1/08
Express Magazine for
Sheet Metal Processing in North America
Made in the U.S.A. Cadco products bring European flare to rural New England
Lighting the way LED technology aids tool set up
Making their mark Arrow Cryogenics answers customers’ call for laser marking
The Wild West Jesse James pioneers fabricated sheet metal chopper frame
Special TruLaser Laser cutting without pit stops
1/08 CONTENT
9
10
24
30
40
Demonstration part cut on a TRUMPF laser.
2
Express Vol.1/08
15
34
TOPICS
FABRICATING
15 Family Mentality Leads to Successful Business Overcoming a secret and keeping the business within the family have pioneered B&J Inc.
CUSTOMER FOCUS
28 New Path to Familiar Goals Sponsorhips are a strategy at Heinzig Metalltechnik.
LASER MARKING
24 “Would You Like Laser Marking with That?” Arrow Cryogenics grows by offering laser marking.
DISCUSSION
FEATURE
10
Rebel Thinking That’s Ahead of the Curve
Maverick Jesse James defies the odds and goes on to build a custom-built motorcycle empire.
30 Laser Technology 101 Q & A Jochen Deile discusses the advancements of TRUMPF’s laser R&D department, and what we can expect for the future.
TO THE POINT
PUNCHING
05 Looking Back, Moving Forward
34 Bringing Home the Bacon Foodservice equipment company rides food industry wave with innovative thinking and American loyalty.
STANDARDS 06 23 40 40
PANORAMA INSIDE THE PRODUCT PERSONALITIES CREDITS
Special TruLaser The 24 hours of TRUMPF From page 19 Express Vol.1/08
3
Looking Back
TO THE POINT
Moving Forward
Rolf Biekert, President and CEO
2007 was a year of ups and downs, fi lled with a certain degree of anxiety and unrest for the American public. The year brought energy costs to their highest level ever, and consumers had to dramatically alter their spending habits to compensate. The collapse of the housing market was followed by a credit crunch affecting the worldwide financial market, and the dollar was at a historic low versus the Euro. While the year was not as prosperous as many businesses had anticipated, a sagging economy and a weak dollar did not stop TRUMPF from having a successful 2007. Two key themes for TRUMPF in 2007 were growth and continued innovation. In March, TRUMPF opened its new production facility in Monterrey, Mexico, and in September, TRUMPF acquired one hundred percent of Advanced Fabricating Machinery in Mississauga, Canada. As a testament to TRUMPF’s continued commitment to innovation and existing product enhancement, the TruCoax 3200 laser resonator for the TruLaser 2030 was unveiled in November at FABTECH Chicago. Yet, perhaps the most significant sign of TRUMPF’s continued market presence was and continues to be the company’s North American investment at its Farmington, Connecticut headquarters, with its ongoing construction of the new Laser Innovation and Technical Excellence (LITE) Building. The building will be the largest Nd:YAG and CO2 laser manufacturing and development facility of its kind in North America, containing more than 85,000 square feet of production space designed for lean manufacturing and state-of-the-art production, including clean rooms for the production of CO2 and Nd:YAG laser
resonators. The investment signals a strong belief in the North American market. As businesses look to the current year, much of the same fear and ambiguity that consumers and companies faced in 2007 has grown even stronger in 2008. The American public faces an increase in unemployment, softening consumer spending, an unstable stock market, and the fear of a recession is spreading. Yet, companies like TRUMPF continue to step up to the plate proving that despite economic uncertainty, the manufacturing industry can still thrive, innovate and inspire. In the spring of 2008, TRUMPF will officially open the doors of our new LITE Building. Recent innovations, such as the TruCoax 3200 laser resonator, will be produced in the state-of-the-art building. The LITE Building will represent a new chapter in TRUMPF history as we look to increase and diversify our research and development and manufacturing activity in North American locations, and tap into new markets. In order for companies to remain successful and competitive, they must adapt to changing times, and continually innovate and diversify, because they never know what the next day may bring. While TRUMPF will continue to closely monitor U.S. and international economic developments, we will also continue to forge ahead, serving the needs of our customers and continuing to cement our name as a leader in the industrial laser and machine tool industries. Express Vol.1/08
5
PANORAMA
TruBend 3180 Flexible and productive precision bending machine
TruBend 3180 > Additional information: Shane Simpson, Phone: 860-255-6039 E-mail: shane.simpson@us.trumpf.com
TRUMPF introduced the newest member of the TruBend 3000 Series press brakes, the TruBend 3180, at FABTECH 2007 in Chicago, Illinois. The new TruBend 3180 was designed to provide manufacturers with more capability, flexibility and productivity at an economical value. The machine features a new crowning system that uses hydraulic cylinders, combined with a passive crowning technique, as well as a new 5-axis backgauge with ± 3 inches on the X 2 axis. Another highlight of the TruBend 3180 is its new Delem T3000 control. It has a large color monitor with standard 2D graphic programming and optional 3D visualization. Operation is facilitated by the radius programming and machine diagnostic functions, as well as the online “HELP” guide. The TruBend 3180 is the largest member of the TruBend Series 3000 press brake family.
Tresco Consoles Celebrates 40th Anniversary Internationally recognized as a leader in the custom console market A premier manufacturer and leader in the custom console market, Tresco Consoles of Calgary, Alberta Canada celebrates its 40th anniversary this year. With over 2,500 installations worldwide, Tresco stands out among console manufactures by virtue of its willingness and ability to develop custom console solutions, responsive to individual
end-user application requirements. Their consoles are designed for control room organizations that serve the oil and gas, military/security, transportation, and utilities markets. Recognized for its innovative electromechanical work surfaces, monitor interfaces, and fully customizable monitor mounting solutions, Tresco was the
first console manufacturer to integrate Edge Sensing technologies into its adjustable work surfaces. By using flexible fabricating equipment such as TRUMPF punching and bending technology, Tresco is able to customize their products to each customer’s individual needs.
A complete custom console solution from Tresco Consoles.
6
Express Vol.1/08
PANORAMA
Sheldon Manufacturing Supports Fred Hutchinson Cancer Research Center Contributions allow Center to purchase essential equipment for 14 laboratories Giving back to the community is important to Sheldon Manufacturing. In 2007, Sheldon Manufacturing provided enough donations to the Fred Hutchinson Cancer Research Center of Seattle, Washington, to purchase equipment for 14 laboratories. Ongoing contributions from companies such as Sheldon Manufacturing aid in the center’s scientific research on the prevention, detection and treatment of cancer, HIV/ AIDS and other serious diseases. Among the equipment that was donated were a new water bath, incubator, and oven, all used to help accelerate clinical research, eliminating the problem of lab technicians waiting for equipment. Having an additional incubator has increased the center’s capacity for growing bacteria and fungi and helps to prevent the challenging problem of cross-contamination. The additional water bath now means multiple experiments can be conducted simultaneously. Sheldon Manufacturing, Inc. was founded in 1970 with the goal of being a worldwide leading manufacturer of constant temperature equipment. Various grades of stainless steel are used in the production of their precision laboratory and medical equipment. TRUMPF punching machines are the first step in a complex manufacturing process at Sheldon, which relies on accuracy and reliability for its equipment production. > Additional information: www.shellab.com or www.fhcrc.org
Arboreal panels from Ceilings Plus created the eco-friendly look of the Clinton Presidential Library.
Bamboo Ceiling from Ceilings Plus Makes Debut in New Clinton Presidential Library Arboreal panels qualify for energy efficient credits
One of Sheldon Manufacturing’s high-grade medical incubators.
As an eco-friendly material, bamboo is enjoying a strong U.S. acceptance, and customers are now using it as an attractive and affordable ceiling finish. More than 9,000 square feet of arboreal ceiling panels with a custom bamboo finish were installed in the recently completed Clinton Presidential Library in Little Rock, Arkansas. Arboreal ceilings, manufactured by Ceilings Plus of Los Angeles, are lightweight aluminum panels finished with wood or other natural veneers. In addition to the bamboo panels in the main exhibit areas, Ceilings Plus provided the custom painted and Grau-anodized aluminum ceiling and wall panels throughout the Clinton library. Arboreal panels are fabricated with automated CAD/CAM equipment, enabling Ceilings Plus to economically produce panels in hundreds of sizes and configurations to satisfy the unique design requirements of the Clinton Library. The relationship between TRUMPF and Ceilings Plus started ten years ago. Since that time, TRUMPF punching machines have been used to process ceiling panels for the Swiss Re Insurance HQ building as well as ceiling panels for the American Museum of History “Sphere” in New York City. Express Vol.1/08
7
PANORAMA
Under One Roof
New Services Center in Ditzingen
Opened on October 12, 2007: The new Services Center at TRUMPF headquarters.
On October 12, 2007, TRUMPF opened its new Services Center in Ditzingen, bringing TRUMPF’s Logistics and Training Centers together under one roof. In one section of the building, the Logistics Center, employees dispatch spare parts to customers quickly and reliably, around the clock, seven days a week. The second section of the building is devoted to training, and
Otis Elevator Company Awarded Beijing Olympics Contract Company spearheads Beijing’s transportation logistics Otis Elevator Company of Farmington, Conn. is celebrating the 2008 Beijing Summer Olympics early. In total, Otis has won 25 Beijing 2008 Olympics-related contracts, including the Beijing Subway Line 5 and Line 10, the Tianjin Olympics Sports Center soccer venue, National Aquatics Center, the Beijing Transit Center and the Tianjin Light Rail. Otis has been selected to provide more than 1,300 elevators and escalators with contracts valued at more than $100 million for several 2008 Beijing Olympics-related projects. Otis was selected for the project based on the company’s experience with international Olympic games, its contribution in providing energy-efficient and environmentally friendly products and their reputation as the No. 1 elevator company in the world. Today, Otis is China’s leading elevator company. Otis also has elevators in the Eiffel Tower (Paris) and Burj Dubai, the world’s tallest building (United Arab Emirates), and uses TRUMPF’s TruPunch and TruLaser machines in the production of its elevators. 8
Express Vol.1/08
Ditzingen is home to the TRUMPF Group’s largest training center. The center offers a comprehensive range of training courses to continuously inform customers and employees about TRUMPF products. New classrooms with the most modern equipment combined with a 26,000 square foot demonstration room equipped with 18 dedicated training machines, create the ideal conditions for successful knowledge transfer.
An example of a Gen2® elevator. More than 250 Gen2 elevators will appear in a number of 2008 Olympic venues in Beijing.
PANORAMA
Walker Crane & Rigging Corporation Key Player in “Cow Parade” Company provides transportation logistics for unique West Hartford, Connecticut event Each year, in cities across the United States, replicas of cows are painted, put on display, and auctioned off to benefit regional charities. In Connecticut, the “Cow Parade,” takes place in West Hartford Center. The exhibit starts in the fall, lasts until early January, and culminates with an auction benefiting several local charities and non-profit organizations. Walker Crane & Rigging Corporation was contacted for Connecticut’s first “Cow Parade” in 2004 by Guida’s Dairy (the top sponsor of the event and a longtime customer of Walker’s) to transport the cows from their warehouse to West Hartford and set them up throughout town. This past year, Walker once again volunteered to provide the transportation logistics for the “cow parade” and was rewarded for their efforts with the commission of their own cow. Fabtron Inc. of Plainville, Connecticut, was responsible for producing the crane section of the Walker cow, which was cut using TRUMPF’s TruLaser 4030. Walker began its relationship with TRUMPF in the late 1960’s, providing trucking and warehousing service for all of TRUMPF’s local transportation and storage needs. Walker now handles TRUMPF’s machinery moving, warehousing and machine transportation requirements throughout North America. Ed Roy, owner of Walker Crane & Rigging, with Walker Crane’s “Move-A-Head” cow in West Hartford Center.
Cambridge Provides “Green” Industrial Heating Solutions Blow-Thru® Space Heaters offer more heat, use less energy, and provide better indoor air quality
In today’s push for large corporations to “go green” the term energy stewardship has become the new buzzword. Energy stewardship means reducing the energy a building consumes to provide a safe and productive environment. Cambridge Engineering, a manufacturer of energy efficient gas-fired heating equipment, has actually been helping industries go green for over 40 years. Cambridge Blow-Thru® Space Heaters provide more heat, use less energy, improve indoor air quality and reduce air pollution. Their unique technology is now recognized as the best, and most cost effective way to heat large commercial and industrial buildings like manufacturing plants, warehouses, distribution centers, aircraft hangars and
indoor sports facilities. Building studies document 40% to 70 % energy savings, which also means a corresponding reduction in carbon dioxide (CO2) and other greenhouse gases. TRUMPF’s TruPunch 5000 and laser technology have helped Cambridge Engineering design and manufacture Blow-Thru® Space Heaters and their patented burners, which are a crucial part of this green heating technology. > Additional information: www.cambridge-eng.com
An environmentally friendly and energy efficient heater: the Blow-Thru® Heater. Express Vol.1/08
9
FEATURE
Rebel Thinking and TRUMPF
Technology
Keep West Coast Choppers Ahead of the Curve 10
Express Vol.1/08
FEATURE
A foot peg produced on TRUMPF equipment.
History is full of visionary thinkers and artists whose unprecedented projects first meet misunderstanding and contempt and then become mainstream successes.
For acceptance to come during the groundbreaker’s lifetime is rare and requires a little luck, a lot of hard work, and sometimes, a laser. Such is the case of West Coast Choppers owner Jesse James. It is no surprise that James, famous for his own maverick personality, comes from an ancestry of pioneer stock that includes the original Jesse James, notorious outlaw and Wild West folk hero. But you might not expect to learn that James has had more than a few successful ideas that people initially judged impractical.
The motorcycle business Like many an entrepreneur, Jesse James’s story begins in the corner of his mother’s garage, where James liked to tinker with motorcycles. James had been working as a bodyguard, a job which required him to travel for up to a year at a time. During breaks, James returned to work on his bikes – something he had enjoyed since childhood. After an injury forced him to stay home for a month, James decided to start his own business. Although today West Coast Choppers (WCC) is a multimillion dollar company with 250,000 square feet, 80 employees, and an exclusive, high-profi le clientele, not everyone was supportive of the hobby-turned-business venture. “Building bikes was considered [goofing] off,” explains James. “It wasn’t really thought of as a profession – most bikers were considered greasy, dirty scum. It definitely wasn’t considered something that you could raise and support a family on. No one said ‘That’s a good move, you should do that.’” Fortunately for James, the naysayers were wrong. James was soon busy with work, moved out of the garage, and opened his own shop. In the early days, James made a lot of motorcycle fenders, several hundred per week, he estimates. He used hand-held electric shears to cut both sides of the fender, and each week consumed a pair of the hundred- > Express Vol.1/08
11
FEATURE
The new CFL II motorcycle.
dollar shears. “You could get them sharpened or get new jaws, but they never really worked the same as a new pair,” says James. “It was an added cost, which I didn’t like. That’s what led me to TRUMPF.” At a WESTEC tradeshow in the mid90s, James met a TRUMPF power tools representative. “Their hand shears were quadruple the price of my regular shears – probably more. I thought ‘I can’t justify that, but they must be good.” So I buckled down and bought them. I still have the same set today. I’ve cut thousands and thousands of feet of metal and never had to have them sharpened or replace the blades. I could have saved all that money – thousands of dollars – by buying a more expensive, better tool earlier.” James still uses the shears on his bikes. When he’s shaping a gas tank, he’ll use them to cut patterns out of 18-gage steel. He has even used the shears on Discovery Channel’s “Monster Garage,” a reality television show which James hosted. “So, when it came time to look for other products, I thought, ‘Well they make this little thing that’s awesome, this big thing is going to be awesome too,” says James.
wasn’t looking for a laser, but a TRUMPF machine demonstration caught his eye. He explains, “They ran a little cog plate with gear teeth and some intricate design in 14 seconds and I said, ‘Okay, I’ll take it. I don’t know what I’m going to make with it yet, but I’ll take one.’” Once again, not everyone saw the wisdom in James’s decision. “I took a real chance buying the laser,” he says. “Everyone here thought I was crazy and said ‘what the @$#*%! is he doing? We don’t need that.’ Now, a couple of years later, they’re like, ‘Oh my god, this is the greatest invention I’ve seen in my life!’ My mind was already open to it. It took everyone else a little while to look at things a different way.” James says the fabricating machinery allows him to develop more complex parts and maintain the artistry. The technology augments what he already does, but raises the quality and repeatability to a level he claims he couldn’t repeat by hand. “I’m trying to use (the laser) in more of an artistic way, to make more complicated pieces,” says James. “It’s nice to take a bunch of laser parts that are cut out really beautifully and then hand weld them together. It’s still hand fabricated; it’s just a more modern version, but the part still has a soul.”
The laser purchase
The sheet metal bike frame
The first time he saw a TruLaser 3030 laser cutting machine, James was at another tradeshow. He had been sending out parts for water jet and plasma cutting and, put politely, was unhappy with the quality. James
One of James’s most recent innovative ideas takes shape in a patented frame design for his new Chopper for Life, CFL II. The advanced frame, made possible by laser and press brake technology, took a year and a
12
Express Vol.1/08
FEATURE
Assembling bike components in the West Coast Choppers shop.
“I still have the same set (of shears) today. I’ve cut thousands of feet of metal and never had to have them sharpened.” half to develop and is made out of sheet metal. Typically, motorcycle frames are manufactured almost entirely with metal tubing. In James’s new design, there are only three tubes. Everything except the neck, rear drop-out and the billet section that the oil tank hooks to, is laser cut and bent on a press brake. “A tube can bend and there’s equal load any way you bend it,” explains James. “With a box section you can make stress concentrations go away completely. You can take the load off any where you want by making the shape rectangular and elongated. It’s harder to bend something that’s boxed in and reinforced, than a piece of tubing. It’s just stronger engineering-wise.” James, who spends a lot of time off-road racing, credits some of the inspiration for the laser cut, box section design to the off-road industry. “I wanted a similar approach to building a bike frame, but also that cool custom motorcycle shape,” says James. “I hadn’t seen anyone else do this before and I wanted to see if it could be done. We wanted to make a frame that had a real monocoque design and was super strong – a very straight and true frame.” Since the groundbreaking design was a first of its kind, James and his team developed everything from scratch. No small task: the frame consists of approximately 26 pieces laser cut with nitrogen, mostly out of 1/8th and 3/16th inch cold rolled steel, and has 47 precision bends. One unusually-shaped rear section part requires 11 bends. In fact, with all of its elaborate bends, the new frame design has been referred to as sheet metal origami. “That’s what it looks like…folded, faceted metal,”
agrees James. “If you took paper and folded it into a frame, this is what it would look like.” Producing the bends with consistent accuracy was a challenge for WCC’s non-CNC press brake. “No two pieces would come out the same,” explains James. Even though WCC produces fewer than 20 of its one-of-a-kind custom choppers annually, repeatability is still critical, particularly in the production of its frame kits and parts, which comprise 60 percent of the business. A TruBend 5085 press brake and the machine’s six axis backgauge feature helped to straighten out the repeatability and fi xturing issues.
A good start The new frame will be used in WCC’s custom bikes and sold as a kit to customers who want to build a custom bike themselves. So far, customers seem to like the frame, which is available for purchase through the WCC website. “I think we’ve sold about 75 since November,” says James. “It’s a good start.” “As long as they buy it, I seem smart,” he adds. “I think it’s a little over the industry’s head right now. It’s so different that people don’t know what to say. They use a lot of curse words to describe it. Some people say they hate it, because they don’t know what they’re looking at and there’s nothing to reference it to.” In his characteristic nonconformist fashion, James doesn’t care if people don’t understand his creations. He only builds motorcycles for people he likes and his refusals to A-list clients are infamous. “I > Express Vol.1/08
13
FEATURE
The frame of the CFL II bike, made possible with TRUMPF’s laser cutting and bending technology.
“I hadn’t seen anyone else do this before and I wanted to see if it could be done.” don’t cater to what anyone likes – ever,” says James emphatically. “I always try to do something completely different and modern, and my way. It will probably take a couple of years before this frame catches on with people.” And by then, they’ll be at the end of a long list of those hoping to own a West Coast Chopper. As for the future, you can expect TRUMPF technology to continue to play a role in WCC innovations. How often does James find something new to laser cut? “Every day,” he admits. “I laser everything. The laser has caused us to shift everything across the board. We’re just getting to the point where we’re figuring out how to use it A foot board for to its best potential.” the new CFL II bike. 14
Express Vol.1/08
> West Coast Choppers
Company Name: West Coast Choppers Founded: 1980 Staff: 80 Product Line: Creater and producer of custom-built motorcycles. TRUMPF Machinery: TruLaser 3030, TruBend 5085, C-160 Shears Contact: www.westcoastchoppers.com
FABRICATING
Family Mentality Leads to Successful Business The owners of B&J Inc., Cherie and Gregg Fisher.
B&J Inc. is located in the shadow of Reno’s Casino lights in Sparks, Nevada. You’ll know you’ve found it when you come upon a building that looks like a red castle.
Inside is current president and CEO Cherie Fisher, who began working for the family business as a receptionist more than 20 years ago. Her parents, Bonnie and Jay Thiessens started the company in 1972. After high school graduation, Jay took a job in a machine shop and worked his way up through the company. Jay’s employer granted him permission to use company equipment after-hours and on weekends to do work for a few small customers. Jay’s business soon grew and customers asked him to expand into sheetmetal work. From an initial $200 investment and the partnership of Bonnie and Jay, B&J has expanded to 54,000 square feet, 45 employees, and almost $7 million a year in revenues. Today sheet metal comprises approximately 70 percent of B&J’s business. “We manufacture internal metal components for an array of industries including electronics, gaming and security,” Cherie explains.
All in the family Current B&J vice president Gregg Fisher came to the company in 1984 as a welder from the U.S. Navy. At B&J, Gregg met Cherie. A mutual > Express Vol.1/08
15
FABRICATING A B&J Inc. employee welding a part in place.
friend introduced the two, and they began dating. The move was a bold one for Gregg. Not only was Cherie the boss’s daughter, but Jay’s modus operandi was to ensure her boy friends were familiar with his gun collection and his desire to protect his daughter. “He just wanted to make sure Gregg’s motives were in the right place,” Cherie smiles. “We dated for a year and a half and we’ve been married for 17 years now.” The couple has two children: a 16-year old daughter and 13-year old son. Bonnie works nearly every day, handling the company’s bookkeeping. From the beginning, her role at the company was important; although its critical nature was kept secret for many years. Every evening Bonnie read to Jay documents that affected the company. When Jay turned 55, he finally admitted publicly that he didn’t know how to read. “I remember when he told us,” says Gregg. “I thought he was joking. I was shocked, as was the rest of the world.” Cherie adds, “People were shocked at first, but then very supportive. Once he revealed the secret, he could do something about it.” After his admission, Jay hired a tutor and learned to read. He also encouraged employees to broaden their job-related knowledge through educational courses and training. Even though Jay no longer comes in on a day-to-day basis, he still serves as chairman of the board. 16
Express Vol.1/08
FABRICATING B&J Inc. creates complex product designs with the help of its TRUMPF equipment.
“We have the most technologically advanced laser in town. We take complex designs and turn them around in days.” Relationships pay dividends “We partner with our employees and take care of their needs,” explains Gregg. “We have firm guidelines – we want quality people – but we reward them with quality benefits. It’s definitely a partnership.” So far, the strategy has worked. B&J recently won a Nevada Psychologically Healthy Workplace Award, created to show the effect of reduced employee stress on “bottom line” business costs. Also, in a recent survey, B&J employees said they appreciate the company’s improvement of production techniques and investment in new technology. “It helps them see that the company is moving forward,” says Cherie. “And hopefully makes their lives easier too.” Relationships are also a factor in new machinery acquisitions. “I want someone I can partner with, who listens to my concerns, and takes the time to talk to me about fully exploring the machine,” explains Gregg.
A change in partner “The TRUMPF purchase was a huge departure for us,” says Gregg, who acknowledges various machine colors on the shop floor. “In this part of the country, a lot of companies bought your standard turret press. But the further I looked into TRUMPF, the more it made sense to do something different.” In particular, Gregg liked TRUMPF’s unique punching machine features, including 360-rotation of all tools and precision alignment between punch and die. “There are times we don’t sharpen tools for up to two years – all because of the way the machine is built,” explains Gregg. “And when you tell programmers that every tool is indexable, you give them total freedom and flexibility.”
Freedom and flexibility were among the reasons Gregg wanted automation, specifically the ability to run lights-out operations. Before using TRUMPF equipment, B&J “had three machines going 20 hours a day, right through the weekend, and guys working lots of overtime” he explains. “I knew there was a better way.”
A better way “Early in my career I worked at times 15 to 16 hours a day. I would sleep here just to put another sheet on the machine. That wasn’t working well with two kids at home,” says Gregg. “Once I saw TRUMPF, I said to every other company, ‘this is what I want to do. I want to stack finished parts on a pallet.’ No one else came close.” When the company needed a press brake, again Gregg turned to TRUMPF. “Some of our parts for off-road skid plates and gaming equipment don’t have a single straight edge and are almost impossible to gauge by a four-axis system,” explains Gregg. Thanks to a TRUMPF V 130 press brake with six-axis backgauge, the company easily bends parts without perpendicular edges, such as a cloud-shaped part for a piece of gaming equipment.
Flexibility in the schedule In 2005, Gregg purchased a TruLaser 3030 laser cutting machine with automated loading features. “Flexibility to do extremely tough parts is the biggest benefit,” says Gregg. “We have the most technologically advanced laser in town. We take complex designs and turn them around in days.” As a result of automation, employees can run multiple machines at the same time. “Automation keeps us on track so we can afford to > Express Vol.1/08
17
FABRICATING
Jay and Bonnie Thiessens Literacy Foundation As soon as Jay Thiessens overcame his illiteracy, he became a major advocate for the cause. Recently, Jay and his wife, Bonnie, started the “Jay and Bonnie Thiessens Literacy Foundation,” which provides the tools and support for people struggling with illiteracy in Western Nevada. In addition to being a voice on literacy issues in his community, Jay has gone national with his message serving as the keynote speaker at numerous conferences and events throughout the United States where he speaks openly about his struggles with illiteracy and how he overcame them. In 2000, B & J Machinery won the prestigious “BlueChip Award” in recognition of the hurdles faced and overcome during Jay’s battle with illiteracy. The award is sponsored by MassMutual, and recognizes successful businesses that have overcome major obstacles. Instead of hiding his former disability, Jay uses his personal experience to help others fighting the illiteracy battle – hoping his success will give them the confidence they need to succeed.
The “red castle” otherwise known as B&J Inc.
“Our processes and people are a huge part of our success. If you strive for the best, everything else fall in line.” break in and not run behind schedule,” Gregg adds. “It gives operators the flexibility to handle whatever comes their way during the day.” B&J has become a local technology pioneer – something its competition admits. Gregg explains, “We’re doing business with former competitors. Now we call them partners. We’re going to turn around parts this weekend that would have monopolized one customer’s laser for two weeks.”
A progressive approach Cherie concurs, “We’re definitely known in town for being progressive.” In fact, the company’s latest purchase, a TruPunch 1000, materialized as B&J was exploring a progressive cellular approach to manufacturing smaller lot sizes. As is common for job shops, about 18
Express Vol.1/08
80 percent of B&J’s work is comprised of jobs for between 100 and 2,500 parts. “We rotated the new machine into a lean concept,” explains Gregg. “We tied the punch with a press brake, hardware machine, and packaging materials, so we can set up and turn parts in hours instead of weeks. The die loading on TRUMPF punching machines is so quick. We average part to part turnover times of less than 6 minutes.” Processing times are taken seriously at B&J. Any job that doesn’t make margin is tagged for future improvement. “Our processes and people are a huge part of our success,” explains Gregg. “When you look at our building, you know it’s someplace different. We don’t want to be the biggest; we want to be the best. If you strive for the best, everything else falls in line.”
> B&J Inc. Company Name: B&J Inc. Founded: 1972 Staff: 45 Sales: $7 million Product Line: Manufacturer of precision sheet metal and machined products for use worldwide. TRUMPF Machinery: TruLaser 3030, TruPunch 1000, TruMatic 500-1600, TrumaBend V 130 Contact: www.bjmachine.com
SpecialTruLaser
Photo: corbis
The 24 hours of TRUMPF
Greater efficiency and quicker to the finish line – TruLaser Series 5000
2 SpecialTruLaser
24 hours without a pit stop
The new TruLaser Series 5000 leaves the competition in the dust
It runs and runs and runs. Using the approved strategy of Le Mans, the new TruLaser Series 5000 would win a 24-hour race by making the fewest number of pit stops and thus shaving its running times. The modern flatbed laser cutting machine simply adapts to the differing “road conditions” – in this case, sheet metal types and gauges. Even working at night presents no problems. The single cutting head strategy, the automatic nozzle exchanger, the intelligent cutting head interface and the integrated collision protection all ensure – in combination with extensive automation – that the new TruLaser Series 5000 can get along with just a single set-up cycle. It can virtually do without “pit stops” during the entire sheet metal processing run, and that means extremely high productivity levels.
Single cutting head strategy
With the single cutting head strategy incorporated in the new TruLaser Series 5000, sheet metal of any thickness can be processed with just one cutting head. The newly engineered beam guide automatically adapts to the material and adjusts the laser beam. “ Automated operation, no production interruptions “ No contamination of the beam guide system “ Continuous processing, considerably less downtime
Automation
From semi-automatic loading to a fully automatic manufacturing cell with warehouse interface – the new TruLaser Series 5000 can be individually equipped with all the desired automation components. “ Well thought out material flow patterns “ Reduced downtime “ Individualized automation options
SpecialTruLaser
Automatic nozzle exchanger The automatic nozzle exchanger replaces the nozzles at the cutting head automatically, quickly and safely. This makes it possible to process a variety of parts and materials, even during unmanned shifts. “ Automated system operation is possible because manual nozzle exchanging is not required “ The operator can program when worn nozzles are to be automatically replaced
Integrated collision protection The integrated collision protection concept enables the cutting head to simply swing away in the event of a collision with the workpiece. “ Reduced downtime “ Cutting head interface and the machine suffer no damage “ Operations can be resumed without any additional adjustment work
Intelligent cutting head interface The deflection mechanism at the intelligent cutting head interface ensures that the operator can return the cutting head exactly to its former position in the event of a collision, with just a single motion. “ Greater safety through continuous monitoring: deflection mechanism with sensor-based cutting head monitoring “ In the case of minor collisions, the cutting head will move automatically to the original position “ Supply tubing and cables can be ideally integrated into the interface
SpecialTruLaser
The long-distance runner among Flatbed Laser Machines The new TruLaser Series 5000 kicks out more pieces in less time, because it hardly ever takes a break.
24
Toothed drive Stainless steel, 0.4 inches thick Processed in 58 seconds
Face plate Aluminum, 0.08 inches thick Processed in 28 seconds
Carrier plate Mild steel, 1 inch thick Processed in 1:26 minutes
Bracket Stainless steel, 0.8 inches thick Processed in 1:50 minutes
Star Mild steel, 0.3 inches thick Processed in 1:52 minutes
Connector Stainless steel, 0.25 inches thick Processed in 1:04 minutes
Would you like to run production with a minimum number of “pit stops”? Do you have questions about the new TruLaser Series 5000? Or about the individual components? Then give us a call. We’d be glad to be of service. You can reach the expert, Jim Rogowski, by phone at 860-255-6033 or by e-mail at james.rogowski@us.trumpf.com.
INSIDE THE PRODUCT
LED technology for TruBend Series 5000 yields increased efficiency and productivity.
LED technology benefits TruBend Series 5000 Optical tool set up and positioning aid increases efficiency.
A typical fabricator wants to distinguish his operation from the competition with a focus on innovation, efficiency and productivity. TRUMPF is dedicated to creating new features that improve existing products, as well as developing new products to meet fabricators’ everchanging needs. One result of TRUMPF’s innovative R&D efforts for existing product enhancement is the optical tool setup and positioning aid for the TruBend Series 5000 press brake. The optical tool setup and positioning aid improves productivity and handling of the TruBend Series 5000, giving the operator the ability to easily set up tools and bend at multiple bending stations. The optical tool setup and positioning aid is the name derived for a large number of LEDs (interval of 1mm), which are integrated in the cover of the upper tool clamp, directly above the scale. While setting up the tool, the LED panel indicates which tool stations have already been fitted, and while the operator is working, the LED panel indicates at which tool station the next bend will be performed. When setting up tools using the optical setup aid, the operator inserts the tools at the location of the LED lights, rather than having
to read the setup sheet and then locate the tools according to the scale on the machine. The optical positioning aid further increases productivity while bending parts by identifying the next bend location, eliminating mistakes and constant reference to the control or setup sheet. With less time needed for tool setup and shorter cycle lengths, improved efficiency and productivity are two benefits from enhancements to the TruBend Series 5000. The TruBend Series 5000 press brakes are flexible precision bending machines with an excellent cost-benefit ratio that are easy to operate. Press force ranges from 55 tons up to 360 tons and bending lengths are available from 47 inches to 173 inches. Additionally, two to six backgauge solutions are available, depending on the complexity and geometry of the parts to be manufactured. > Additional information: Shane Simpson, Phone: 860-255-6039 E-mail: shane.simpson@us.trumpf.com Express Vol.1/08
23
LASER MARKING
Arrow Cryogenics has the capability to laser mark on a variety of materials, including their own business cards.
“Would you like laser marking with that?� Arrow Cryogenics grows by offering laser marking.
24
Express Vol.1/08
LASER MARKING
With the TruMark Station 7000, Arrow Cryogenics has the ability to mark small objects, such as these tweezers.
“Offering laser marking to our current customer base opens doors.” Steve DeMotts started out finishing. And he hasn’t stopped since. At the tender age of 16, Steve got his first job operating a vibratory deburring machine. Little did he know that was the start of a successful career in metals and plastics deburring, deflashing and finishing. Steve steadily rose through the ranks to become the manager of a machine shop deburring department. But he had higher ambitions. He saw a tremendous opportunity in offering innovative materials finishing services. So, in 1983, he struck out on his own to launch Arrow Cryogenics in Blaine, Minnesota. Like many successful companies, “we started in a garage and grew from there,” said Steve, owner and president of the company. Arrow soon became a leader in creative methods of cryogenic deflashing and deburring, one of the most efficient and cost effective processes to remove flash from injection molded parts. The process can also be performed on a wide variety of materials, including rubber, plastic, silicone and light metal die castings. The process uses ultra-cold (-320.44°F) liquid nitrogen during deflashing and deburring processes. Components are lowered to a temperature that allows the material to become brittle. Then, using nonabrasive cryogenic grade media, flash is easily removed without altering the finish on the parts.
Three keys to growth: innovate, innovate, innovate… Arrow Cryogenics is well known for its ability to innovate new finishing processes. “A lot of the processes that we develop are unique,” said Steve. “We can produce a finished part that other people have a hard time accomplishing.” Another example is thermal deburring which removes burrs with a 6,000 degree Fahrenheit flash of heat. “Between the cold (cryogenic), the heat (thermal) and everything in between, we can always find the most cost-efficient and best deburring or finishing process. That keeps our customers really competitive,” he said. “We have very high production capabilities, but also specialize in small lot production and quick turn-around,” said Steve. “Never say no” is a mantra at Arrow. They are always eager to take on unusual jobs with difficult materials and nearly impossible parameters, projects that other finishing shops won’t touch. They are a true one-stop materials finishing shop, offering 22 different processes, including precision deburring, def lashing, t her ma l debu r r i ng, elec t ro-pol ish i ng, medical-grade cleaning, passivation, shot peening, vapor polishing, cryogenic stress relieving and, most recently, laser marking. A visit to the Arrow Cryogenics website (www.arrowcryogenics.com) offers a complete listing of the company’s process capabilities. > Express Vol.1/08
25
LASER MARKING A sample of one of the parts that Arrow Cryogenics has the ability to mark.
“We can produce a finished part that other people have a hard time accomplishing.”
Customers demand laser marking. Arrow delivers. Many of Arrow’s most popular processes come about as a result of customer demand. Laser marking is the latest example. “There were some customers who were unhappy with their current suppliers and asked us if we’d entertain the idea of getting into laser marking,” said Steve. Just as with all his other processes, Steve did his homework. Once again, versatility was high on the list of requirements. “We did extensive research on what types of lasers we wanted,” he said. “After checking on many different brands, we decided on TRUMPF lasers because of their reliability. And, with so many different types of TRUMPF lasers available, we could process nearly any part submitted to us.” Arrow currently has four TRUMPF (marking) lasers. Arrow’s most recent purchase was a TruMark Station 7000, TruMark 6130 marking system, and the TruMark 6230 “green” laser marking system that specializes in marking copper, gold and plastic parts. But Steve isn’t stopping there. “We want to have a variety of TRUMPF laser marking machines; our goal is to get at least six,” said Steve. This leaves several machines configured 26
Express Vol.1/08
for high production runs that can stay set up, eliminating costs associated with continual setup and tear down. “And we still have the variety of machines that give us a wide range of capabilities.” This will even include clean room marking and, “down the line we’re going to be getting a laser engraver, so we’re going to be able to mark and engrave everything from aluminum, to steel, to stainless steel, to plastic and rubber, from very small to large parts. Laser marking is a value-added service for Arrow’s highly diverse roster of customers in aerospace, automotive, computer, electronics, food service, high technology, hydraulics, military, OEM manufacturers, water purification, pharmaceutical and medical and dental. “What we’re trying to do with laser marking is get people to switch from other means of marking. Offering laser marking to our current customer base opens doors.” Although all of Arrow’s customers are laser marking prospects, medical and dental – two fields that demand a high degree of microscopic precision – comprise a large portion of Arrow’s marking jobs. One such precision marking assignment specified a complex series of five marks on a 1/8 inch diameter rod. Consistent accuracy was of the utmost importance. After the customer received the marked parts from
Arrow and reviewed the measurements, they reported the smallest margin of error they have ever seen, well below their acceptable limit. “Our customers are very demanding on dimensions and the TRUMPF (marking) lasers hold the dimensions very well,” said Steve.
Lasers starting to blot out ink Marking lasers are used in many different applications – metals, plastics, ceramics, organic materials, etc. – and mark almost anything. W h e n c o m p a r e d t o i n k- b a s e d technologies, laser marking provides several key advantages: unlike inks, it’s permanent; marking is fast (milliseconds per character) with no drying process; it’s programmable and flexible; it’s environmentally clean with no inks or solvents to dispose; it reduces supply inventory with no inks, pads, stamps, solvents, etc.; and it can be microscopically precise. Today, 90 percent of laser marking applications are non-aesthetic – bar codes, expiration dates, identification numbers, indexing marks for downstream production, and specifications (particularly for parts having high liability in the case of failure). The remaining 10 percent are aesthetic applications such as company logos, product differentiation, and anti-counterfeiting.
LASER MARKING An Arrow Cryogenics employee laser marking parts on the TRUMPF TruMark Station 7000.
Even produce distributors are getting into the act by utilizing laser marking to brand organic materials like apples and eggs with their logos.
Keeping customers on board by keeping them competitive Laser marking is one more way Steve’s company helps its customers maintain their competitive edge. “We help protect our customers’ business so it doesn’t end up going overseas or to a domestic competitor,” he said. “It (keeping customers competitive) is huge. We help them because we offer so many methods of deburring and finishing.” And who is Arrow’s biggest competitor? “Ourselves,” said Steve emphatically. “We are primarily a job shop so we have to make sure we can process a part better and more economically than our customers can do it themselves.” Steve’s key competitive advantage is his work force. “Our biggest asset here is our people. We have 70 employees,” he said. And, experience counts, too. “25 of our people have been here longer than 15 years.” Steve DeMotts has come a long way from a business that was started in his garage twenty five years ago. While Steve continues to carefully manage Arrow’s growth in order to maintain high quality, Arrow Cryogenics now has room to grow with 80,000 square feet of space, and additional room for expansion.
> Arrow Cryogenics Company Name: Arrow Cryogenics Founded: 1983 Staff: 70 Product Line: A leader in creative methods of cryogenic deflashing and deburring. TRUMPF Machinery: Two VMc 3 with VWS 800 VMc 4 dual head with VWS 800 TruMark 6130 with TruMark Station 7000 Contact: www.arrowcryogenics.com
Express Vol.1/08
27
CUSTOMER FOCUS
When Iceland’s Thorir Olafsson plays for the NettlestedtLubbecke team, fans’ enthusiasm also includes accolades for the sponsor.
New paths to familiar goals What do handball, taekwondo and art have to do with corporate success ? Quite a bit, in the opinion of Mario Heinzig. His successes prove him right.
“We have been at work here for 55 years now. And in spite of that, hardly anybody in Rahden had ever heard of the Heinzig Company.” Mario Heinzig was astonished and dismayed at this when, two years ago, he took over management of the Heinzig Metalltechnik GmbH, a company his grandfather had founded. He acted accordingly, and today, Heinzig earmarks about half his marketing budget for sponsorships. “That boosted our 28
Express Vol.1/08
familiarity tremendously in the past two years. It is reflected, for instance, in the number of job applications we receive. Word has gotten around that at Heinzig you can find a good job or apprenticeship position, and particularly among our younger staff, identification with the company is growing. That’s an invaluable effect.” To boost awareness of his company, Mario Heinzig decided to pursue two of his passions:
CUSTOMER FOCUS The sculpture crafted by Thomas Schutte was a contribution to the “sculpture projects muenster 2007”.
athletics and the arts. Today, his company supports a number of regional athletic clubs and events. Heinzig Metalltechnik GmbH sponsors both the Espelkamp-Mittwald Tennis Club and the premier-league handball team fielded by the TuS Nettelstedt-Lübbecke Sports Association. The local reference in his sponsoring activities is particularly important to Mario Heinzig. “We earn most of our money right here in the region and our employees live near Rahden. That’s why we want our money to advance the region’s interests”, is how Heinzig explained his sponsoring philosophy.
A passion for sports Heinzig has a special attachment to the third sports club his company supports. In the “normal workday world” Heinz Scheidereiter operates a combination machine at Heinzig. But in his free time, he is a grand master in taekwondo and wears the eighth-degree dan. For more than 25 years now, he has done volunteer work as a trainer for young athletes in this martial art and combat sport — with noteworthy success. In just the past two years, the Rahden team has captured a number of European and world championship titles. “When Heinz Scheidereiter asked me if I would be interested in sponsoring his club, there was no question about my answer”, Mario Heinzig recalls. The combination machine that Scheidereiter operates was used to fabricate the sheet metal needed by artist Thomas Schütte for his contribution to the “sculpture projects muenster 07”. Not only did Heinzig Metalltechnik GmbH donate the 2.5 tons of steel that went into the sculpture entitled “Model for a Museum”, but it invested more than two weeks of labor as well. That’s a considerable sacrifice for a company whose order books are overflowing. But then again, art is another of Mario Heinzig’s passions. “I have always been interested in art. What’s more, I studied economic engineering in Berlin, and there you are virtually overwhelmed by art.” It was during this period that Heinzig not only met many artists, but also began to assemble his own collection. That accumulation is still modest in scope. “I’m now 32 and I’m hoping to expand the collection over time.” But
Mario Heinzig contributed 2.5 tons of steel for this purpose – and invested two weeks of work time erecting the structure.
> Involvement for the company and the region
even today it includes works by photographers Thomas Struth and Matthias Hoch, video artist Heike Baranowsky and sculptor Roman Signer. At present, Heinzig is also planning to get the company involved in amassing a collection. “In one or two years, I would like to set up a foundation in honor of my grandparents. The foundation would manage the collection and create a forum for artists here in Rahden.” His declared goal: the foundation is to form a bridge between industry and art — in part by awarding annual scholarships in photography to young artists.
Company name: Heinzig Metalltechnik GmbH, Rahden, Germany Founded: 1952 Staff: 90 Sales: $12 million Product line: Engineering and fabricating assemblies made of metal and sheet metal. Jobshop manufacturing: sheet metal processing, tube processing, connector technology, chipping technologies, surface finishes. Tool and equipment construction. TRUMPF machinery: TRUMATIC 600, TruLaser 5030, TruBend 5085, TrumaBend V 1700 (TruBend 5170) Internet: www.heinzig.com Express Vol.1/08
29
DISCUSSION
Laser Technology 101 Q&A
with Jochen Deile, manager of new laser products, TRUMPF Inc.
30
Express Vol.1/08
DISCUSSION Laser technology has seen incredible advances over the last several years and research and development continues to play a vital role.
One of the key people in TRUMPF’s laser technology department is Jochen Deile, manager of new laser products. Jochen is responsible for the research and development of lasers at TRUMPF. Here we discuss with Jochen the path laser technology has taken over the years, how TRUMPF has made its mark on the industry, and what we can expect for the future. How did TRUMPF get its start in the laser technology field? In 1979, TRUMPF introduced the first laser machine to the market, a combination punchlaser machine called the TRUMATIC 180 Laserpress. Purchased from a U.S. company, the laser power was only 750 W, and the resonator was as big as today’s entire laser machine. Unfortunately, it was also very unreliable and required Ph.D.s to operate it. In the early 1980s, TRUMPF decided to build its own laser and introduced a 1000 watt version in 1985. Two years later, the first flat bed laser cutting machine was introduced. Today, TRUMPF is the largest manufacturer of industrial lasers and has not only CO2 lasers, but also disk lasers, fiber lasers and Nd:YAG lasers, in a wide range of laser powers.
Jochen displays a typical “mode burn” generated from a laser beam.
Can you explain the importance of the new Connecticut laser factory to the North American manufacturer, as well as to TRUMPF? What statement does the building make about laser technology in the 21st century? The performance, cost and quality of a modern laser cutting machine is determined by its laser resonator. TRUMPF has been setting standards in laser technology over the last 20 years, by developing and producing laser resonators for our latest machines at TRUMPF’s North American headquarters in Connecticut. In order to benefit from the close connection between R&D and the needs of the North American customer, vertical integration in Connecticut provides a level of knowledge, > Express Vol.1/08
31
DISCUSSION
An interior look at the TruCoax 2000.
“TRUMPF has been setting standards in laser technology over the last 20 years.” process and service expertise that overseas manufacturers cannot provide. The consolidation of all TRUMPF’s laser functions into the new building gives us the room necessary for expansion in the growing market, and also shows the commitment TRUMPF has towards the North American customer. How has laser technology changed from its inception to present day? It couldn’t have changed any more dramatically. After the first lasers were built in research labs people were impressed with the physics, but nobody could envision an application for them. Today, lasers have penetrated every aspect of our lives: medical applications, telecommunications, entertainment and of course, material processing has been transformed completely by lasers. 32
Express Vol.1/08
What are the biggest challenges related to the laser technology market? How is TRUMPF overcoming these challenges? We have different challenges in different areas. Laser cutting is a mature market and it becomes more and more difficult to grow in this market segment. In other areas, there is laser technology already available, but the markets have not developed yet, and it is TRUMPF’s goal to educate our customers and show them what is possible with laser technology. What do you see as the future for lasers and laser applications in terms of cutting/welding? Are there any recent products introduced by TRUMPF that exemplify their future? On the welding side, TRUMPF sees its disk laser technology as the future. With new diode laser technology developed in our location in Cranbury, New Jersey and used as the pump
source for disk lasers, TRUMPF will see advances in output power and cost per watt for the thin disk lasers. Diode direct laser technology will also become an alternative to current lamp pumped Nd:YAG lasers where beam quality is uncritical. On the cutting side, TRUMPF will continue to introduce CO2 lasers with more output power to increase the performance and capacity of its 2D machines. On the 3D laser processing side, TRUMPF introduced the TruLaser Cell 7040. This machine makes it possible for 3D laser processing to enter into a similarly mainstream high productivity market as the established 2D cutting market. High speed, high accuracy 3D material processing (cutting and welding) with one machine will enable many job shops to move ahead of the competition again – this time by moving from 2D to 3D operations.
DISCUSSION Are there any new or developing markets where you feel laser technology will gain momentum? How is TRUMPF adapting to changing market demands? The newest laser technology that is required by the market, but that will also create new markets, is the short pulse laser technology with pulse lengths of a few pico seconds. The pulse lengths interact in a different way with the work piece and allow for new processes and applications. The laser pulses are so short that there is basically no time for the work piece to heat up, and the material is removed through an ablation process, rather than through melting of the material. One interesting application for these lasers is the structuring of solar cells. TRUMPF has developed a completely new family of pulsed lasers to meet the demands of these new applications. What is the importance of the TruCoax 3200? Why was the resonator developed and what will it bring to TRUMPF’s product line? The TruCoax 3200 was developed to boost the performance of our TruLaser 2030. It has even better performance in thin sheet metal, but more importantly, the increased output power expands the thickness range the machine can cut. This expansion of capabilities and performance makes the machine very attractive for a wide range of customers. How do you view the future in terms of solid state and CO2 lasers? TRUMPF will continue to set the standards in CO2 lasers. The new TruCoax 3200, for instance, will continue to expand the success of our TruLaser series with integrated automation. TRUMPF will also see higher and higher output power levels from our TruFlow lasers, and thin disk lasers will see great advances in output power and cost per watt. Together with diode direct and fiber laser technologies, solid state lasers will be used only for special applications where they offer advantages. What is TRUMPF’s process for researching and developing new laser technologies? New lasers and laser technologies are our future and we have several development locations around the world focusing on different technologies. This also enables us to understand the requirements of the local markets better and utilize the knowledge that is available in these markets and countries. But most importantly, we make sure we have the best and most innovative researchers and development engineers on our teams and ensure that they have the equipment and support they need to improve our existing products and develop new ones.
Ronald Larose, a member of TRUMPF’s engineering department, and Jochen Deile comparing mode burns to determine laser power.
“Today, lasers have penetrated every aspect of our lives.”
Jochen demonstrates how easy it is to change a diode module on a disk laser. Express Vol.1/08
33
PUNCHING
34
Express Vol.1/08
PUNCHING
Bringing Home the Bacon. Foodservice equipment company rides food industry wave with innovative thinking and North American loyalty.
Owner of Cadco Ltd., Mike Shanahan, poses with a part punched on a TruPunch 1000.
When you dine at a restaurant or purchase a piece of cookware, you rarely think about the equipment designed and manufactured to prepare the steak you are about to enjoy. And while you wouldn’t think the griddle you just purchased to make blueberry pancakes came from a small company in rural New England, you couldn’t be more wrong. While most foodservice equipment used today is manufactured abroad, Cadco, Ltd., a leading provider of high-performance and durable foodservice equipment, and their subsidiary BroilKing, a manufacturer of high-quality and durable countertop kitchen appliances for consumers, has really been cooking from their home base in Winsted, Connecticut since 1996. Specializing in commercial kitchen appliances with an emphasis on countertop convection and combination ovens, the company sells to over 700 high-end companies. Cadco’s products are available through a select group of foodservice dealers in the United States and Canada, but what makes the company really stand out is that they design and manufacture many of their products in the United States. Yet, the Cadco, Ltd. story is not as simple as it seems. While the presence of overseas manufacturing has become more prevalent in recent years, Cadco, Ltd. and its in-house subsidiary BroilKing, have made a major capital investment in their Connecticut operation. In order to stay competitive > Express Vol.1/08
35
PUNCHING
A convection oven component, punched with the TruPunch 1000. Sam Grano de Oro, director of manufacturing, holds a completed convection oven component.
in the foodservice and high-end retail industries, the company continuously strives to think outside the box, expand into new market niches, mainstream processes, and implement the best manufacturing equipment to meet changing business objectives. The company has taken chances, something many small companies simply looking to stay afloat would not have done. The Cadco, Ltd. story began in May of 1996. At this time, Cadco, Ltd. was a small “mom-and-pop” type company, and they wanted to keep their business focused on distribution. Initially, the company was not interested in U.S. based manufacturing. According to president, Mike Shanahan, “Cadco, Ltd. started off with fi nished products from Europe. We owned the marketing rights to the products, and our focus was on bringing niche marketing to the foodservice arena, but strictly on the equipment distribution side.” While holding tight to the goal of finding niches in the foodservice market not already being satisfied, and trying to steer clear of turning into a commodity business, Cadco Ltd. knew that if they wanted to stay competitive in the ever-changing foodservice distribution market and compete with companies several times their size, their best bet was to diversify.
Taking a chance with new market ventures and untapped creativity BroilKing approached Cadco, Ltd. in 1998. The owner of the company was in failing health, and was interested in teaming up with Cadco, 36
Express Vol.1/08
PUNCHING
A finished Cadco warming/holding tower.
Ltd. on a joint business venture that would allow the BroilKing name to live on under the already-established Cadco, Ltd. umbrella. The only apparent hitch was that BroilKing was known for manufacturing its products in the United States. As a strictly consumer retail foodservice business, BroilKing provided quality and durable countertop kitchen appliances for consumers, and the business model was quite different from Cadco, Ltd.’s original business objectives. Yet, Mike Shanahan decided to give the business venture a go, as he knew U.S. based products appealed to a large cross-section of the industry. Cadco, Ltd. had already been marketing a few of BroilKing’s products under its name and eventually bought the company in February of 1999. With the purchase of BroilKing, Cadco, Ltd. had officially branched into two companies, serving two different entities. However, when BroilKing was first purchased by Cadco, Ltd. the company was not the high-end retailer it is today. In fact, Cadco, Ltd, spent considerable time upgrading BroilKing’s existing products and working within their product categories. For example, Cadco, Ltd. enhanced BroilKing’s portable ranges with better parts, wiring, and product signage and introduced new products such as a restyled griddle and a series of warming trays for the retail foodservice market. Reactions were positive, with BroilKing earning a top ranking for their portable griddle in the January 2007 online consumer review for the Wall Street Journal. The decision to reshape the BroilKing line of products not only allowed the company to diversify and expand its product offerings, >
“Once I saw the capabilities of the TruPunch 1000, I knew that TRUMPF’s equipment would give me the finished product I was looking for.”
Express Vol.1/08
37
PUNCHING but also afforded Cadco, Ltd. and BroilKing the opportunity to move into a higher-class of consumer retail foodservice equipment.
Lean manufacturing and a new machine by way of Italy On the Cadco, Ltd. side of the business, the company had been working with UNOX, an Italian company that provided countertop convection and combination ovens. In 2006, UNOX converted into a TRUMPFonly shop. In July 2006, Mike Shanahan had the opportunity to visit Italy where he was introduced to TRUMPF. UNOX demonstrated why they decided to make the change with their equipment. Mike was immediately impressed and saw the potential that TRUMPF equipment could have on his own business. As BroilKing was on the manufacturing side of the business, Mike knew he needed a machine that was going to be able to keep up with consumer retail demands, as well as producing a high-quality, finished piece. One of BroilKing’s products, the backplate of the griddle machine known as the “backsplash” was a product being subcontracted out. Mike sought to revamp its production process and realized a solution by bringing its manufacturing in-house. “A lot of the products that we make on the BroilKing side of the business need to have smooth edges and look aesthetically pleasing to the consumer,” said Mike. “Once I saw the capabilities of the TruPunch 1000, in combination with the deburring roller tool, I knew that TRUMPF’s equipment would give me the finished product I was looking for.” In addition to the purchase of TRUMPF equipment, Cadco
began to implement lean manufacturing concepts into its facility in 2002. During his trip to Italy, Mike saw how UNOX, with assistance from TRUMPF, integrated lean manufacturing techniques. Through the concept of lean manufacturing, Mike and his management team learned that putting equipment in the best possible position on the shop floor creates a better process flow. By making this change, they were now able to remove old equipment that was no longer of value in this revised production process. By deciding to spend the money to make necessary process changes and equipment upgrades, Cadco, Ltd. and BroilKing quickly began to experience the productivity benefits and return on investment from their new process flow. In addition, Mike hired a lean manufacturing consultancy, Productivity Inc. of Shelton, Connecticut, that visits the company on a quarterly basis to assess process flow, as well as make recommendations to improve product production. They also provided on-site training seminars to his employees so they could see how the (lean manufacturing) process could lower costs and improve their operation and products. Both Cadco, Ltd. and BroilKing now experience a reduction in production time and cost, and see the benefits of assembling parts in-house; a side of the business he was wary of entering back in 1998. According to Mike, “While this new machine costs hundreds of thousands of dollars, it has a payback period of less than four years. It will allow us to eliminate six existing older machines, and simplify the process of preparing our metals for final assembly.” Furthermore, Cadco is now able to better control the quantity and quality of his inventory.
“A lot of the products that we make on the BroilKing side of the business need to have smooth edges and look aesthically pleasing to the consumer.”
One of Broilking’s triple buffet servers.
38
Express Vol.1/08
PUNCHING
“It will allow us to eliminate six existing older machines, and simplify the process of preparing our metals for final assembly.” A Cadco employees works with a part in the assembly-line process.
“We used to outsource our parts for production,” said Sam gran de Oro, director of manufacturing, “but we are now capable of better control over part inventory and quality.” In 2000, Cadco, Ltd. took another monumental step and relocated to a larger, more modern facility in Winsted, Connecticut, in order to better serve its customers; a testament to Cadco’s partners decision to move BroilKing’s manufacturing processes in-house and to keep up with the demand for the company’s U.S. based products.
Introducing the future of the foodservice industry As a result of the quality, flexibility and increase in production achieved by TRUMPF’s TruPunch 1000, Cadco, Ltd. and BroilKing are eager to expand their product line. Always keeping their customers’ desires in mind, the company will be delving into a new market niche in the spring of 2008, by unveiling a series of warming carts. In addition, the company recently designed and manufactured a warming cabinet/buffet server for Chef ’s Catalog magazine, a publication which offers high-end quality cookware, dinnerware and kitchen supplies for the chef and home cook. Cadco, Ltd. now has the ability to effectively design and manufacture holding towers for ovens, a project that was once not possible, but is now a reality, due to the company’s choice of machinery. While still small in nature compared to some of their competition, Cadco, Ltd. and BroilKing are holding their own in the foodservice and retail markets, and remain firm in staying a U.S. based manufacturing company for the industry. Mike Shanahan took a chance by breaking
out of Cadco, Ltd.’s mold by diversifying his product range and inviting manufacturing into his business. Through continued change, re-growth and mainstreamed processes, Cadco, Ltd. and BroilKing continue to ride the food industry and high-end retail wave. The company recently purchased a TruBend 3066, so that their bending processes can become as efficient as their punching processes, and their flow can be improved even more. Perhaps the next time your food is prepared, it will be made on a Cadco or BroilKing product, produced on TRUMPF machinery.
> Cadco, Ltd. / BroilKing Company name: Cadco, Ltd. / BroilKing Founded: 1996 Staff: 25 Product line: Specialize in commercial kitchen appliances with an emphasis on countertop convection and combination ovens, as well as high-end consumer kitchen appliances. TRUMPF machinery: TruPunch 1000, TruBend 3066 Internet: www.cadco-ltd.com or www.broilking.com Express Vol.1/08
39
PERSONALITIES
CREDITS Owner of Bartlett Brainard Eacott Inc., Mr. James Eacott III in front of the LITE Building.
TRUMPF Express Volume 1, 2008 Magazine for Sheet Metal Processing Published by TRUMPF Inc. Farmington, CT 06032 www.us.trumpf.com Responsible for the content Sheila LaMothe Editor-in-Chief Chrissy Timreck 860-255-6112 chrissy.timreck@us.trumpf.com
The “LITE” at the End of the Tunnel: Building Completion Comes to a Close With the completion of TRUMPF’s Laser Innovation & Technical Excellence (LITE) Building in sight, we asked James Eacott III, owner of Bartlett Brainard Eacott, the company contracted in the production of the LITE Building, to reflect on the last eighteen months, from building concept to finished product. Has BBE encountered any major challenges on the project thus far? W h i le not ne c e s s a r i l y a “c h a l le nge ,” the highly technical components of the building’s infrastructure have required a high degree of coordination and collaboration with a large number of construction team members. T he need for tea mwork a nd effective communication in order to manage modifications has been essential to the project’s success. What non-construction challenges have you faced in the production of the LITE Building? The soil conditions in the area are not ideal for excavation and concrete work, and if we have a bad day weather-wise, the soil becomes difficult to work with. On occasion, we have had to alter our strategy to incorporate weat her a nd ground conditions, whi le balancing the work plan in order to meet our deadlines. 40
Express Vol.1/08
“Going green” is a big topic nowadays. Does the LITE Building incorporate any “green” elements?” T RU M PF h a s m ade a s ig n i f ic a nt investment in mechanical and electrical systems for the new building, making sure all systems are energy-efficient. Day-lighting is a feature of the building, the window glass is energy-efficient, and all large motors have drives that have helped to decrease energy expenditures. In addition, the building is prepared to accept geo-thermal solutions in the future, and photovoltaics has also been researched. Are there any unusual facts that the public might want to know about the LITE Building? The number of windows used in the design and construction of the building has really pushed the envelope – the windows are larger than the normal construction project and were all custom-made to fit within the building’s design plans.
> For more information on the LITE Building please contact: Steffen Wilhelm, Phone: 860-255-6626 E-mail: steffen.wilhelm@us.trumpf.com
Editorial Staff Mike Gordon Susan Grohs Sheila LaMothe Karen Miller Design and production John Mik, MIK Advertising Printing and assembly Paladin Commercial Printers, LLC Contributors Catherine Flynn Robert Devol pr + co. gmbh, Stuttgart Photographs Steve Adams Photography Bowers Imagineering Cambridge Engineering Ceilings Plus Otis Elevator Company Sara Rubinstein Photography Sheldon Manufacturing Tresco Consoles TRUMPF Archive West Coast Choppers – Shannon Brooke
Lights, Camera, Action Talented fi lmmakers with the skills to create a cinematographic masterpiece often lack the equipment necessary to capture the magic of the movies. For Redrock Microsystems LLC, a need came into focus: provide low-budget fi lmmakers with affordable digital equipment capable of the high-end results supplied by traditional fi lm.
All they needed was a cast of fabricators capable of the production task. Regal Research, a longtime TRUMPF user, answered the call with a performance worthy of the spotlight. With each cut of the camera, Regal Research and Redrock Microsystems offer independent fi lmmakers an award-inspiring performance.