Engineering apprentice saves employer 86 per cent on pump costs

A University of Sheffield AMRC Training Centre apprentice has slashed operational pump costs by 86 per cent for the UK's largest aircrete block manufacturer by significantly reducing water usage, repair costs and downtime.

Alex Whinfrey-Gibson, 22, joined H+H Limited two years ago, while studying in his second year of a maintenance engineering apprenticeship at the AMRC Training Centre, which is based at Rotherham in South Yorkshire. 

One of his first projects involved upgrading centrifugal slurry pumps to improve reliability, reduce repair costs and optimise the production process. Alex successfully identified a bottleneck in the company’ production line that was causing a critical inefficiency in its slurry pumping process. 

He said: “The work I did to upgrade the centrifugal slurry pumps  resulted in a significant improvement in mean time between failures (MTBF) which meant less frequent failure of equipment. It has led to massive savings for my company, alongside several benefits in other key areas.”

Alex’s fresh-thinking and approach to the upgrade project has:

• Reduced downtime, saving both repair costs and time spent on maintenance, allowing for greater operational efficiency;
• Lower operational expense due to reduced water wastage and energy consumption, while reducing environmental impact;
• Increased system reliability and a positive impact on employee morale as operators no longer have to deal with frequent equipment breakdowns;
• Enabled employees to make better use of their time to focus on higher-value tasks, improving overall productivity.

The raft of improvements certainly impressed bosses at H+H. Geoff Wray, site manager at H+H Pollington said: 

“Alex has been a breath of fresh air for us, taking on what had been quite a complex problem to resolve. We have already seen significant benefits in respect of uptime on our slurry pump fleet, which of course brings with it various financial and production volume benefits.

“What I am really pleased to see now, however, is how Alex is moving the solution on further and leading a project on upskilling the team on site with some of the things he has learned over the last couple of years. This will put us in a good place for years to come.”

Manufacturing aircrete blocks involves converting fly ash into a highly abrasive slurry, which is difficult to pump and often leads to frequent pump failures. Traditional pumps, while essential, are expensive and hold the potential to significantly disrupt the operation line.

Alex saw an opportunity to optimise H+H's operations by upgrading the existing pumps. To implement this, he partnered with Atlantic Pumps, a company he knew was well-suited for handling abrasive slurries from his previous job experience as an apprentice technical application engineer at AESSEAL.

He said: "I started by analysing the existing equipment to identify the root causes of the failures. Through a six-step process, I collaborated with experts, conducted tests and implemented changes to the sealing technology, lubrication schedule and staff training."

Nikki Jones, director at the AMRC Training Centre, is incredibly proud of Alex's achievements and said his exceptional work at H+H is a testament to the power of apprenticeship programmes. 

She added: “Alex’s story demonstrates how apprenticeships can nurture young talent and drive innovation and growth within businesses. His innovative approach to problem-solving leading to significant cost savings and operational improvements showcases the impact that apprentices can have on the industry."

Alex said his apprenticeship has been a ‘transformative experience’, equipping him with the skills and knowledge to succeed in his career. That’s why he is proud to be a STEM ambassador at the AMRC Training Centre, volunteering his time to inspire students and school leavers to pursue engineering as well as those looking for a career change. 

He said: “My own upbringing in Doncaster, an unprivileged working-class background, exposed me to individuals who had great potential but haven't had the opportunities in life to realise their passions and capabilities. 

“I want to change that and give back to the community. This is why I am so passionate about the STEM ambassador work at the AMRC Training Centre.”

Alex is set to complete his maintenance engineering apprenticeship at the AMRC Training Centre later this year, after which he will continue working as project and reliability improvement engineer at H+H’s Pollington factory.