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INSPIRED FOR TUBE
Number 14 May 2011
riginally, the Italian textile firms were using the
words "Made in Italy” to distinguish their products from those made in other European countries who did not take too kindly to goods entering their
markets from our country.Today, in the era of the global
market, those three words have become synonymous
with absolute quality and desire for millions of people
from all continents.
It seems that today the "Made in Italy" brand is the third
most renowned after Coca-Cola and Visa.
O
Opinion
17 March 2011
150th anniversary of the
Italian Republic
INSPIRED FOR TUBE
Made in Italy
It is clear that the present meaning of "Made in Italy”
placed in different forms on articles of fashion, food and
wine or a machine tool goes beyond a mere geographical indication and bears a clear reference to the Italian
"lifestyle"; a concept that encompasses many aspects
and meanings. It is worthwhile to mention a few that
have more immediate feedback in the modern industrial world: the ability to innovate, which results from the
undeniable Italian design and high quality of the products, both from a reliability standpoint, the legacy of a
tradition of craftsmanship that has evolved successfully
into industry, as well as from an aesthetic point of view,
the result of the inherent Italian flair for "beauty".
To understand why these skills have developed in Italy
it is sufficient to take a look at the work of Leonardo da
Vinci with machinery and mechanisms of the Atlantic
Code, the mechanisms in the Madrid Code or the outstanding studies relating to flying.
With these deep-rooted values the Italian mechanical industry has reached absolute levels of achievements.
Today, Italy is the third largest producer of machine tools
and it is easy to verify the consideration and appreciation of these products the world over. Italian machine
tools are synonymous with quality and reliability.
As Italians, we can be very proud of being global machine
tool manufacturers and exporters of a quality label.
Giovanni Zacco
Market Development Manager
3
Contents
INSPIRED FOR TUBE
INSPIRED FOR TUBE
5
FURNITURE
9
AUTOMOTIVE
Doing what is needed when needed
From “Sofia” to Beyoncé ... an exceptional cast
12
AGRICULTURAL MACHINERY
16
BLM GROUP
18
FURNITURE
21
JOB SHOP
24
JOB SHOP
26
ELEVATED PLATFORMS
28
AGRICULTURAL MACHINERY
More flexibility with automation
Process efficiency depends on the software
The chair is produced by a man-machine union
The good thing about the lucky choice
The small lots strategy
From laser to new engineering solutions
The advantage of being born on a farm
pdf version and other news can be found in:
www.blmgroup.com
INSPIRED FOR TUBE
Inspired for tube By
Area Comunicazione
BLM GROUP
Giovanni Zacco
Emanuela Colombo
Cristina Guzzetti
e-mail: pr@blm.it
tel. +39 031 7070 200
Produced by
BLM GROUP
Via Selvaregina 30
22063 Cantù (CO) Italy
www.blmgroup.it
Number
INSPIRED FOR TUBE
Nr. 14 - 5/2010
Design and Graphics by
Studio Grafico Page
Vincenzo De Rosa
Fabrizio Santini
Printed by
AleCom Srl - Bregnano CO
Photo
Fabrizio Santini
Vincenzo De Rosa
Reproduction, even only in part, of
the articles and illustrations published
in this newsletter is strictly prohibited unless otherwise authorised.
In Greek, Oikos means “house” and no other
name could be more perfect and fortunate to
Furniture
Doing what is needed
when needed
security door manufacturing. The company was
set up in May 1990 by Fabio Buscato and Mario
Biancolin who had taken over and revived a
company previously operating in the same
INSPIRED FOR TUBE
indicate a company operating in the field of
field. This objective was also reached thanks to
the laser tube that made production set to “lot
1” flexible. Lots consisting of 15 identical doors
are no longer manufactured, but only a single
door is manufactured as a single piece
according to a lean manufacturing model.
e have been operating in this field since 1984” says Fabio
Buscato “As a result, We have almost thirty years of experience and this has enabled us to make Oikos (the name
comes from a Greek customer, the meaning of which we learned only afterwards) a worldwide leading company thanks to a quality product in
line with the most advanced and current market demands. As soon as we
took over the company, we focused on the construction details of our
products and tried to be more present on the market. We implemented
a double strategy: a technical action to improve the product; a commercial action to extend our presence on the market that at the beginning
was exclusively Italian (until 1997-98) to open up first to Europe and later to eastern Europe.”
“W
Design + security = security door
Over the last ten years, or rather since the year 2000 onwards, the security door has undergone a design evolution, from a security product to a
design element. “Previously - explains Buscato – the security door, being an apartment entry door, had to “communicate” with the other internal doors; today, its image has changed and it has become a design element that must“communicate”and match with the furnishing. As a result,
those who are able to propose aesthetical solutions matching the inte-
5
Furniture
INSPIRED FOR TUBE
rior furnishing market design trends with the
basic function of a security door are winners.Today our company is renowned for this ability on
the market - especially on the foreign market and it is considered as the enterprise that is most
tuned in on interior furnishing trends. Presently, 30% of the production is exported but the
percentage is growing exponentially. On foreign
markets we sell the product not so much as security product, but more as a furnishing and design component. We commercialise our products in the United States, Africa, Senegal, Nigeria,
South America, Spain, Israel, Greece, China and
Germany.The only market that considers the security concept as fundamental, is that of the Eastern countries.”
“In Italy – specifies Buscato – we are organised
with a network of retailers operating in the field
of doors and windows while abroad retailers are
interior designers, as previously stated.They are
high-level interior designers, all working with
the same brands.
Quality certification is an important aspect of our production cycle.To sell abroad we are
subject to random controls by
several certification bodies who
check that the production
process strictly and accurately
corresponds to the company
declaration.These strict controls,
however, allow us to obtain a
quality level certification for our
products”.
Laser is synonymous with Lot 1
Oikos started off with a craft made production
cycle where no special attention was paid to the
precision of what was a security door and not a
mechanical component. However, this operating method involved some problems during installation that were regularly solved by the blacksmith or by the product installer.“The important
evolution took place when we decided to modify the door frame that used to be manufactured
at the bending press with an open profile and
wide tolerances (0.4 – 0.5 mm)” continues Buscato.“Then, we decided to use a closed profile
that featured a definitely better accuracy (0.1
mm); consequently, the machining accuracy and
the higher rigidity made installations easier and
improved the overall quality of the end product. This change marked the actual passage to
an industrial production cycle. It was during this
phase that the laser system was adopted by our
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MAY 2011 NUMBER 14
Furniture
INSPIRED FOR TUBE
company. Switching to a closed profile with the
previous manual machining operations would
guarantee a higher rigidity, but would not assure the accuracy that has now enabled us to
simplify installations considerably.The choice of
an ADIGE LT722D Lasertube by the BLM Group
has proved winning, although at the beginning
the problems related to the cost and startup
of such a large plant frightened us. However, we
are reaping the benefits, particularly as regards
the easier installation on site.Today, even a person without experience is able to install a security door manufactured by us just by following
the instructions”.
The LT722D laser has offered a cost saving advantage thanks to time reduction, but the major advantage consists in obtaining the so long
awaited “lot 1” concept. Oikos no longer deals
with multiple lots, but only with single doors that
are tailor-made with customised measures, holes
and machining operations.
“We no longer need to assemble products in
lots – explains Buscato – but enter in the production program a single door that is manufactured as a single piece based on a lean manufacturing model.The laser enables us to obtain
a very short production process. The frame is
manufactured in 15 minutes; there is no need
for bending, drilling, cutting at 45° and making
slots on different machines. The end product is
manufactured and ready by using one machine
only. From January to February we have increased the business turnover by increasing
work with less personnel”.
“Once upon a time up to 15
identical doors were produced
at the same time. Today, however, this market, that is typical
of social housing, is no longer
found. A dimensional standard
exists, but today it is always
more convenient to manufacture one frame at a time. There
are no storage and transport
problems since we make what
is needed when needed.”
Produced and shipped
within 24 hours
In conclusion, the main advantages introduced
by the LT722D system are the following: machining accuracy and the manufacture of one finished
piece in only one passage without requiring additional processing. The accuracy repeatability
7
Software
Artube - Composer
INSPIRED FOR TUBE
Furniture
Composer is a software instrument
developed by ADIGE within the
Artube software to facilitate the
production of items that are similar
to each other but different in terms
of position and/or number of
common processing operations.
guaranteed by the industrial process allows a considerable saving during other process phases.Assembly and installation problems on site are virtually eliminated and the same frame concept is
becoming standard for all products.This is because
the profile being used for the frame has been developed to exploit at the best the laser tube system that offers a wide range of possibilities. “Since
January we have been trying to launch the product in the production phase in the morning and
have it loaded onto trucks within 24 hours”,states
Buscato. We have not yet reached that result,since
the bottleneck is caused by wood panel working
in the joinery, but we are solving the problem
thanks to a rapid paint that allows us to process
the panel today and install it the next day. Laser
and paint are two elements that have allowed
to optimise the production cycle.”
The Composer parametric module of the CAD/CAM ARTUBE
manufactured by ADIGE plays a
fundamental role in the automatic production of a door without requiring the design phase.
Starting from the information
contained in the production order of the operative program,the
cutting program of the LT722D
system is processed.
The answer meets expectations
The relationship with BLM has been ongoing
for a long time:“When we started the project
– Buscato explains – BLM actively collaborated to obtain a good result. It certainly is a rather
heavy machine to handle. We want to be sure
before giving any guarantee regarding the
possibility of reaching a certain result. However, we appreciate anyone who has a serious
8
MAY 2011 NUMBER 14
behaviour and is able to give a pondered response and to maintain it. We were not enticed
by the low price and we privileged the result
instead. Price is always an essential feature, but
first of all the machine to be purchased must
meet the demands of the customers, which is
more important than price. Another fundamental aspect is the guarantee of a follow-up
service, the machines being rather complex
and thus requiring an appropriate technical
assistance: BLM has deserved full marks from
this point of view.”
Process files
The single processing operations,
created by means of CAD Artube, are
saved in a database suitably divided
by tube section. Each module can be
used to create repetitions of a
specific process in different tube
positions.
The use of this instrument is
particularly advantageous in some
specific sectors. For example, just
The security door is environmentfriendly
“Thinking about the future – Biancolin concludes
– foreign markets will become increasingly important for our product, in which over a period
of five years the average price of a door has virtually doubled.We are increasingly oriented towards a high-end market that requires a product with an increasing added value as regards
design.
In this view, the high flexibility assured by the
Lasertube is very important with reference to a
single product.Those who are still tied down to
high figures today must cope with heavy losses. Moreover, it is necessary to be flexible when
producing, but also to meet the new standards
and requirements of the building and furniture
sectors. For example, nowadays, thermal insulation is strongly felt with the “clima-haus” standard of the province of Bolzano or Trento that is
developing in accordance with the American
LEED standard.Therefore, our doors as well must
be environment-friendly to leave future generations with the same resources that we received.
What does it have to do with doors? The simple fact of using coverings with a 15-year guarantee does not require any replacement and
assures a certain thermal insulation. These are
services offered in addition to security and are
added values that guarantee the future success of the product.”
think of the manufacturing of frames
for doors and windows in which
some holes, slots or ordinary
machinings are always repeated in
the same manner in all frames, but
must be positioned in different
number and positions in relation to
the type of door or window.
Graphic interface
Avoiding the tube or profile
processing design phase, a graphic
interface, external to the CAD-CAM
system, allows all the stored modules
corresponding to a specific tube
section to be displayed and to be
positioned along the tube axis.
At the end, the result can
immediately be verified from a
graphic point of view and therefore
the machine programme can be
created directly.
Automotive
activities that the Brazilian company Alpino Industria Metalurgica, of Italian origin, has been involved in.
The tube bending technology that BLM has developed over the years has confirmed the various stages
of the company’s growth: from the “Sofia Loren” to the “Beyoncé” with a current output of 1,800 pieces a day
INSPIRED FOR TUBE
From the furnishing to the automotive industry, passing through the “white” industry; this is the range of
for FIAT. In fact, since the very beginning, each new machine has been given the name of a famous woman.
From“Sofia”to Beyoncé ...
an exceptional cast
rom its name, Alpino Industria Metalurgica Ltda, it is clear to see the Italian origins
of the Company, which was set up in S. Paulo in 1955 by the fathers of the current owners,
Sergio Alonso, Sales Director and Marco Giampietri, Industrial Director and which originally
manufactured chairs and tables with tubular
elements. “It is not always easy to get along, but
this is a fundamental value that has been handed down and we want to continue with it” say
the two gentlemen.
The relationship has always been based on mutual trust; just think that initially, their parents signed an agreement according to which the signature of only one of the partners would have
been sufficient to make even the most fundamental of decisions such as to sell the business.
That’s something in the past; nowadays it is no
longer so as there are other partners, but the spirit still remains. “No relatives can enter the company unless they have the right qualities and
our goal is to continue with the business”.
F
“Nowadays, our main customers are car manufacturers – explains Alonso – but it hasn’t always
been like this because in the beginning we made
furnishing components with tubular elements,
such as tables and chairs. Our customers not
only get punctuality, quality and price, but also
added value thanks to the competence and
technical innovation that is hard to find elsewhere in Brazil. We always have a solution for
the customer, even for the most complex component, thanks to technology. We always try to
keep up and invest heavily, even in difficult times like 2008, when the crisis had a really strong
impact and came suddenly, like everywhere else
in the world; regardless of this, we still purchased an all-electric BLM ELECT 80 tube bending
system. I remember being at the Milan trade fair
in October and having heard about the crisis,
not knowing what people were talking about,
but when I got back to Brazil, everything had
come to a grinding halt, although the situation
was a little particular as there was still demand,
but the banks were not financing growth as there was no money to invest”.
The milestones of success
The technological evolution was fundamental
for the company’s growth and marked each
milestone, even at the hardest of times like in
1966 when the company got flooded or after
the 1998 crisis during which the DYNAM0 tube
bending systems were purchased to allow work
to start for Whirlpool, Electrolux and General
Electric in the gas cooker field.
“When we installed the BLM machines, we
managed to develop a whole series of products that we were unable to manufacture before both as regards bending and end forming” says Giampietri.
“The BLM started many years before, in 1972
when BLM was the only company to have taken the Brazilian market seriously and set up a
representative office. Other manufacturers did
not have this vision and BLM pioneered. Since
9
then, we have had almost all the machines in
the BLM range. The first was a B38, which is still
operating at the premises of one of our former
employees, who set up his own business; at the
time, it was considered an automatic tube bending system as it carried out 12 bends in sequence.
When we bought it, my father called it “Sofia” as
a homage to Sofia Loren and since then all our
machines have been given the name of a famous lady; from “Madonna”,one of the first CNC
3-axis tube bending system (B63CNC) sold in
Brazil to “Cicciolina” (purchased in 1987) - a B63
B6X+PMB with which we managed to make a
63 radius bend on a 63 mm tube – something
that no-one in Brazil was able to do (and which
today only a few can accomplish)”.
“In 1972, we were still making furniture - continues Giampietri - but at the beginning of the
80s we started in the automotive field, having
developed a bending machine in-house for
large diameter tubes. In fact, at the time it was
difficult to import machines to Brazil as the import taxes could reach anything up to 100%,
10
MAY 2011 NUMBER 14
but we managed to start working with top
brands like Scania and Caterpillar, who are still
important references”.
In 1989 the purchase of a B120
and a ST130 (5 passes), which
are still existing, confirmed the
definite turn from furnishing to
entirely focus production on the
automotive industry. “Having
installed a machine like the
B120 allowed us to take competitive advantage on the market. We were the first to manufacture 114 mm tubes with an
average radius of 125. This machine was fundamental to gain
more experience in the bending technology.
This was then followed by SWING 32, the first
machine with a LH/RH curving direction that
was installed in 2000. With BLM we have always
had a relationship as partners. BLM have never left us alone when we have had problems and
we have always reached useful and valid solutions together. Today we have added three DYNAM0 machines, two of which were purchased
last year and operate in the“white”industry and
automotive fields. Just to give you an idea: Beyoncé, a DYNAM0-E with automatic loader, produces approximately 1,800 pieces/day for FIAT.
A great competitive advantage
Unlike other cases where the choice of the lasertube was intended to give production a turning
point, at Alpino transition to the laser was simply to keep up with technology. Today, however, pieces that required various steps like drilling,
pressing and cutting are now carried out in a
single step and this in itself is a great competitive advantage.
“Pieces with 8-10 different steps now come
straight out of the laser system” continues Gi-
Automotive
INSPIRED FOR TUBE
ampietri. “The laser has simplified production
and has allowed us to do things that could not
be done before, thereby offering new solutions
to our customers. For example, we had a piece
that was welded with a screw and nut, but now
we do this with lower processing times and without any problem. The laser makes it possible to
approach different customers to the usual ones.
Many people still have no idea of the potential
of lasertube technology, which needs to be explained to customers. Many don’t believe that
a laser cut piece can cost less than the same piece
processed with a drill and press, that the hourly
cost is much less and it’s difficult to convince
them, but it’s like that”.
Target “euro5”
Alpino Industria Metalurgica Ltda has a head
count of 240 employees in addition to the 30
operators in the building of a joint venture
with a Belgian company operating in the automotive field, where large tubes of up to 120
mm in diameter are processed on a BLM
Dunam8 tube bending system.
"Of course you can always improve, but obviously our opinion on the BLM Group and its
technology is positive, otherwise we would
not have bought their machines for the past
40 years, "says Mr. Alonso. "BLM has always given us great technical support and above all
they have never left us on our own. People
change, but not companies, and most of all the
existing close relationship remains.”
For the future we are trying to start a second
joint venture to develop and manufacture exhaust systems for trucks. In Brazil, the Euro 5
will begin as of 2012 and we are preparing for
then, so that we can offer our customers the
entire product, not just the pipes. We are building a new 3,000 square metre facility, which
will be operational by the end of the year. If we
want to grow we need to look for new markets. In the coming years, a 7-10% per annum
growth is expected in Brazil, whereas we expect to grow by 20%."
The script is written, the cast is exceptional, and
the happy ending ... is a must.
11
Väderstad is among the leading names
renowned in Sweden for the production
Agricultural machinery
of tillers and agricultural machinery
for ploughing and sowing through a fully
automated cycle that starts from the raw
material store and ends with the laser cutting
of semi-finished tubes and robotized welding
INSPIRED FOR TUBE
of the machinery produced. At Väderstad,
extreme automation is the main tool that
binds efficiency and flexibility in the
production cycle.
More
flexibility
with
automation
o describe the Swedish company Väderstad, specialized in the
production of tillers and agricultural machinery for ploughing and sowing, we should start from the company’s background. In fact, this family business was founded by the father of
the current owners, who have experienced the life and growth of
the company first hand, with Andreas Stark, Production Director together with his brothers Crister, Bo and sister Christina, respectively, Head of the Board, Manager of the Scandinavian market and Managing Director, who run the company founded by their father, Rune
Stark.
T
What an idea!
While listening to Andreas Stark telling us about the story of the
company, you cannot but be impressed by the strong contrast between today’s avant-garde organization, which can boast an automation level in its production that is difficult to find elsewhere,
and what it was in the beginning, characterized by such a simple,
but effective idea. In fact, Rune Stark, started by manufacturing a
12
MAY 2011 NUMBER 14
13
INSPIRED FOR TUBE
Agricultural machinery
Agricultural machinery
INSPIRED FOR TUBE
14
rigid tine harrow to be used in a small farm
at a short distance from where the company
is today. The result was so effective that neighbours asked to have others made for them and
this was the beginning of the business. The
family-run business was therefore set up by
Rune together with his wife Siw and it is now
run by their four children.
“My parents started in our farm – says Andreas
– but soon, due to the size of the first pieces of
machinery, the poor power connections and
the roads that were too narrow for heavy traffic, it was necessary to move to larger premises, which took place in 1967 when the company rented a barn in another farm and in 1972
we started building where we are now”.
The story of Väderstad is characterised by continuous growth and started from the idea of
a farmer who was particularly able and business-minded.
“In the two-year period from 1989 to 1990,
agriculture suffered a strong depression, but
that was the time for us to expand into other
areas of interest starting with the manufacture
of seeders, which today account for 60-65% of
our turnover”.
MAY 2011 NUMBER 14
From the warehouse to laser tube
Fully automatically
Even from the production organizational point
of view there have been many changes, which
from the initial artisan phases have gradually
brought Väderstad to the extreme level of automation that it has today. The company is
structured in relation to the production flow
of the materials, starting from a building where
the raw material is stored. When a truck arrives, the raw material is unloaded and positioned (semi-automatically) on shelves.
At this point, the warehouse is closed and manning is not required. When a job order needs
a certain type of material, a request is received
on the warehouse computer to retrieve a bundle of tubes; the material is automatically selected and picked-up by the automatic bridge
cranes, which place it on trolleys travelling underground that exit the warehouse and transfer the bundle to the building where the laser
machines are located; the bundle is then unloaded in a tidy manner near the machines.
The ADIGE LT8 laser cutting systems cut the
tubes according to the job requirements and
unload them tidily.
An big robot collects the pieces and places
them in appropriate trolleys that are stored in
another transit warehouse depending on the
job order requirements. Each trolley contains
pieces that are required to weld a particular
frame. The boxes that are stored in the transit warehouse are then collected and transferred to the welding robots where each frame
is physically assembled.
Goal achieved
“We have a very high number
of different products and an
even higher number of articles
and components in production”
continues Andreas Stark. “When
we have to weld a frame, we
have the items available to
make it, but the next one, more
often than not, is different; therefore we need to have other articles available.
Before purchasing the laser system, most of the tube machining was done in-house, but a
part was purchased from companies who used laser systems.
Now everything is working and
we can proudly say that we
have achieved the goals that we
had set”.
Our strong points are quality and solutions”
concludes Andreas. In Sweden, we have an
80% market share, but in the rest of Europe
there is a lot of competition. Some of our competitors have laser systems, but no one uses
our production concepts. Among other things,
it was not easy to find a laser system that was
suitable to meet our specific needs; some were
too small and others too big.
In the end, we found ADIGE who understood
what we were looking for and provided us with
what we needed to the extent that if there
weren’t a recession in progress, we would have
had our third LT8.
This is because our view of the future is positive in relation to the increase in the price of
grain. As to production innovations, we are already thinking about developing products
that were impossible to think of producing,
whereas at an organizational level, we realize
that we can still improve.
In fact, in the welding area, no material should
be waiting to be processed, that’s why in the
future, the cut tubes must arrive directly from
the laser machines”.
Agricultural machinery
way possible. We started an extremely flexible manufacturing cycle aimed at producing
a single machine at a time. The goal is now to
produce what is necessary for the next shift or
the next day. Today is Thursday and we have
entered in the production system the output
for next Thursday. The raw material is in the
warehouse, whereas other articles may not be
in our facilities yet and must be delivered by
our suppliers, but in the meantime the laser
data of what has to be cut is transferred to the
system and the parts that need to be welded
tomorrow will be in the warehouse tonight.
INSPIRED FOR TUBE
For this reason, in the past, we had a considerable amount of material spread out around
the welding stations, but now it is completely
different.
The first step was to use a single warehouse
with a forklift operator who retrieved the various articles and delivered them to the welding stations. In this way, however, we had an
enormous warehouse of cut and machined
tubes and when there were errors in the machinings, we had to step in and at times throw
away the pieces. It was a slow way of working
and, moreover, when you machine a tube that
has been cut on different machines, you cannot expect precision. We wanted greater precision to use welding robots and then we
wanted to develop our machinery in a completely different way and this was the main
reason why we went for laser cutting, which
allowed us to process any shape and size. So
we started to search for a solution to our requirements and what can be seen now is the
end result.
A traditional production works in batches,
whereas our objective was to produce a single example of a machine in the most efficient
“
15
OFFICE
The BLM Group has always focused on proposing something
much more important and strategic than a single machine or
product, assuring its customers a really efficient production
process in which the reliability of its solutions is combined with
BLM Group
a wide range of dedicated and specific software instruments to
bring out the best of it. This is the value guaranteed by the BLM
Group; this is the value that makes BLM stand out and
INSPIRED FOR TUBE
renowned on an international scale.
Process efficiency
depends on
the software
fficiency: it is one of the most important
characteristics of any industrial production process. Product quality is a characteristic taken for granted and reliability a
simple starting point to launch a new commercial product both in terms of supply and
procurement. Time loss, material waste, scrap
and any other “symptom” of inefficiency within the production process are no longer costs
that can burden market prices. Therefore, the
“challenge” also regards the organisation of
production logics and strategies related to the
single processing phases to eliminate or at
least reduce whatever is not an added value
to the finished product.
The BLM Group works with the same logic, but
above all proposes and extends it to its customers. All the efforts made to manufacture innovative, quality, flexible and reliable machines
would be vain without tools (i.e. software instruments) able to exploit them to the maximum
and above all to include each processing phase
in a global and efficient logic context.
Over the years, the BLM Group has developed
in-house software environments useful not
only to simplify machine programming, but
also for production planning, preliminary
checking of single programmes, process sim-
E
16
MAY 2011 NUMBER 14
Part Prog
Pa
ulation and estimation of time and production costs. All the above to guarantee, once
again for quality control and most of all process
efficiency.
From machine programming…
To complete its laser cutting systems, ADIGE
has developed an in-house CAD/CAM environment called Artube that covers all the advantages already offered by the laser tube during the workpiece design phase and exploits
them at the best. The result is, once again, not
“only” workpiece quality but also the guarantee of carrying out the entire production
within times and with modes that are the most
advantageous for the customer. Among the
various specific functions offered by ADIGE
laser machines we can mention: minimum bar
swarfs, optimisation of discharging position in
relation to the workpiece length and type,
management of automatic cutting technology, possibility of adapting the process to the
quality of the raw material if deformed or covered with rust (for example).
… to hourly cost estimation
once the machine programme has been created, it is necessary to estimate the workpiece
Part Prog
Lasertube 1
WORKSHOP
Artube
time and cost. To this end, the BLM Group has
designed an additional software system called
Part Viewer, allowing a sophisticated graphic
simulation to be displayed– again in 3D – of
the workpiece being programmed. Thanks to
Part Viewer it is possible to preliminarily check
the cutting conditions, the settings of each
workpiece and, above all, to make an accurate
estimation of the cycle time and of the actual
hourly production that can be obtained with
the machine under those conditions.
Part Prog
INSPIRED FOR TUBE
BLM Group
MODELS
2D - 3D
Multi-piece lots are not a problem
art Viewer
Info
ProTube Express
Job 1
Part Prog
Lasertube 1
Job n
Info
Part Prog
Lasertube n
A new instrument has recently been implemented allowing to meet the demands of the
manufacturers who produce multi-piece lots
on their own laser tube and of those who wish
to coordinate production with various other
systems they have.
The new instrument for production planning
and automatic programming of multi-piece
lots is called Protube Express Thanks to Protube Express it is possible to manage the production of several workpieces in one environment only, to optimise manufacturing by
setting priorities and destination (in the case
of several machines).
The most advanced compacting integrated
algorithms (nesting 3D) allow to automatically preset the mode to minimise time and material as much as possible, to obtain a preliminary indication of the number of bars required
for each section, to evaluate the choice of various bar lengths and to choose the most convenient one during the material procurement
phase.
Once the sequence of workpieces to be manufactured has been set on each machine, it is
possible to obtain again the estimation of the
total time required for the production of the
lot, considering loading times, bar changing
and discharging times, as well as all the supplementary times related to secondary functions that have been preset.
17
Furniture
INSPIRED FOR TUBE
The chair is produced by
Virco is the largest manufacturer of school furniture for “grades K through 12” which are 5 years
old through 18 years old in the United States. Product development has always been the key
factor for the growth of a company that believes in automation as a tool for improving the
process and not for replacing human resources, which are fundamental to achieve the utmost
from each machine. In fact, the union between a skilled operator and a BLM robotized bending
unit has revolutionized the production cycle of chairs.
hile throughout most of the United
States a big snowstorm is creating difficulty,we are in Torrance, near Los Angeles on a splendid sunny day with a pleasant
temperature.
However, our interest is not in sunny California
or the“Studios”, but in a decisively important industrial context; as Jerry Farrell Corporate Director of Technical Operations explains, Virco is
the largest manufacturer of school furniture for
”grades K through 12”in the United States.
W
18
MAY 2011 NUMBER 14
A leading “family-run business”
The company was founded by Julian Virtue in
1950. The first customer was the Los Angeles
Unified School District. The company then expanded and acquired a table producer in Conway, Arkansas, followed by the production of
chairs and other furnishing articles that are
manufactured in Torrance and Conway.
Virco has multiple facilities, including its newest
lovation in Conway, Arkansas, covering an area
of 120,000 sq.m, 40,000 sq.m of which are the
manufacturing facilities and 80,000 sq.m of
which are the warehouse and assembly shop.
Then another two facilities in Conway Cover
an area of approximately 25,000 sq.m where
compression-molded plastic products are
manufactured in one and pre-assembly is performed in the other. Last, but not least is the
facility in Torrance that covers 45,000 sq.m and
in which more or less the same things as in the
Conway facilities are manufactured, excepting
a few differences regarding some of the pro-
a man-machine union
duction processes.
As mentioned in the beginning, with 190 million dollars worth of orders, Virco is the leading manufacturer of school furniture for “under 18s” in the United States. The company is
still family-run. Bob Virtue, son of Julian Virtue,
is the current President, CEO and Chairman of
the Board. Bob’s son, Doug Virtue is Vice-President. Both believe in the fundamental values
that have no doubt been handed down from
father to son: voice, dignity, equity, leadership
and merit.
Not by chance, Virco has led the school furnishing industry in the certification field for
emissions as regards quality of indoor air, being the first company to obtain the Greenguard® for Children and Schools indoor air
quality certification for classroomfurniture.
From five to a single process
Customers who contact Virco turn to them for
quality and, needless to say, for price. As to
quality, what is intended is also the ability to
offer a vast range of products.“We offer many
different solutions such as colours and styles
to meet the market demands”, explains Jerry
Farrell, who guides us on the visit through the
company.
“Our market has changed considerably over
the years and we are not the type of company who imports the whole product from China, although we are aware that some of our
competitors do. To resort to increasingly lower costs is not our job, but, on the other hand
we always try to find the best compromise and
this is why we have chosen a BLM tube bending machine that meets our requirements in
terms of flexibility and quality”.
“One thing that I strongly encouraged in our facility right from the beginning was automation
with the use of robots in the assembly process
and generally throughout the facility”.
“I took this road 17 years ago by installing the
first welding robots and today we have more
than thirty operating robotized stations. The
BLM machine was delivered in 2008 and, it revolutionized our production process”.
“Generally, we take the most
difficult components and put
them on that machine because we know that with only
a few attempts we will be able
to achieve a repeatable result”.
“When we purchase new machines, we do it
with the aim of improving the process. I can
give you an example of a chair that we make
in three different sizes”.
“Before purchasing the BLM bending unit, five
different bending processes were necessary.
It was probably the most complex article that
we had ever bent. Now with the BLM tube
bending unit, we can do it in one single
process”.
“When selecting a machine, the decision is well
weighed out and assessed. What follows is a
very close relationship, almost like a partnership with the machine supplier leading to longlasting cooperation, which is what has hap-
19
Furniture
INSPIRED FOR TUBE
pened with the BLM Group” .
“When Virco purchases a new machine, the selection is not made on the basis of the cheapest price alone, but it is made according to the
possibility of it being inserted in the production process that we intend to implement. Important features, such as programming ease
and after-sales service/technical assistance are
evaluated.
Automation without doubt, but
managed by man
As regards competition with the markets like
China and others that are growing such as
Thailand and Vietnam, Virco strategically focuses on three main issues: good service, good
quality and the ability to meet the customer’s
every need with new products.
“When a customer requires new articles, we
are able to respond very quickly,” emphasises
Farrell.“At the end of June, a school requested
a completely new product for delivery by the
beginning of August. We designed, manufactured and supplied it in less than two months.
20
MAY 2011 NUMBER 14
To achieve these goals, it is fundamental to
have the right people. If not, then there is very
little you can do. Therefore, automation at Virco is not to be understood as a way of replacing human resources, but of improving the
process and to do so competent people are
needed”.
This is the reason why we put
our most difficult pieces on the
BLM tube bending unit, as we
have skilled people who know
how to operate the machine
and are able to manage the
product”.
Production is carried out mainly at the Virco
facilities seeing as there are various divisions,
however, there are still some small jobs that
are outsourced. “Some parts of our products
are laser-cut” – continues Farrell – but before
thinking of installing such a system, I have to
have the right people. Today, the problem of
outsourcing lies in programming; if you want
to run a just-in-time production to meet the
customer’s demand precisely when required,
outsourcing creates a problem. Of course, there
are also advantages, but with the increasing
flexibility of the machines, we should aim at
doing more in-house and outsourcing less. In
the future, we should, therefore, invest in the
process”.
Virco considers the assistance that it offers
its customers of utmost importance, starting
from the support offered to school managers
for purchasing furniture on a large scale, thereby saving time and money, and continuing
with scheduling collection to recycle the old
furniture. Our program “Cash for Cardboard”
has allowed the school community in the Conway area to recover more than 100,000 dollars
through recycling. We at Virco are proud to be
renowned for our continuous commitment
towards quality, which includes employment
and the environment”, concludes Farrell.
Laser tube has a fundamental role at MDL.
The company is an OEM and as such spans
the most different of fields although, in recent
years the manufacture of structures for solar
centres has been taking on a leading role.
In particular, the decision to install an ADIGE LT
Job Shop
panel systems and couches for shops and
go unscathed through the difficult economic
situation of the last two years.
INSPIRED FOR TUBE
722 system has allowed the company to
The good thing about
the lucky choice
DL (acronym of Marcello Diego Lavorazioni) of Capriano del Colle located in the province of Brescia is a
company that has been specialised in commercialising steel products since 1989, with
special regard to contract tube processing. In
recent years this sector has increasingly
evolved from the simple cutting-to-length
to the supply of quality semi-finished products including the manufacture of assembled
structures, thanks to the cooperation of a specialised partner. As a result, MDL proposes itself as a supplier of actual finished products
that it manufactures with the knowledge of
who has analysed the multiple potentials and
opportunities offered by tube processing in
terms of project and structure optimisation. A
tubular structure assures many advantages
compared to a structure designed by mixing
tube and bent steel sheet, both in terms of coupling and sturdiness, not to mention production time and associated costs.
“MDL is certainly the answer to the requirements of all those companies that require com-
M
21
INSPIRED FOR TUBE
Job Shop
plex services in the filed of steel product processing, with special reference
to tube transformation” explains Marcello Zanini, who runs the company together with his brother Diego.“We supply semi-finished tubes to any sector
and our activities also include welding
or bending of tubes as well as the manufacture of drawn tubes, round, square
or rectangular welded tubes with burrs
on the two sides. The services offered also
feature internal and external washing, customised drilling and processing of round,
oval or square tubes or simply the cuttingto-length of tubes and bars”.
22
90% production within 150 mm diameter
The equipment installed at MDL facilities includes six ADIGE automatic sawing machines,
but above all it is the laser tube cutting technology that characterises the activity. The first
laser tube installed over more than three years
was associated with the innovative LT 722 ADIGE system in 2008.
“Both in terms of plant type and ease of programming I can state that ADIGE represents
the state of the art from a technological point
of view” says Marcello Zanini. “In our first experience with laser tube we privileged the cut
potential in terms of maximum processable
dimensions up to a diameter of 250 mm. On
the other hand, with ADIGE’s LT 722 we process
up to a maximum of 150 mm; a range which
covers approximately 90% of our production.
“In hindsight”, the initial choice of large diameters has been more restrictive than proactive.
MAY 2011 NUMBER 14
It is true that where large workpieces are cut,
the small ones can be processed as well, but
from the point of view of system performances,
by nature they are not comparable. Certainly, today, with two systems available and a third
one coming up, equipped with fibre laser to
cut highly reflecting materials, we are in a position to cover a very large portion of market
demands”.
“Perhaps we have made the right choice to invert investments considering that the majority of the work regards the medium-small tube;
but that’s ok. The in-field experience has allowed us to focus on what we really needed
and to correct the course” explains again Zanini.“In fact, by purchasing the ADIGE system we
have privileged other aspects that we knew
were of fundamental importance, such as the
programming ease which, in the majority of
cases, means the possibility of carrying out
complex cuts as well. The standard database
of the LT 722 cutting parameters is extremely complete and articulated to the point that
in the vast majority of cases we can immediately carry out an optimum cut”.
A “tutor” by your side
Due to its nature, MDL addresses various sectors: automobile, water-sanitary, heating, furniture, components and drapes. The company is a job shop and as such it spans the most
different of fields although, in recent years the
manufacture of structures for solar panel systems and couches for beauty shops and centres has been taking on a leading role.
“Following the crisis of the last two years, we
The LT 722 combines productivity with the utmost cutting accuracy on any type of tube section, which is of fundamental importance for
coupling, considering the structures being
manufactured.
“I think that we have been lucky to purchase
this laser tube system before the crisis” continues Zanini.“It has allowed us to make up for
desertions that have occurred in the most traditional sectors, and to acquire new customers
and new application fields.
Above all, however, it has allowed us to recover important trade names that we had lost due
to rather long response times and to the excessive hourly cost with only one laser tube
available, that, moreover, is more performing
on larger diameters.
Due to the inherent characteristics of the LT
722 and to the availability of two laser cutting
systems, today we have acquired such a flex-
“It is like working beside a tutor,
since if cutting passages are set
with the risk of colliding or require conflicting motions, the
machine does not carry out the
functions and signals the error”.
The laser semi-finished product
is a finished product
Of the quantity of material processed by MDL
over a period of a year, 60% is distributed among
the sawing machines and the remaining 40%
among the two laser tubes; these percentages
witness the importance and strategic role of investing in a technology that is as productive and
flexible as laser cutting. This fact is further confirmed by economic evaluations considering
that the business turnover produced by the laser
is by now predominant compared to that generated by the sawing machines. Costs are soon
worked out considering an hourly price of 30
Euros for blade cutting as compared to 80 Euros per hour of laser cutting.
“There is also the advantage that with the laser,
the semifinished product is a finished product
ready for assembly while the sawing machine
allows just the cut-to-length involving the need
for deburring and recovering the workpieces”
Zanini concludes.
“Furthermore, I admit that from time to time I
have some simple and particularly urgent cutto-length operations carried out by the laser
machine because the LT722 produces twice
as much compared to a sawing machine as
there is no blade changing and therefore no
down times. Not to mention the cut quality
that has no deburring and accuracy problems.
Not by chance, we are replacing two sawing
machines with a new LT FIBER laser tube system with fibre source that we believe will allow us to open up new and important horizons in the field of copper and brass tube
cutting.”
Job Shop
I bought the equipment in July
2008 and it was installed in September; since then it has not
stopped, not even once.”
ibility as to reach a production close to the justin-time, with a lower hourly cost than before.
We wanted to become flexible also in the laser
cutting field as we have always been in the
blade cutting field thanks to the six ADIGE automatic sawing machines.
I talked about luck because although it may
seem a farsighted decision taken at the right
moment, I am sincere in telling you that it is
not the case. We needed and we decided to
take this step, but when it was planned I never imagined what would have happened in
such a short time. I considered it a strategic investment that was important for MDL, but never thought of it as the company safety net.
However, this was the right choice because if
I had realised about the crisis that was about
to hit the economy, I would have certainly waited and perhaps we would have ended up like
several other companies.”
“Flexibility is mainly generated by the ARTUBE
programming software that is extremely userfriendly and direct, but also by the operating
software of the LT722 system allowing rather
fast production changes and therefore machine downtimes that are considerably reduced” Zanini adds.
INSPIRED FOR TUBE
have been obliged to considerably extend our
operating range to cover new sectors in order
to recover that 20% business turnover that we
had lost” explains Zanini.“It has not been easy,
but we have been able to count on a sound
partner: the ADIGE LT 722 laser cutting system
that is one of a kind in terms of performance
and timing. Among other things, the almost
total reliability.
23
OEM
INSPIRED FOR TUBE
The company takes its name from its founder Rubino Andreazza. Or rather, it takes part of the
name and part of the surname since Rubizza is a perfect mixture of the two. However, Rubizza is
also a perfect combination of the typical characteristics of the entrepreneur: passion for work,
farsightedness, ability to make important decisions and the courage to take action also at less
appropriate moments, even forcing the situation for a fundamental investment.
The small lots strategy
n 2003 the first laser tube installed at the
company facility was the ADIGE LT702,
which also holds the record of being the
first BLM system sold in the region. The purchase of this machine was difficult considering that the investment was very binding for
Rubizza at the time. Until then, the machines
they had were simple tube bending machines
and investment in the laser technology was a
big commitment. However, Rubino Andreazza had understood the situation and with the
support of the BLM Group made the big step
proving to be a winner.
I
The partner supplier
To hear the company history told by Mr. Rubino Andreazza is exciting.Together with his wife
Vainer Pagliarin Andreazza founded Rubizza
in 1992 and made of it a company that today
employs 35 people and is becoming increasingly important in Brazil.
“We started in a 100 sqm room where we
24
MAY 2011 NUMBER 14
moulded accessories for furniture. In 1996 our
products were no longer commercialised on
the market.Therefore, we started to bend tubes
with a first “CNC” machine that was very simple.Thanks to this machine however, we gained
the know-how and experience in the tube sector that proved fundamental to make us 100%
job shop and penetrate other markets. We are
looking at 1998 and from then on our company history, with the purchase of a first NC863
tube bending machine that allowed us to work
for the agricultural machinery and automotive sectors, starts cooperating with the BLM
Group. We put our bets on them and focused
everything on product quality. A partnership
relation was built up with the BLM agent, who
help us to start-up and find work to operate
the equipment.
Therefore, the cooperation has been an important factor; in fact today we have eight BLM
machines, among which the laser machines in
particular that have completely changed the
operating mode and the production cycle. BLM
is a partner for Rubizza. “When we were in
need, we always received assistance and support”, Mr. Rubino states.
High quality focus
When the building facility was changed in
1999, Rubizza made another basic step in its
growing and expansion process that in 2001
was confirmed with the purchase of a BLM
SWING tube bending machine with R/L bending direction allowing to process also small
and complex workpieces. However, this meant
the passage from a simple bending to an automatic bending, that involved an important
technological change.
The most courageous and strategically fundamental step was made with the LT702 laser in
2003.“The laser was a challenge – says Andreazza
– and after many years I can say I won. With the
LT702, work has increased adding more important and demanding customers.
OEM
INSPIRED FOR TUBE
The laser tube has allowed us
to simplify work in as much as
presses and dies are no longer
required, not to mention the
ease of manufacturing that facilitates a just-in-time production management. Finally, we
are able to manufacture complete pieces with special joints
that we could not produce before.”
The company growth is confirmed by the regular frequency with which machinery is purchased. After the first laser, a second SWING
tube bending machine was purchased. Then,
from 2007 to 2009, another two new-generation tube bending machines were purchased. First a DYNAM0 ELE was purchased,
and then an ELECT-L for tubes up to 80 mm
in diameter, both all-electric machines. To end
the cycle, in 2009, the second laser system
was purchased: an LT8 Laser tube with 3D
head designed to cut up to 220 mm diameter tubes. This equipment has made it possible for us to have job orders in the field of
agricultural equipment and trucks.
Unlike what usually happens, the Rubizza
laser history started off from the tube and
only later did it cover steel sheet. In fact, two
years ago, they also entered the flat laser sector to expand their range of action and di-
versify market outlets, considering the large
steel sheet demand. Today customers look
for quality, precision and respect of delivery
times. It is not by chance that Rubizza is a reference point also for the S. Paulo area. Today,
they have no competitors but partnerships
with other companies of the area since they
focus on top quality.
Rubizza does not refuse mass production, but
prefers small lots to further confirm the entrepreneurial farsightedness of Mr. Rubino.
This is, in fact, a strong point in a world where
many refuse small quantities in favour of large
ones.“Now there is no specific sector, we work
a little for all sectors with small lots thanks to
which the company has been able to grow.
Obviously this requires high flexibility” concludes Rubino Andreazza.
25
Elevated work platforms and
walkways. This is the product
whose leading worldwide
Elevated platforms
producer is Premekon, a Finnish
company that combines its
engineering technique gained
and refined on the field with its
INSPIRED FOR TUBE
advanced technology and
production means. The
introduction of the laser tube
and of a modern tube bending
technology has significantly
contributed to improve
engineering solutions.
From laser to new en
he Finnish company Premekon is specialised in the manufacture and marketing of elevated work platforms and walkways supplied as a finished product complete
with stairs and storage space. Characterised by
top quality and absolute reliability, these products are the result of advanced production methods during implementation and of an engineering skill that is one of a kind. The company
was established in 1984 as an engineering office specialised in the production of welded
structures and only in 1991 did production start.
This was of great advantage since it allowed to
experience first hand and analyse the engineering and production problems of various
sectors. Competence and know-how are the basis of success.
“We have never been just a simple workshop
- says Martti Immonen, Managing Director of
Premekon - but something more, thanks to the
engineering part.
T
26
MAY 2011 NUMBER 14
Today 12 out of 45 people are
specialised engineers to confirm the importance that we
give to the development and
engineering phase of our products.”
Substantial project differences
The fact that the use of laser tube is a strategic
turning point for the activity of any company no
longer makes the headlines. However, in the case
of Premekon it is worth pointing out once again
as laser has brought important advantages in
terms of productivity (before the laser, traditional
tube processing methods were in use), but above
all of new product engineering opportunities.
“When purchasing a laser system we basically expected two types of advantages” explains
Mikko Polkki, Production Manager of the com-
pany.“On one hand, being able to concentrate
tube processing operations on a single machine and on the other, obtaining a higher efficiency during the welding and assembly
phases downstream. We not only thought
about the cutting phase when improving accuracy and efficiency (approx. 25/30% increase
in production), but also and above all about
the processing phases that follow.
Laser introduction, with an LT Combo system
to cut tubes and steel sheets has also allowed
to differentiate production. Previously, 90-95%
of the production consisted of walkways, stairs
and storage areas; now this figure is reduced
to 80%. The remaining 20% is accounted for
by contract work for various tube users. Generally, we work with reduced workpiece lots
and our main characteristics, more today than
yesterday, is flexibility.”
“As compared to the past, introduction of the
laser system also involved the modification of
INSPIRED FOR TUBE
ngineering solutions
single components; the workpieces look the
same but to the contrary they have some substantial engineering differences exploiting the
possibilities offered by modern laser technology in terms of new and better combinations of
structural elements” says Veikko Olkkonen, Research & Development of Premekon.“The LT
Combo system has allowed us to widen our view
regarding the processing possibilities; among
other things thanks to BLM's CAD/CAM ArTube
it is very easy to create programmes and the results are immediately visible on the machine.
Customers noticed and appreciated the modifications carried out following the adoption of
the laser system that has led to more precise and
accurate products”.
Handrails in one process only
The laser machine was installed in December
and after only a few months, in April to be precise, a BLM ELECT-L tube bending machine was
installed.“I have known the BLM Group since
University and I knew that no other company
that had such experience in tube processing”
explains again Martti Immonen, Managing Director of the company. “Automation, by increasing the production process efficiency, allows to reduce prices making them still
competitive.
In the future, automation and high-tech will be
increasingly important to improve efficiency of
the production process and to control production costs in relation to market demands.That’s
why the choice of making another important
investment was made after only a few months.
The tube-bending machine has allowed to modernise our production process thanks to an advanced technology allowing to manufacture
stair handrails in one step only adding just the
angles with one weld.The most outstanding features of this machine is the operating speed and
the capacity of manufacturing quality radii, again
with a positive influence on the possibility of
studying and designing structures with details
and components that were unthinkable in the
past without the laser and tube bending machine. For example, we manufacture many
handrails in aluminium that we cannot cut with
laser (we could, but it is not recommended) and
we make many handrails for the building and
construction sector”.
Automate to compete
“Low cost competition among countries exists,
but with products that anyone can manufacture”concludes Martti Immonen.“The difference
lies in what not everybody is able to manufacture. Quality and engineering are therefore our
strong points.
In the future, automation and high-tech will be
increasingly important to improve efficiency of
the production process and to control production costs in relation to market demands”.
27
Landoll is specialised in the construction of agricultural machinery, and
over the years has added the production of trailers, forklifts and
INSPIRED FOR TUBE
Agricultural machinery
equipment for military purposes. Product diversification, direct control
of the whole production cycle and above all a deep knowledge of the
customer’s problems are factors that, together with the use of a more
advanced lasertube technology, make Landoll a leading company
in each of its fields of activity.
The advantage
of being
born on a farm
gricultural machinery, trailers, forklifts
and military equipment. These are the
production sectors in which Landoll is
divided; a company created in 1963 by Don
Landoll, Owner and President of the company who tells his story:
“I was born and grew up on a farm, and ever
since I was a child I liked welding and building
objects and metal structures. I started off repairing agricultural equipment and machinery. Then, after school, I worked for three years
in a company specialised in the manufacture
of equipment for parks and farms. That was
my first industrial experience. In 1963 I set up
my own welding facility for contract work. I
A
28
MAY 2011 NUMBER 14
employed one person only and so it took some
time before starting to launch a range of products of my own. The business I built now consists of 670 employees distributed in several
production facilities.”
Leader in all sectors
“Our strong point is product diversification –
continues Landoll – and the capacity of implementing it in-house. We buy the raw material and manufacture finished products with
a low degree of outsourcing. In fact, we have
a well-equipped facility to produce whatever is required. It is a very important aspect, especially today where absolute control of the
production process is required, expecially in
the field of agricultural machinery.” Landoll explains how just-in–time-production requires
a production capacity that is independent of
any supplier. We are of the berlief that no-one
can make our parts better than ourselves. By
outsourcing work we risk the chance of creating potential competitors” concludes Landoll.
His products are known for their high quality
and are positioned in a definitely high market
segment.“Product know-how is another strong
point of our company” explains Don Landoll.
“We maintain our own farms and know very
well what jobs must be carried out by our machines, which helps us to develop products
Agricultural machinery
INSPIRED FOR TUBE
that meet the demands and expectations of
our customers. Also from a sales point of view,
our sales people must have a thorough knowledge of our products in order to communicate
the added value that we are offering to potential customers.”
An 18 m long bet
In such a complex reality – including eight Landoll production facilities – the use of advanced
technologies is of fundamental importance
and the lasertube is an integral part of this
mechanism.
A Jumbo and an LT8 are the ADIGE systems installed and used to cut all the tubular com-
ponents of the company’s various products.
“I came across the BLM Group at Fabtech in
Chicago – says Landoll, and I was looking for
the best way to further improve the manufacture of our products. Since we live in a small
community, we must all do our best to increase
production with the minimum amount of
manual work. First of all, labour is expensive
and not easy to find.
As a result, we decided to buy the LT JUMBO.
We needed a machine that could do everything. A smaller machine could have been
faster, but would not have met all our requirements. Initially, we bought a 14” system;
then we were offered a 20” system that was
29
Agricultural machinery
INSPIRED FOR TUBE
immediately available and we purchased it
with a view to buying a smaller machine later,
as soon as we were able to fill it up.
derstood the significance of having a machine
designed to do whatever we desired in automatic mode” points out Landoll.
With the quality level of our products, we are
constantly seeking efficient manufacturing
methods. From this point of view, we certainly
took a bet with the LT JUMBO, mainly as far as
the maximum length of the machinable tubes
(47 feet) which is as important as the maximum
diameter.
“The greatest surprise that we
had with the LT JUMBO is that,
in the end, it is as fast as smaller
machines. The jumbo processes a huge quantity of tube in a
24 hours a day, five and half days
a week.”
Our objective was to obtain the
maximum length possible and
to machine tubes up to 18 m
length so as to produce with a
higher efficiency without worrying about cut-offs.
At Landoll we had already gained a certain experience in tube cutting. The experience was
achieved on a steel sheet cutting machine
equipped with an additional module for tube
machining in which we had to manually load
one workpiece at a time.
“Due to this experience, we immediately un-
30
MAY 2011 NUMBER 14
Ally of robotised welding
The LT8, purchased some time after the LT JUMBO as initially planned,is appreciated for its speed
and excellent cut quality, as well as for its loading
and unloading features.The presence of the single bar semiautomatic loader in addition to the
conventional bundle loader located at the rear
makes it ideal for the several single parts to be cut.
“It is a very useful and efficient configuration”
points out Landoll who continues to refer to laser
systems in general:“We have gained advantage
in manufacturing components that required 90°
junctions that can now be carried out with more
accuracy and in a different manner so as to facilitate and speed up welding.We now have the
capability to efficient produce holes, slots and
other features on a tube in a single process ”.
One of the best features of the LT8 is the steady
rest being positioned close to the cutting head.
This helps to guarantee the required precision
for automated welding. The facility includes
20 robotised welding units that can be used
only if there are precise components.
Thinking about future investments, Landoll
states:“First of all it is necessary to be able to seize
the opportunities with quality products. All customers want reliable and easy to use products.
Of course, cost is also important and efficiency
in production must be taken into account. At
present, our sales exceed our production capacity. We must therefore increase our production response and control costs and manual that
is quite considerable”.
Certainly, Landoll shows his appreciation for
the BLM Group products and in particular for
laser technology. As for the future, he is rather
optimistic, expecting further investments to
be made in laser systems designed to operate
in the LT8 and LT JUMBO dimensional ranges.
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