to gears and machined parts, we can also offer you castings, machined forgings, stampings and fabrications. China High / medium volume requirements The China sourcing office, established in 2002, has benefited our customers by showing substantial cost reductions on high volume requirements. Over ¾ million parts per year are sourced and quality approved by our experienced staff. Also we offer a quality inspection only service on behalf of western companies who do not have their own facility. India Medium volume requirements From our sourcing facility in India we buy in forgings, machined parts and gears in typical medium volume batches and most UK material specifications are widely available in India. Parts can also be sourced in the semi-finished condition and completed on our hi-tech machines in the UK

O U T S O U R C I N G - P R O D U C T R A N G E

Aluminium Casting - Sand, Gravity & Die Cast

A range of forgings are

being purchased and finished in our UK factory

A range of products from Components Worldwide

Investment Castings

Machined

Components Machined Forgings

Stampings & Fabrications

We can now offer an

inspection only service to western customers

Transmission Components

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T H E A D V A N T A G E S O F D E A L I N G W I T H M I N I G E A R S & C O M P O N E N T S W O R L D W I D E

We look forward to receiving your valued enquiries for metal based components

Please refer to our Technical Sales Team contact details on next page

Mini Gears was chosen along with Jaguar Land Rover to host a showcase of best factory practice to visitors

from 15 countries hosted by the UKTI

Directors and members of the award winning team who are fully involved in the running of all of our divisions

Why choose Mini Gears / Components Worldwide? • We are a very successful company dealing on a global scale who can

supply a vast range of metal components to our customers’ needs. • The original company Mini Gears was established over 40 years ago

and the family owners are fully involved in all aspects of the business.

• We have a very strong financial background which means we are a

very secure supplier to you and are able to pay our worldwide suppliers on time which is critical in today’s market to securing ongoing production levels.

• We are always looking for new opportunities and listen very

carefully to our customer requirements and this has established many long term partnerships spanning more than 25 years.

• All our factories and suppliers are approved to at least ISO9001

Standard and our long term reputation for quality products stands testament to this.

Mini Gears 35,000sq.ft (3252m2)factory ideally located near Manchester Airport with good transport links to all major cities and ports

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Main Sales Contacts

C O N T A C T D E T A I L S

NIGEL WALKER Business Development Manager

nigel@minigears.co.uk Mobile: + 44

(0)7775 762 434

To arrange a visit

please contact Nigel

Quotations

If you would like our Technical Sales Team to quote for your production parts please send us

your drawings with a note of batch / annual quantities either by email, fax or post.

Email: enquiries@componentsworldwide.com

Tel: + 44 (0) 161 432 0222 Fax: + 44 (0) 161 432 0444

Visit our website: www.componentsworldwide.com

Mini Gears (Stockport) Ltd / Components Worldwide Top Gear House, Bletchley Road,

Heaton Mersey Industrial Estate, Stockport, Cheshire SK4 3ED United Kingdom

Our UK Technical Sales Team will be pleased to answer your enquiries

Keith Martin

Operations Director

keith@minigears.co.uk

Neil Darwent

Technical Sales

Engineer

NeilD@minigears.co.uk

Malcolm Husband Technical Sales

Engineer

malc@minigears.co.uk

Jeff Vernon

Gear Technology Manager

jeff@minigears.co.uk

Paul Darwent

Chairman

paul@minigears.co.uk

Neil Fogg Technical Sales

Manager

neil@minigears.co.uk

February 2011