Context
The National Composites Centre (NCC) in Bristol is one of the UK's leading advanced manufacturing and research facilities, operating high-volume production using automated preforming cells, each comprising multiple robots and sensitive high-performance technologies. The NCC appointed Intersafe to carry out PAT testing across both office equipment and the highly technical laboratory environments that sit at the heart of their operation.
PAT testing had previously been managed in-house by the NCC's maintenance team, but the complexity of the manufacturing environment made the case for an external specialist.
Challenge
PAT testing at the NCC is not a standard exercise. The nature of the facility introduced a set of technical and operational demands that required careful preparation and genuine collaborative working to navigate:
Equipment that cannot be tested with a standard PAT procedure: The automated preforming cells at the NCC are comprised of multiple interconnected robots and high-performance technologies, none of which can simply be unplugged and tested in the conventional way.
Specialist PPE and area-specific access requirements: Certain areas of the facility required specialist personal protective equipment and adherence to specific access protocols before testing could take place.
Minimising production downtime in a high-output environment: With manufacturing continuity a top priority for the NCC, testing needed to be carried out as efficiently as possible.
Solution
Intersafe, part of Complii, took a collaborative, site-first approach, and working in genuine partnership with the in-house team throughout:
Proactive site visit before quoting: Intersafe visited the NCC in advance of quoting - walking the site, understanding the nature of the equipment, and identifying what the testing would actually involve before committing to a methodology or a price.
Collaborative approach to determining test specifications: Rather than arriving with a fixed approach, Intersafe's engineer worked directly alongside the NCC's maintenance technician to understand the test specifications for each item in the robotic manufacturing cells.
Compliance with all PPE and area access requirements: Specialist PPE and area-specific protocols were followed throughout, with Intersafe's engineer adapting to the requirements of each zone within the facility without disruption to operations.
Efficient delivery to protect production continuity: Testing was sequenced and managed to keep production downtime to a minimum - a priority that was understood from the outset and actively maintained throughout the engagement.
Results
All PAT requirements were successfully completed across the NCC's office and laboratory environments, with production kept running, and the in-house maintenance team's workload significantly reduced:
Full PAT compliance achieved across all items: Every item across both the office and the highly technical laboratory environments was successfully tested to the correct specification - including the complex automated performing cells that had previously presented a challenge for in-house resources.
Production downtime kept to a minimum: The efficient, well-prepared approach to testing meant the NCC's manufacturing operations were disrupted as little as possible, with the team's planning and sequencing directly protecting production continuity throughout.
Workload significantly reduced for the in-house team: By taking on the full PAT testing programme, Intersafe freed up meaningful capacity within the NCC's maintenance team, allowing them to focus on their core responsibilities rather than managing a complex testing process alongside their other duties.
“Health and safety is our top priority here at the NCC. Our workshop is full of state-of-the-art equipment, capabilities, and technologies that were unfamiliar to Intersafe’s engineer at the outset. We worked together to understand the test specifications and were able to successfully complete all PAT requirements. His hard work helped keep production downtime to a minimum and significantly reduced my workload. I look forward to working with Intersafe again.”
Dee Caines, Maintenance Technician, National Composites Centre