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Stephen AinsworthStephen Ainsworth has extensive experience in the majority of aspects of Manufacturing Engineering in a wide variety of different Industries. He is a Founder Member of the Association of Industrial Laser Users (AILU) and a GLG Council Member.

He completed a 5 year Engineering Apprenticeship with Jaguar Cars in 1977, and gained a BEng in Combined Engineering at Coventry University. Stephen worked for Jaguar Cars in various Roles within Manufacturing Engineering and Maintenance until 1988, and was primarily responsible for the Facilities to manufacture the Rotating Parts for the Jaguar XK, V12 and AJ Series of Engines. During this period he also gained extensive experience of working with Laser Systems, Industrial Robots, Gear Manufacture, Engine and Transmission Assembly and Test, Press Tool Die Change and Maintenance, and the Pressing and Assembly of Automotive Suspension and sub-Frame Parts and BIW Skin and Structure Panels.

Robot Drilling and Riveting CellHe then joined one of the leading Factory Automation System Houses as a Project Manager, and in 1990 moved to be a Project Manager at a leading Robotics Company. In 1993, he formed S.J.Ainsworth Consultancy Ltd, and has worked on a variety of different Projects including Warehouse Process and Layout, Robot Cell Design, Build and Installation and the Design, Build and Installation of Laser Cells for Cutting, Brazing, Welding, Surface Treatment Measurement and Marking, utilising CO2, Nd-YAG, Diode and Fibre Lasers. Some of these required the application of Laser Remote Welding techniques.

Other Successfully completed Contracts have included

  • Simultaneous Engineering within the Automotive and Aerospace Industries
  • Project Management of Facility Installation for Automotive and Aerospace Automated Manufacturing Lines and Robot Cells
  • Identifying the Facilities required for new Manufacturing Processes
  • Best Practice solutions for the Introduction of new Materials or Processes
  • Warehouse Process and Layout Optimisation
  • Design for Manufacture Optimisation
  • Assembly and Piece Part Costing Projects
  • Establishing and Managing Press Tool Die Maintenance Facilities including Recruiting and Training the Toolmakers and Administrators required
  • Lean Manufacturing Studies and the implementation of the Recommended Actions
  • Utilising SMED techniques to reduce Press and RTM/RIM Tool Change Times
  • R&D Projects to develop and test techniques for Laser Processing Carbon Fibre Components
  • Cost and Waste Reduction Exercises within Manufacturing processes
  • Factory Automation Projects, including introducing SCADA and MES Systems
  • Quality Improvement Processes
  • Implementation of a Warranty Control Process within an Automotive Manufacturer
  • Risk Assessment and CE Marking Exercises on Production Processes and Process Plant
  • Manufacturing Facility Assessments as part of Due Diligence Teams

Stephen has also presented a number of papers at Seminars organised by the “Make it with Lasers” campaign and AILU, and has delivered Lectures to Students for Liverpool University as part of their Laser Processing Module, and for Warwick University WMG on Body Joining Techniques as part of their MSc Body Design Course.

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