Page 24 - MetalForming August 2015
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22 MetalForming/August 2015
www.metalformingmagazine.com
and change how we operate internally. We can work more to a just-in-time model, schedule more accurately and pre- dictably, and minimize or even eliminate deviations from our planned production schedules.
“Predictability brings numerous additional benefits,” Jim continues. “In short, better planning leads to better execution.”
Technology Makes Good Operators Great
When discussing the justification for investing in the automated material-storage tower for the laser, Jim is quick to note, “We don’t ever want to have a conversation out on the floor about a backup at the laser.” Marian adds that an addi- tional investment was needed to prevent merely moving the potential bottleneck from cutting to bending.
“Keeping pace with the new laser’s output required a sig- nificant investment in downstream press-brake bending,” she says. “As a result we added a servo-hydraulic press brake (an Amada HG 1003 model) late in 2014. It has greatly improved angular bending accuracy compared to our older brakes.”
Improved bend-angle accuracy, according to Amada offi- cials, is due to the thickness-detection system (TDS) designed to detect the thickness of the workpiece material. The TDS automatically adjusts the entry depth of the forming tool based on sheet thickness, guaranteeing consistent and accu- rate bending angles.
“Our fabrication supervisor realized significant produc- tivity right from the start with this new brake,” says Marian. “He in fact said to me, ‘This technology makes an average operator a great operator, by taking the variability out of the process.’
“For us,” she continues, “it means that we need less expertise from our operators. The brake is outperforming our older brakes by at least two to one, and as much as three to one on some parts. We get faster setups, and as close to zero scrap parts as possible. That machine is money.”
Efficiency is Endemic
Efficiency gains are clearly evident in every corner of Weaver’s new digs. There’s nothing like a fresh, greenfield approach to plant layout and design. So in addition to the gains created via automated material handling at the laser— “We ran a recent job for 38 hr. straight without human inter- vention,” Marian says—optimized material flow from the new plant-floor layout also brings significant gains.
In addition to laser cutting and press-brake forming, the company also performs roll bending, milling, saw cutting, arc and resistance welding, CNC punching, and powder coating.
“We suffered 18 years of frustration at the old location,” says Jim, recalling time wasted moving product from build- ing to building. “I estimate that by bringing all operations under one roof and optimizing the equipment layout for an efficient flow of goods, we’ll pick up at least 1 hr. of produc- tive time per employee per week. That alone will justify the move to the new facility.” MF
