Knowledge Transfer Partnership Case study – Rossendale Group - School of Engineering at Liverpool John Moores University

About This Case Study
North-West lifting equipment suppliers, the Rossendale Group worked in partnership with Liverpool John Moores University to deliver this Knowledge Transfer Partnership (KTP). The aims of the KTP were to review and evaluate current design and manufacturing systems, evaluate alternative I.T. based systems and design, plan and commission a new system for the Rossendale Group plc.

About The Sponsors
The Department for Trade and Industry (DTI)

The DTI drives the ambition of 'prosperity for all' by working to create the best environment for business success in the UK. The DTI help people and companies become more productive by promoting enterprise, innovation and creativity.

Project Outcomes

• The company now has design processes in which it can be 100% confident
• Successful redesign of two major products
• Commercial application of teaching at the University
• Employment by Associate with host company
• Ongoing partnership with second KTP in place

The Company
“We have completed one KTP programme and are half-way through our second. The KTP programmes have helped us to introduce leading-edge technology into the company that we would not otherwise have had the resources or the confidence to work with. As a result we have moved from being just another player in our industry to a recognised innovative leader.”
Simon Bamford, Managing Director, Rossendale Group Plc

The Rossendale Group plc supplies lifting equipment to all industry sectors.

About The Projects
The project originally aimed at installing the new design system for four of Rossendale’s products. However, it became clear that the academic partner would be able to make a significant contribution to the design itself, not just to the design system. The option of developing the design system around redesigned products rather than the existing designs was tested with the first product, the spreader beam. This rethink was justified following successful manufacture. The product was praised by both the Lloyds Register inspector, who suggested that the product should be patented, and by the client’s equipment user, who told his engineering manager that he wanted this equipment every time.

Benefits
The company has achieved a redesign of two traditional products. These are now lower cost, higher value products which give the company higher margins and improved regard in the market. The exercise taught a great deal about critical aspects of the design in respect to safety, product quality and cost.

Staff have learnt to use the technology developed to redesign further products and improve document design. This has also enabled the company to respond more quickly to customer requests for designs and drawings.

The project has enhanced the company’s image with customers, employees and competitors as a technological leader and highly capable producer of high quality equipment.

The redesign reduced manufacturing costs from £40,000 to £20,000 on the first job.

Results

• Two significant product redesigns
• Sales turnover increased by 120%
• Increase in margin by 50%
• Reduced lead times by 90%

The Associate
Sarah Clegg worked as the Associate from Liverpool John Moores University (LJMU) with lifting gear company Rossendale Group on new product designs.

Benefits
Sarah Clegg gained a thorough understanding of modern 3D CAD software and its applications in a manufacturing company. She also gained a thorough education in mechanical engineering and its applications in the company. She also benefited from her experience of product redesign and taking the company through major change.

Her personal confidence in her engineering ability was greatly improved by her experience and she is now the company supervisor for the second KTP programme at Rossendale Group.

Results

• Software training in SolidWorks, DriveWorks, ProEngineer linked directly to on the job experience
• NVQ Level 4 in Management completed
• LEEA Qualifications completed
• MPhil ongoing
• Offered and accepted role as Product and Service Development Manager in the company