History

Then, it was a small general fabrication and sheet metal workshop with only 4 employees located in Station Rd, Haverhill, catering to a number of local businesses. It was incorporated as Felten Sheet Metal Ltd in 1979 by the founder, John Fellows.

With increasing order levels and production demands we look to acquiring a cnc punching machine and having explored the machinery market, the company made it's first inroads into cnc technology with a Pierce-All CNC 7000 punch press. This was the forerunner for many more plant and machinery investments to help keep FSM at the top of it's game. 

Having worked alongside John for another engineering company, Bo Siwicki was invited to work for Felten Sheet Metal as it’s works manager. The challenge was to take the factory management pressures from John allowing him to concentrate on sales with a view to expanding the business. Bo became Technical Sales Director in 1997 and is still here today.

Following an enquiry we start making door entry panels for Status Electronics, a London based distributor of access control systems venturing into designing, marketing and branding their own equipment. Their type of product was unfamiliar to us but we persevered and in time they became part of the FSM portfolio: Access Control, security related products and accessories. 

Mark Casey applied for a vacancy as a Pierce All punch setter/operator through the local job centre. Well, what can one say! With no previous experience and having survived his first week, Mark proved a fast learner and went on to become a design CAD engineer. He then advanced to Production Manager alongside some sales responsibility. In 2007, Mark was promoted to his current position of Operations Director.

With an ever increasing need for room caused by increased work volumes, additional plant and size/nature of some projects we were getting involved with, we outgrew our 5,000 square foot premises in Station Rd. As a result, we moved across town to our current location. An expansion that allows us to operate from a 15,000 square foot factory, today.

Following up leads received via our access control contacts, we investigate the feasibility of manufacturing steel communal entrances for local authority apartment blocks. Subsequently, we receive our first order for 26 doors and screens for the Stonebridge Park Estate in the London Borough of Brent. However, our very first unit installed was in London Rd, Dunstable. The rest, as they say, is history.

Having looked at the laser cutting machine market, we settle on an Avebury SR250 model from the Rhodes Group and manufactured in Luton. This allowed us to look at markets we didn’t know existed and helped improve the lead time and quality of products we supplied. It offered existing and new customers a one stop facility which at that time, most fabricators did not have. At £185k, this was the companies largest investment to date.

To assist with managing an ever increasing workload within our customer's demanding timelines, “Prodman”, a computer based production control system, is introduced. This system ended our use of manual time recording and gave us more versatility in production planning allowing us to maintain a satisfied client base.

Colin Fellows, a chartered accountant by profession, joins the family business as finance director. Welcome Colin! Five years later in 2002 he takes over the role of managing director from his father John who becomes chairman of the board. 

The introduction of "Solid Edge" CAD software gives us a 3D solid modelling and design capability enabling access to markets hitherto not open to us. The benefit of parametrics built into this system enabled our extremely busy designers maximise the use of their time to everyone's advantage.

At that time, we were heavily involved with supplying dealing and trading room furniture to the financial sectors. Our customer was selling and promoting these products internationally and this event significantly impacted their business. This rippled all the way down the line and had an adverse effect on us. However, we learned lessons, took what ever measures were appropriate and worked through it. We are a stronger business as a result.

Our original Avebury CO2 laser cutting machine was replaced with a Trumpf Yag laser around the turn of the century. This proved less than adequate for the markets we were beginning to explore. They required us to work with materials needing more power than a Yag could generate. Trumpf subsequently offered to replace this machine with one of their CO2 lasers. This gave us the versatility required for these products to be processed.

After much discussion and deliberation, the directors decide to present a more modern image of the business reflecting the wider breadth of products and services on offer. We change the company name from Felten Sheet Metal to FSM Manufacturing.

To help improve competitiveness and efficiency, we commence an upgrade programme to our forming capability and capacity with our first Trumpf Trubend 3120 press brake. This involved a major investment in machine, press brake tooling and staff training. However, having proved it's worth, a year later we added an additional machine.

Having reviewed different ways of working, we undertook a Lean Manufacturing programme using an external consultant to facilitate the process. This "5S" process proved to be extremely successful in improving our house keeping and efficiency of operation both on the shop floor and in the offices. It is still operating today alongside a continuous improvement culture.

In March of this year, we move away from CO2 and get our first fibre laser cutting machine. This machine has an increased  sheet capacity of 3000 x 1500 and has the additional benefit, as a result of fibre technology, of reducing by a third the electricity required to generate the same 4kw of laser power as our previous machine.

Kevin Ager re-joins FSM as Sales Director. Kevin was previously employed at FSM from 1988 until the late ‘90s as a Design Engineer.  One of his early projects was to help create a steel door system, which developed over the years into the FSM range of steel security doors.   Having gained a wealth of experience in sales, design engineering and project management, Kevin re-joined the company in 2013.  Kevin’s customer-centric approach and passion to deliver results has been key in FSM’s growth and in building long-term relationships.

With demands and technology constantly moving on and in an effort to stay ahead of our competitors and inline with clients requests, we upgrade our production control system and replace our dated software with something more dynamic: Progress Plus. This system enables better control of our production planning, purchasing, job costing and quoting ensuring a seamless process from quotation to delivery.

During the year, we had our doors tested and certified to the Warrington Certisecure STS 202 BR2 strength level. That challenging process enabled FSM to gain Secured By Design status. SBD certification allows us to tender for security door works previously not within our scope and assures our clients the products we supply conform to the required strength and security standard.

Ten years after the company name was changed to FSM Manufacturing, we hold a review of our corporate presence. We decide to refresh our logo and company colours to present a more modern and progressive image of the business.

When we purchased our first fibre laser cutting machine in 2011, we signed up to a 5 year replacement programme with Trumpf. This enables us to keep up with the latest machine tool technology as well as allowing an agreed part exchange price for the outgoing machine to the benefit of both parties.

Founded in 1978 and incorporated in 1979, we celebrated 40 years of trading at "Go Ape" in Thetford forest. From humble beginnings and through challenging times, we as a company and everyone within FSM, have grown and prospered in a sustainable manner paving the way forward for everyone's future.

During the latter part of 2018, we installed solar panels to our roof with the first energy generated in the last week of December and our first full year of production in 2019. This has proved to be a success contributing to global carbon reductions as well as savings in our energy bills. 

With an ever increasing demand for fine finishing and graining of a variety of products, we invest in an additional linishing machine: Ellesco Timesaver 32. This machine has the additional benefits over our Grinding Master of hole and edge de-burring, automated height setting, improved speed and quality of finish over the full width of the abrasive belt.

As part of our 5 year replacement programme with Trumpf Ltd of Germany, April saw the arrival of our new laser cutting machine despite challenges along the way from Brexit and Covid19. We maintain a good working relationship with Trumpf so the programme continues and is in place with the next machine due in 2026. 

Following a lot of research and resources during the challenging past two years, FSM worked with Verto UK Ltd to launch their new brand image and website. The company would like to thank everyone for their time, contribution, effort and patience to enable this to happen.

Continuing implementation of our green policy, sales director Kevin Ager gets our first electric vehicle, leading by example in our commitment to carbon reduction and sustainability. This marks the next phase as we strive towards a greener future, embracing innovation and environmental stewardship in all aspects of our operations.

Gareth Lane is the third staff member to achieve 40 years’ of service with FSM. He joins John Fellows who formed the company in 1978 and Bo Siwicki who joined in 1981. Between them they have 129 years of experience. All are still active within the business although Gareth is the only full-time member.

Congratulations Gareth. Only 10 years more and you can have a gold watch!!!

Having reached its full capacity, a complete upgrade of our computer system was required. This involved new servers, individual work stations and engaging our IT support company to enable us to process and take advantage of the latest technology available. This major investment underpins our complete commitment to our customers, suppliers and staff.

It allows FSM to move forward in the current tech driven climate.

In this instance we opted for the latest version of our previous TruLaser 3030. Having an increase in power, more efficient fibre optics and a host of technical enhancements and improvements, we are looking forward to the next 5 years with increased productivity from an already efficient starting point.

Congratulations to Mark on reaching 40 years of service.

From no previous experience, Mark rose through the ranks to the position of Operations Director culminating in his latest achievement, joining the 40 years service club. How time flies when you're having fun!