October Industry Watch: Business
Recent activities and events in the business of metalworking and fabricating.
Posted: September 30, 2009
(BLACK RIVER FALLS, WI) . . .
expanded their cutting capabilities by installing a new Messer MG Titan II cutting system. Michael Dougherty, president of D&S, announced, "This sizeable investment in new equipment enables us to expand the range of projects we are able to accommodate internally, resulting in a more efficient and economical approach to the manufacturing process."
Quality manager Joe Lane explained that the new unit, which replaces the company?s existing
ESAB Avenger and Sector Technologies Model ST1200 equipment, was researched and selected by a team of employees. "The Titan II unites oxyfuel and high definition plasma technologies within one integrated system by placing them on a common rail. This enables us to increase machine duty cycle and versatility while reducing the time and expense associated with operator training. This system also accommodates raw material as lengthy as 85 ft, a significant increase over our existing capabilities and a major differentiator in our industry," he revealed.
The speed and quality of the oxyfuel cutting process is enhanced through the integration of automatic height sensing technologies. This proprietary feature eliminates the need for manual adjustments to compensate for material shifts caused by heat or natural distortion of the steel. As a result, the 4-torch system will consistently deliver uniform cuts throughout the entire production run for parts as thick as 6 in. Rapid cutting speeds for components as slim as ¼ in will be achieved by employing the single torch of the high definition plasma process. Automated programming, utilizing the company?s existing MRP software, results in seamless nesting.
According to Lane, the Titan II uses downdraft tables that draw air from the bottom of the cut to significantly improve air quality by removing particulates and dust from the cutting process. It also eliminates wastewater, reducing the time and expense associated with weekly maintenance.
D&S, which is certified ISO 9001:2008, has served as a custom manufacturer of large scale components, assemblies and complete weldments for Caterpillar, Oshkosh Corporation, Parkson, The Trane Company, CNH and other corporations for more than 40 years. This installation coincides with the completion of the company?s extensive building expansion program that re-engineered the floor plan for the entire production facility, including machining, laser, high definition plasma and oxy-fuel cutting, manual and robotic welding, liquid spray painting and shot blasting to assembly and testing. The resulting reduction in raw material handling will dramatically improve work flow, yielding significant cost savings. www.dsmfg.com
LSA LASER (PLYMOUTH, MN) . . .
moved into a new 26,000 sq ft manufacturing and office facility in Plymouth which more than doubles the size of the previous operations of this precision laser processor of components and assemblies for the medical device industry. This manufacturer performs laser cutting, laser welding, laser ablation and laser marking used in a broad range of medical devices, including defibrillation leads, stents, catheters, surgical instruments, dental instruments, orthopedics, hearing devices, neuro applications and a host of other applications.
Thomas Noll, LSA Laser president, announced the move by stating, "These new facilities are designed to accommodate our rapidly growing work with the medical community. While we have more than doubled our physical plant and offices, more significantly we have expanded our R&D capabilities and laser technology range to include a large scale research and development department. To form partner relationships with customers, we go far beyond the manufacture of components and products. We often team with customer design engineers throughout the product development process. Together, we work through various design iterations utilizing our laser machines and engineers to refine a design and an appropriate manufacturing process."
LSA Laser is certified ISO 13485:2003 and has over 11 years of experience supplying the medical device industry. The company utilizes twenty-two laser welding and cutting systems, with up to six-axis motion control and computer aided manufacturing capabilities, to produce components used in guidewires, pacing leads, surgical instruments, electrical leads and assemblies. Many are made of exotic metals in very small sizes. Some of the materials include platinum, titanium, nitinol and nichrome in sizes down to .001 in, which is smaller in diameter than a human hair. www.lsalaser.com
JET EDGE, INC. (ST. MICHAEL, MN) . . .
introduces its new waterjet parts website, https://waterjetparts.jetedge.com, a user-friendly, secure source for ordering consumable and replacement water jet parts. This designer and manufacturer of waterjet systems for precision cutting, surface preparation and coating removal carries a wide variety of competitively priced parts, including waterjet cutting heads, abrasivejet cutting heads, dual pressure valves, high pressure tubing and high pressure fittings. Custom waterjet swivels, lines and coils are also available.
The company is offering all new online accounts 25 percent off on their first online order made through December 31, 2009 (this offer applies to all parts, except for nozzles and hp hoses). Established in 1984, Jet Edge systems are used around the world in a broad range of industries, from the world's leading airlines to automotive, aerospace, industrial manufacturers, machine and job shops.
In addition to waterjet parts and accessories, Jet Edge also manufactures precision waterjet cutting machines, waterjet pumps, portable waterjet cutters, and ultra-high pressure water blasting tools for cleaning and surface preparation. www.jetedge.com
GF AGIECHARMILLES (LINCOLNSHIRE, IL) . . .
announced a reorganization of its Swiss facilities to adapt to the ongoing worldwide economic crisis. The move will include realigning resources to boost efficiency, accompanied by some layoffs to reduce current excess capacity. In addition to these changes, the company is working to ensure maximum profitability through continued investment in research and development and customer service.
Production of EDMs that previously took place in Geneva, Switzerland, will now be integrated into the company?s manufacturing facilities in Losone. The Losone campus will also house some aspects of research and development, along with the sales organization serving Switzerland and several other European nations.
The campus in Geneva continues to be responsible for the majority of GF AgieCharmilles? research and development efforts, as well as housing the company?s international headquarters. International marketing, customer service and worldwide spare parts will also be located in Geneva. The company, a leading North American supplier of wire EDM, CNC and manual diesinking systems, and high speed/performance and 5-axis CNC milling machines, currently employs approximately 1,000 individuals through its Swiss operations.
"The current economic hardship has presented an enormous challenge to manufacturers around the world," says Glynn Fletcher, president of GF AgieCharmilles in North America. "Some layoffs will accompany the realignment of our production resources, but our primary goal is to increase efficiency so that we may continue to provide standard setting products and services. Even as we make these changes, we continue to invest in our customer service and support centers and develop new technologies."
The manufacturer just invested in a new state-of-the-Central Art phone system to serve their U.S. and Canadian customers more efficiently, and can now connect or forward calls directly to any of their U.S. locations utilizing VOIP technology. GF AgieCharmilles will be unveiling a variety of new machines and technologies at EMO 2009, including the HSM LP High Speed Machining Center and Cut 1000 Oil Wire EDM, along with the new IQ Generator and a new HEM milling product line. The company will also introduce the Laser 1000 5Ax, a new machine created to provide surface texturing on a wide array of materials.
To maintain its commitment to customer service and support, the company recently invested in its CRM system, along with adopting voice over internet protocol for its call centers. The company has also put additional resources behind its Privilege Club, which provides benefits to customers.
In other news, the company has developed and contributed sample code for programming in Visual Basic to MTConnect. The solution was created internally and made available to the MTConnect Institute to further the standard?s development.
"MTConnect will do a lot to transform modern manufacturing," says Eric Ostini, the GF AgieCharmilles product manager who developed the sample code. "Increasing productivity and efficiency is the key to strengthening the global competitiveness of American manufacturers. Creating a common communication protocol for all manufacturing equipment will redefine the productivity we can achieve." The Visual Basic sample code will be used in GF AgieCharmilles? booth at EMO 2009 in Milan, where attendees can see its application to their operations. www.gfac.com/us
ACS PRECISION LLC (MERCERSBURG, PA) . . .
recently added a certified pre-owned 4 kW Mitsubishi LXP laser system to its equipment capabilities. The LXP is capable of processing material up to 0.75 in thick steel and can accommodate a 4 ft x 8 ft sheet size. The laser adds even more diversity to the existing fabrication processes already in place in an 11,900 sq ft flexible job shop that focuses on the Northeast and Mid-Atlantic metropolitan areas.
ACS president Sandra Tillman-Daniels commented on the decision to add this technology to the equipment lineup. "The laser is a perfect complement to our waterjet and CNC machining equipment," she said. "With a laser in our portfolio of services, we are able to cut thin gages of material in intricate shapes with the speed and accuracy that our customers need. Plus, it allows us to free up our waterjet to focus mainly on the fabrication of heavier sheet and plate aluminum, and other non-ferrous materials."
ACS Precision?s services include sheet metal fabrication, machined weldments, structural components, precision machining and, rubber and plastic and safety guarding products. www.acsprecision.com
AMERICAN WELDING SOCIETY (MIAMI, FL) . . .
recently published a revised edition of the AWS C4.2, Recommended Practices for Safe Oxyfuel Gas Cutting Torch Operation. The standard known, as C4.2/C4.2M:2009, supersedes the 2006 edition.
The 62-page book describes the oxyfuel gas cutting process and latest procedures and safety requirements, using terminology compatible with ISO documents. Illustrations show torch and nozzle configurations, and examples of production-cut surfaces. The standard makes use of both U.S. Customary Units and the International System of Units (SI).
The revised standard is the joint effort of the AWS C4 Committee on Oxyfuel Gas Welding and Cutting, made up of volunteer industry suppliers, end-users, and researchers. AWS C4.2/C4.2M:2009, Recommended Practices for Safe Oxyfuel Gas Cutting Torch Operation is available at 888-WELDING or www.aws.org/standards for $68. American Welding Society members can purchase the standard for just $52. www.aws.org
BISON GEAR & ENGINEERING CORPORATION
(ST. CHARLES, IL) . . .
was recently recognized for its commitment to employee health and well-being and its innovative health and wellness initiatives yielding measurable employee health improvement by receiving the "Healthiest Company in America" award from Interactive Health Solutions (IHS).
"Everyone talks about health care today, but more than a dozen years ago Bison Gear began creating a corporate culture that encourages individuals to take responsibility for their own health and to take an active role in their preventative care," said CEO Martin Swarbrick.
The award is based on clinical evaluations of employee participants across an index that tests for indicators of heart disease, diabetes, smoking and other measures of health status that are in part controllable by an individual. When Bison constructed its headquarters and manufacturing facility in St. Charles in 1997, the gearmotor manufacturer budgeted for a completely equipped employee fitness center. More recently, it has invested in an onsite clinician ready medical resource center. In addition, a cross-functional team of Bison "Health Ambassadors" has been formed to develop and communicate health awareness and improvement programs throughout the company.
Working with IHS, Bison hosts an annual Wellness Fair for employees and their family members that includes free diagnostic testing and counseling. "Years ago, we were fortunate to win the business of an up and coming exercise equipment company," said Ron Bullock, chairman and owner of Bison Gear. "That customer relationship, which still endures, has contributed to the health of our business. More importanly, though, it made us more aware of the benefits of proactive health management and that has been an even greater contribution to every Bison associate."
Founded in 1960, Bison Gear designs and manufactures fractional horsepower electric motors, gearmotors and gear reducers used in industrial and commercial OEM applications worldwide. Bison's integrated production facility in St. Charles manufactures gearmotors and reducers in parallel shaft and right angle configurations, as well as AC and DC electric motors. www.BisonGear.com
(NEWTON, KS) . . .
rolled out their redesigned corporate website, www.buntingmagnetics.com that features improved navigation, better product information and a more streamlined experience for purchasing products online. Throughout the site, video and improved photography will be incorporated onto all the product pages.
"This new website is part of our continued effort to provide our customers with the best service possible," stated Charles Whitt, Bunting® director of marketing. "A part of this commitment is to have a website that gives constant updates on product information while at the same time being easy to use. We feel that this redesign helps accomplish that goal."
The new website allows customers to quickly find their sales representative through the Locate a Rep feature, keeps visitors up-to-date on recent news releases and give industry-specific examples of how Bunting® products are used in different applications. Also, the new Flexible Die Division is more prominently featured on the new site.
Since 1959, privately-owned Bunting® has been serving manufacturers of metal products. The company?s world headquarters and main manufacturing facility in Newton manufactures magnetic separation equipment, and magnetic and non-magnetic conveyors for use in manufacturing and recycling industries. The company also has a manufacturing and distribution facility in Elk Grove Village, IL, that sells a full range of magnets, including magnetic assemblies, cut magnets, flexible magnetic rubber and magnetic tools. www.buntingmagnetics.com
CARL ZEISS IMT (MAPLE GROVE, MN) . . .
opened a new West Coast Tech Center in Irvine, California. "We are dedicated to supporting the high-tech industry on the West Coast by providing customers easy access to our most modern and advanced technology," said Andy Sisler, vice president of sales at Carl Zeiss IMT. "The new technical center will provide more local resources and support for this fast paced market. It?s an exciting time for us because this is a chance to be even closer to our customers, and show our commitment to customer support after the sale."
The new facility is located in an Irvine modern technology park and focuses on application support, contract inspection services, software training, and demonstration of ZEISS equipment. "Providing contract inspection services is an exciting part of what we are building here," states Drew Shemenski, software and applications manager. "With a full suite of metrology systems at this facility, we have the capability to support the inspection needs of everyone from micro-molders, up through traditional CNC job shops, as well as specialists such as gear and turbine manufacturers."
The facility houses the Metrotom 1500, an X-ray based computed tomography system specifically designed for 3D metrology of small, complex low-density parts made of plastic, composite materials or ceramic. It also has the O-Inspect, a multi-sensor system that features both tactile and optical scanning and provide tremendous flexibility for measuring parts that approach the micro range of size. "We have a variety of surface form and geometry systems to really round out our measuring and demonstration capabilities. The team we have in place also brings a depth and variety of experience that really complements the technology. We are looking forward to bringing all these elements to support our customers," states Shemenski. www.zeiss.com/imt
CHINA ISSUES MAJOR ECONOMIC INDICATORS . . .
In August 2009, the total value added to industrial enterprises with an annual sales income of more than RMB 5 million yuan ($732,000) in China rose 12.3 percent year-over-year, or 1.5 percentage points higher than July 2009, reports Industrial Info Resources (Sugar Land, TX). From January to August 2009, the figure showed 8.1 percent growth from the previous year, which is a year-over-year decrease of 7.6 percentage points, according to the Instant Statistic Report of the National Bureau of Statistics of China that was announced September 11.
In August, all 39 industrial classifications showed year-over-year growth:
? textile industry, up 9.8 percent
? manufacture of raw chemical materials and chemical products, up 18.2 percent
? manufacture of non-metallic mineral products, up 17.3 percent
? manufacture of general machinery, up 12.0 percent
? manufacture of transport equipment, up 26.7 percent
? manufacture of electric machinery and equipment, up 13.0 percent
? manufacture of communication equipment, computers and other electronic equipment, up 4.8 percent
? production and supply of electricity, gas and water, up 6.8 percent
? ferrous metal smelting and pressing, up 13.3 percent
In terms of different products, of 494 different products, the output of 364 products showed year-over-year growth:
? output of coal was 260 million tons, up 14.6 percent from the previous year
? output of crude oil was 16.32 million tons, up 1.6 percent
? electricity production was 334.3 billion kilowatt-hours, up 9.3 percent
? pig iron production was 52.33 million tons, up 22.0 percent
? production of cement was 150 million tons, up 24.0 percent
? production of motor vehicles was 1,167 thousand, up 90.0 percent, of which, the output of cars was 657,000, up 96.2 percent.
From January to August 2009, China's fixed-asset urban investments was $1.65 trillion, up 33 percent year over year, or 5.6 percentage points higher than the same period last year. In August 2009, total retail sales of consumer goods reached $147.68 billion, an increase of 15.4 percent year over year and 7.8 percentage points lower than the increase of August 2008. From January to August 2009, the total retail sales of consumer goods were $1.15 trillion, a year-on-year growth of 15.1 percent, but down by 6.8 percentage points growth in the same period of last year.
In August 2009, the consumer price index went down 1.2 percent year over year. In August 2009, the price dropped 1.3 percent in cities and 1.0 percent in rural areas from last year. The price of food increased 0.5 percent, while non-food prices dropped 2.0 percent. In August 2009, the producers' price index (PPI) for manufactured goods went down 7.9 percent year over year. PPI growth in August 2008 was 10.1 percent. In the first eight months of this year, the year-on-year change of the producers' price for manufactured goods was down 6.4 percent. In the same period last year the price of manufactured goods was up 8.2 percent from the same period of 2007.
According to the announcement made by the General Customs Administration of China, in August 2009, the import and export value in China reached $191.7 billion, a drop of 20.6 percent year over year. Of this, the export value reached $103.7 billion, a drop of 23.4 percent year over year, and the the import value reached $88 billion, a drop of 17 percent year over year. China's trade surplus was $15.71 billion.
JOHN DEERE & COMPANY (MOLINE, IL) . . .
The Deere & Company Board of Directors approved an investment plan to establish a manufacturing and parts center in Russia. The project will be located near Moscow, in close proximity to the Domodevedo International Airport. The new site will have the capability to manufacture a broad range of John Deere products, including tractors and harvesting equipment, as well as construction and forestry products. At the same time, Deere will consolidate several depots into one site to improve parts and after-sales service to customers.
"Russia will be a major contributor to meeting the world's future needs for food and forestry products," said Samuel R. Allen, president and chief executive officer. "John Deere's products and solutions can greatly improve agricultural and forestry productivity through the use of advanced technology. Therefore, our investment in this new facility helps Deere prepare to significantly contribute to the Russian government's vision for expanding exports from Russia in these important sectors."
Allen said this announcement is the first step to achieve the vision for Russia that Deere announced in July 2009 at the US-Russia Business Summit and indicated the company's intention to significantly expand its presence in the country, which Deere views as an important growth market for agriculture, forestry and construction equipment. The project complements Deere's planned investment in a national operations and training center in the Kaluga region and its existing seeding equipment manufacturing facility in Orenburg.
"Our strategic investments reflect Deere's confidence in the potential of the Russian market, the strength of our dedicated dealers and employees, and the support of the Russian national and local authorities, particularly in the Kaluga, Orenburg, and Moscow Oblasts," said Mark von Pentz, president in John Deere's Agriculture and Turf Division. As government policies and market conditions allow, Deere intends to expand the company's presence in Russia in its current facilities and in other locations around the country, von Pentz said.
John Deere is a leader in providing advanced products and services for agriculture, forestry, construction, lawn and turf care, landscaping and irrigation. The company also provides financial services worldwide and manufactures and markets engines used in heavy equipment. Since it was founded in 1837, the company has extended its heritage of integrity, quality, commitment and innovation around the globe.
John Deere has been doing business in Russia for more than 100 years and has recently invested to expand operations, employment and sales in the Russian Federation. Today, Deere's dealer partners span the major agricultural and forestry regions. In total, Deere has a network of more than 70 sales locations across the country with employment in Russia at Deere and its independent dealerships approaching 2000 people.
Deere opened a forestry sales branch in Saint Petersburg in 2002; an agricultural sales branch in Moscow in 2003; a manufacturing facility for seeding equipment in Orenburg in 2005; and added construction equipment sales to the Moscow branch operations in 2009. The company also has announced its intention to develop an operations and training center in Kaluga. www.deere.com
DELCAM PLC (BIRMINGHAM, UK) . . .
the CADCAM developer has maintained its industry-leading levels of research and development expenditure during the first half of 2009, despite feeling the effects of the global economic downturn. The company invested over £4.7 million in R&D during the period, a small increase from the £4.5 million invested in the first half of 2008. This strategy is in marked contrast with some other suppliers in the CAM market, which have cut their investment in development as their sales have fallen.
Delcam also continues to invest in other areas of its business, including the opening of a new Professional Services Group and the addition of a large five-axis machine tool in its Tooling Services Division. Sales during the opening six months of 2009 were £16.1 million, less than 5 percent down from the £16.9 million achieved in the equivalent period last year. This reflects the very challenging market conditions that saw the company?s manufacturing customer base deferring its expenditure on software.
Within this total, recurring maintenance revenues, derived from software maintenance and support contracts, increased by 13 percent to £5.8 million compared with £5.1 million in the first half of 2008. This increase shows the value that customers put in the regular upgrades to the company?s software and the high quality of the technical support provided.
Despite the fall in sales and its continued high levels of R&D expenditure, the company has remained profitable. Pre-tax tax profit for the first six months of 2009 was £0.3 million, against £1.4 million in the first half of 2008. Net cash at the end of the period was a very healthy £5.8 million. This financial strength will leave the company well placed to take full advantage of any improvement in market conditions.
Commenting on the results, Delcam chairman Peter Miles said, "Reflecting the global financial and economic crisis, the trading environment in 2009 has been challenging and the impact of the downturn in the manufacturing sector has been even harder than we initially anticipated at the end of last year. With many companies postponing their investments in capital equipment, it is to be expected that the associated software sales should also be delayed. Given our strong financial position and high level of recurring income, we believe that the business is well placed to see out the near-term challenges. In particular, we are continuing to invest significantly in product development and marketing that provides us with an increasing commercial advantage and will help to support our ambitions to build our market share during the downturn."
The current global economic uncertainty makes it harder than usual to predict how well the company will perform in the second half and especially in the last quarter, which historically is their most important trading period in the year. However, Delcam anticipates an improvement in profitability in the second half of the year.
In related news, the company established a dedicated Healthcare Division to provide a greater focus on this increasingly important part of its business. The new Division will help companies across the medical, dental and associated industries to apply Delcam?s CADCAM expertise and experience in taking advantage of the latest design and manufacturing techniques. Commercial director Bart Simpson has been appointed as the head of the new Division.
"Companies in the healthcare industry face the same demands from their patients that our traditional engineering clients see from their customers for faster delivery of better and cheaper products," explained managing director Clive Martell. "Patients want to receive higher quality products and services, and they want to complete their treatment in the shortest-possible time. At the same time, healthcare companies are under pressure to provide this higher quality at lower cost and to increase their productivity to meet the growing demand. These requirements can only be met through the application of more advanced and more automated technology."
Delcam?s increased emphasis on the healthcare industry comes at a time when the sector is expanding rapidly and when it is much more receptive to computer-based technology. The aging population in industrialized countries and the growing affluence of the emerging economies mean that the healthcare industry is seeing global growth. Through its existing engineering business, the company is established in more than 80 countries worldwide and so can provide international support to larger healthcare providers and original equipment manufacturers.
Equally, Delcam?s focus on the toolmaking and subcontracting industries means that the company?s staff are used to dealing with smaller companies on a local level. All its offices, whether wholly-owned subsidiaries, joint ventures or independent resellers, are renowned for the high level of support they provide to all their customers.
The company is, of course, already active in many areas of the healthcare business. Its design, reverse engineering, machining and inspection software are used in a wide range of applications from the production of prostheses, through to the manufacture of surgical instruments and all types of medical packaging. This is especially true for the PartMaker machining system for turn-mill equipment and Swiss-type lathes. These machines are used extensively for the manufacture of medical and dental components, to the extent that around 70 percent of PartMaker sales already come from the healthcare industry.
In addition, Delcam has introduced several specific products for the healthcare market over the last two years. These include the DentCAD and DentMILL programs for the design and manufacture of dental restorations and the OrthoModel and OrthoMill software for the development of orthotics. The company also offers special versions of its CRISPIN range of footwear design and manufacturing software for the production of orthopedic footwear.
The common theme with all these products is that they take existing Delcam technology and add a dedicated interface that uses imagery and terminology from the healthcare sector. This makes the software easy to learn and quick to use for healthcare professionals, even those that are not familiar with using computer-based design and manufacturing. www.delcam.com
(THÜRINGEN, GERMANY) . . .
a designer and manufacturer of production facilities and equipment, relies exclusively upon Dassault Systèmes? Delmia software solutions for validating its manufacturing facility and equipment efficiency. The digital manufacturing software is helping ATG save time and money by identifying potential problems in the virtual world, prior to production.
"Because of the ubiquity of Catia in our industry design engineering, the seamless compatibility of Delmia data is a huge plus," says Torsten Hessland, CEO of ATG. "Delmia allows us to integrate visualizations and simulations easily into previously existing plant and engineering designs without losing any time due to translation issues."
Working with SWJ Consult GmbH (Städe, Germany), an independent engineering company for planning and project management, ATG is able to create an entire factory or production facility in the virtual world of Delmia. Noted Hessland, "Without the Delmia solutions, it would not be possible to create the necessary interfaces for system evaluation."
To accomplish its goal of proving out factory floor efficiency in the virtual world, ATG is currently implementing Delmia DPM Body-in-White, Robotics, Human, and Automation solutions. Together, these solutions allow ATG to create, modify and validate automotive body-in-white planning for lines and stations in a virtual 3D environment ? inclusive of robotic workcell programming and human behaviors ? prior to any physical production.
Additionally, the virtual commissioning capabilities of Delmia Automation solutions merge the 3D virtual manufacturing models with the actual control systems and robot controllers. The company can then conduct and evaluate "what if" scenarios to optimize production, enabling them to get it right the first time. Any proposed changes to a plant floor layout can be explored beforehand in the virtual model of the plants.
The strength of the Catia/Delmia combined solution is based upon a common data model that allows for continuity of workflow to achieve immense time, quality and investment advantages. "For example," explains Dr. Bernd Hirthammer, CEO of SWJ, "when several robots are involved in the material handling of a component, we can simulate the process offline using Delmia for maximum efficiency. The accuracy of the solution then allows for easy transfer and upload of the program to the real-world equipment."
Currently, ATG is focusing on the development of new materials for carbon fiber technology. "Given today?s focus on energy conservation through weight reduction, we are examining applications where steel or aluminum could be replaced with carbon fiber materials," says Dr. Hirthammer. "This is an excellent application of the Delmia portfolio as we?ve found that our simulation results have been confirmed through real-world prototype testing." www.atg-solutions-group.com
TRILOGY MACHINERY, INC. (BELCAMP, MD) . . .
entered into an agreement with Deratech of Belgium to become their new, exclusive North American agent. Deratech, while relatively new to the press brake and shear market, has taken the industry by storm. Producing eight different styles of press brakes and shears, the manufacturer has positioned themselves to become a leader in the industry offering high quality machines at incredible prices with numerous standard features.
"We are excited about our new North American agent, Trilogy Machinery, and look forward to sharing our quality machines with their market" said managing director Bjorn Rabiot. Trilogy Machinery president and founder Allan Flamholz, says, "we are very enthusiastic about the opportunity to represent Deratech throughout the North American market. They will emerge as a leader in the industry with the quality, craftsmanship and included features of their machines."
Trilogy occupies a modern 50,000 sq ft facility, complete with 25 ton overhead crane capacity, over 2,500 sq ft of office space and a 5,000 sq ft showroom, where they can demonstrate under power Deratech press brakes and shears as well as the full line of ROUNDO bending rolls, including machines equipped with CNC controls. Customers can have samples of their products tested to insure the highest quality results.
Trilogy will handle all technical support for Deratech, as well as keep a full stock of parts and accessories at their Belcamp location. In addition, Trilogy team members will be trained at the Deratech headquarters in Brussels, Belgium, to be able to efficiently and effectively assist customers with applications, support and service. Trilogy will showcase Deratech Press Brakes and Shears at the upcoming FABTECH show in Chicago, November 15-18, 2009. On hand will be the managing directors of Deratech to further answer customer inquiries and demonstrate the machines. www.trilogymachinery.com
EGYPT RECORDS 75 PERCENT INCREASE IN STEEL CONSUMPTION IN FIRST HALF . . .
The Egyptian steel market witnessed unprecedented growth during the first half of this year, recording 75 percent growth in consumption on a year-on-year basis. According to research by Industrial Info Resources (Sugar Land, TX), Egypt consumed about 2.4 million tons of steel in the first half of 2008, but fulfilled steel demand of 4.2 million tons during the same period this year.
Demand for long steel products has been significant, with the country importing about 3.8 million tons during the first half of this year. The large number of imports led domestic steel producers to slash prices of rebar. However, industry analysts indicate that Al Ezz Steel Rebars SAE (EZZ Steel; Cairo, Egypt) and other manufacturers have now raised rebar prices by $36.17 per ton. Currently, the price of rebar in Egypt is about $542.69 per ton.
Globally, the steel industry has been adversely impacted by the economic downturn. Steel producers worldwide have been forced to undertake production cutbacks, defer expansion plans, and lay off employees. The industry, which is still reeling under the effects of the financial crisis, is seeing signs of recovery in some countries. Industry experts say that the Egyptian government's economic stimulus package of $2.71 billion on infrastructure and other development projects in 2008-09 and the proposed $6.6 billion investment during 2009-10 have helped stabilize the domestic steel industry.
A recent report published in The World Today says that in addition to the federal stimulus package, growing demand in Egypt's real estate sector has helped the country's iron and steel sector sustain the repercussions of the global slowdown. The study indicates that the choice of Egyptians to build and buy homes in suburbs rather than in the capital city of Cairo has led to tremendous growth in infrastructure and construction activity across the country.
Egypt records about 600,000 marriages in a year, which has spurred demand for new homes and housing units. The building and construction sector is one of the largest consumers of steel. The report forecasts that by 2013, local steel demand will increase at a compounded annual growth rate of 15.6 percent to 13.4 million tons per year, with rebars accounting for about 82 percent of overall demand.
Egypt's largest independent steel maker, Ezz Steel, produced 2.232 million tons of steel during the first half of 2009, a 7 percent slump on a year-on-year basis. Despite the fall in production, the company's sales of long products grew 10 percent on a year-on-year basis to 1.6 million tons. This has helped in stabilizing the company's revenues, since the sale of flat products declined sharply by 50 percent at the export level and 41 percent in the domestic market. The company, which commands about 60 percent of the domestic market share, operates four manufacturing facilities in Sadat City, Suez, 10th of Ramadan City, and Alexandria.
Ezz Steel owns a 53.2 percent stake in Al Ezz Dekheila Steel SAE (Alexandria, Egypt), which manufactures flat and long steel products. Al Ezz Steel Mills SAE, in which Ezz Steel owns a 90 percent stake, produces long steel products. Ezz Flat Steel SAE, in which Ezz Steel owns a 75.2 percent stake, produces flat steel products. The present combined production capacity of Ezz Steel is 5.3 million tons. The firm employs about 6,000 people.
According to industry reports, Ezz Steel is planning a horizontal integration of its rebar production facility. This process will make use of liquid steel flexible for production of rebars and flat products, and will enable the firm to quickly respond to market demand. With the horizontal integration expected to be completed by mid-2011, Ezz Steel's revenue from rebar is estimated to grow at a 13.1 percent compounded annual growth rate before interest, depreciation, taxes and liabilities.
Steel analysts are optimistic that the global steel scenario will improve by 2010. Ezz Steel already has charted out augmentation plans that will increase its production capability to 6.3 million tons per year by 2010-11. This includes expansion of rebar production capacity by 1 million tons per year, which will take the total rebar production capability of the company to more than 4 million tons per year.
In its Egypt Metals Report 2009, Business Monitor International (BMI; London, England) predicts that the construction sector in Egypt is set to grow 5 percent in 2010. Crude steel consumption in the country has been forecast to increase 0.8 percent, while usage of finished steel products will grow 3.9 percent by 2010. The report indicates that by 2013, Egypt's steel imports will increase 77 percent to 5.27 million tons, while demand for finished steel products will grow 65 percent.
GLOBAL STEEL INDUSTRY POISED FOR RECOVERY FOLLOWING TOUGH FIRST HALF . . .
The global steel industry faced a tough time in the first half of 2009, with the worldwide financial crisis causing industrial production in many regions to decline considerably, particularly in the first quarter. However, according to research by Industrial Info Resources (Sugar Land, TX), recent statistics show signs that the industry may be on its way to recovery.
Some countries ? notably Japan, Italy and Turkey ? registered declines as high as 20 percent in production during the first three months of the year. In contrast, China recorded an increase in industrial production of almost 6 percent in the same period. The International Monetary Fund has revised its world economic forecast to a 2.5 percent growth in 2009, following the gloomy prediction of a 1.3 percent decline it issued in April.
Steel production, following relatively flat worldwide production figures for the first quarter of 2009, has shown a slow but gradual increase in the April to July 2009 period, rising from 89 million tons in April to almost 104 million tons in July.
China continues to record significant growth in its economy and reflects the global trend in increased steel production during the April to July 2009 period, with figures of just more than 43 million tons in April rising to almost 51 million tons in July. Unlike many western countries, the motor vehicle industry in China recorded a 38.8 percent growth during the first half of 2009, largely on the back of government incentives and cuts in sales taxes.
Other countries in the Asian region for the most part have not followed the Chinese trend. India and South Korea have both recorded relatively flat steel production figures, with figures for India ranging from a low of 4.1 million tons in February to a high of 4.7 million tons in March, and those for South Korea ranging from 3.2 million tons in February to 4.2 million tons in May.
The steel industry in Japan hit a low in February this year when it recorded a production of 5.5 million tons. However, steel production increased to 7.7 million tons by July, with inventory of ordinary steel products declining between December 2008 and April 2009, before picking up in May and June 2009.
The decline in the U.S. appears to be slowing down, with many sectors reporting slight improvements from June to July this year. The new orders index in the manufacturing sector rose from 49.2 percent in June to 55.3 percent in July. Steel production in the U.S. appeared to follow this trend, rising from 4.3 million tons in June to almost 5 million tons in July.
After a poor first quarter, Europe's largest steel producer, Germany, began to show an increase in steel production after a low of 1.9 million tons in April, recording a gradual rise over subsequent months to reach 2.7 million tons in July.
It also appears that the various stimulus packages introduced by governments to counteract the global economic crisis have had little effect on steel production figures. This is largely because the packages initiated by the governments were aimed at the construction, automobile and infrastructure areas. Although these packages have the potential to benefit the steel industry, the stimuli will take time to reflect as increased demand for steel.
(SANDVIKEN, SWEDEN) . . .
is investing in a dedicated service center with its own slitting line in Zhenjiang, Jiangsu province, China, ensuring that delivery times of precision strip to all customers in China can be kept to just one week. The service center is scheduled to open during October 2009 with a main feature of a new slitting line operational during November.
Initially intended to supply strip to customers throughout the Chinese market, the center will offer greater supply flexibility and considerably shorter delivery times, with material finished to size from stock held onsite. It will also open up options to supply other Asia Pacific markets from the first quarter of 2010. The new service center will introduce a considerable number of benefits, not only for existing customers in China, but also for those businesses considering relocation to the region, with fast response times and firm delivery dates for precision strip supplies. Sandvik will be able to provide made-to-order material at short notice, supplied locally, and facilitating fast growth of the market sector in the region.
The service center will focus on finishing and delivering precision strip to customers for the manufacture of flapper valves for compressors used in automotive, refrigeration and air conditioning units. It will also supply material to other important market sectors in the region, such as shock absorber manufacturers. Improved delivery times mean customers will be able to reduce their own lead times, offering flexibility to chase new business. Equally, customers can buy just what they need, when they need it, thus reducing the risks from stock ownership and freeing up capital as well.
"In a competitive market place we see real benefits to both our customers and their customers in our ability to supply material with short lead times directly in the local market," explained Andy McCullock of Sandvik Materials Technology. "This fully equipped service center will facilitate greater physical and operational flexibility, with the logistical capability to ship material to multiple sites, thus accommodating customer specific requirements."
Investment in the new Sandvik service center in Zhenjiang is part of a long term strategy, designed to extend Sandvik Materials Technology?s presence in Asia Pacific. www.smt.sandvik.com/strip
(WHITE BEAR LAKE, MN) . . .
expanded its European headquarters in Swindon, England. The world?s largest independent manufacturer of tooling systems for punch presses, press brakes and punch and die components for the stamping industry added 22,000 sq ft that includes new space for manufacturing as well as a dedicated customer and employee training center. The additional manufacturing space enabled the addition of new machines to be used to manufacture press brake tooling, the company?s fastest growing product line.
The expansion will also allow Wilson Tool to make continuous improvements to toward its lean manufacturing goals by creating new flow lines for the production of punch press and press brake tooling. "Changing our layout to flow will improve efficiencies and eliminate waste in our manufacturing processes," said Ray John, manufacturing manager. "Reducing our lead times, particularly for special tools, is a key objective in 2009. Our commitment to lean manufacturing has already enabled us to manufacture cluster tools and lance and form tools in three days. The new facility will give us the capacity to reduce the lead times of our other special tools."
The new customer training center is designed to be an educational destination for sheet metal fabricators throughout Europe. The facility opened on May 13 with a Productivity Seminar attended by 69 customers who were interested in learning more about lean manufacturing for sheet metal fabrication. Customers attended workshops on lean manufacturing as well as practical punch press and press brake demonstrations in Wilson Tool?s Technology Centre. Additional seminar dates and training for specific product lines will be added in the future.
Wilson Tool is committed to serving the European market through expanded manufacturing capabilities and enhanced customer training opportunities. The recent expansion brings the total footprint of the company?s European headquarters to 82,000 sq ft and demonstrates their commitment to this valuable market. www.wilsontool.com
SMARTTCP (FARMINGTON HILLS, MI) . . .
has been selected by Waiward Steel Fabricators Ltd., of Edmonton Alberta, Canada to automate its structural steel welding process. The robotic welding solution, which is designed for steel fabrication, combines hardware and software into a flexible and efficient welding cell that will automate both the robot programming and the weld production of Waiward?s high volume of ?one off? and small batch parts.
"We?ve been looking into robotic solutions for the better part of the last 10 years and haven?t found anyone that could address our low repeatability welding needs until now," said Jim Kanerva, vice president of operations for Waiward Steel. "We researched robotic systems from most major players in the North American market, always finding that there were important components missing to achieve a welding automation solution well suited to our structural steel needs. We selected them because they were the most advanced in addressing our needs."
Waiward Steel, one of Canada?s 50-Best Managed Companies, is an Edmonton-based steel fabricator and erector with extensive experience in the petrochemical, mining, power generation, pulp and paper, and commercial markets. The company?s services include the fabrication and installation of structural and miscellaneous steel, equipment components, hoppers, plate work, material handling equipment and bridge girders. Waiward sustains shop fabrication production levels few competitors duplicate, with Manufacturers? Health & Safety Association (MHSA) certified award winning safety, and ISO-9001 registered world class quality. This is achieved in one of Canada?s largest structural steel plants (216,000 sq ft), home to one of Canada?s largest and best trained structural steel fabrication crews.
"Waiward Steel, like most structural steel fabricators, has to deal with custom fabrications where every single piece, beam or column can be completely different," said Efi Lebel, founder and CEO of SmartTCP. "Our turnkey solution is ideal for just this challenge as it provides the most comprehensive, efficient and cutting edge welding automation solution possible to address positioning, fit up and programming issues, giving small batch fabricators a system that can accurately and reliably weld any weldable part in any number of welding scenarios quickly."
While researching automated welding options, Waiward Steel was very specific in its requirements when talking with robotic solution suppliers. They needed a complete solution to deal with high piece count projects with "batches of one". The solution needed to deal with the specialized welding demands of structural steel including large multi pass welds on thick beveled material, full penetration, heat distribution and the ability to handle inaccuracy/variances in part fitting and joint gaps.
"When we saw their solution, we knew that this was the solution," added Kanerva. "It was as if it was designed specifically for our situation and for our industry."
The solution to be implemented in the Waiward facility will include a bridge gantry system 125 ft long with two head and tail positioners (30,000 lb capacity each) specifically designed for structural steel, one ceiling mounted 6-axis articulated robot, welding equipment and welding automation software. The welding system will allow the company to produce more parts more quickly without additional employees and in the same amount of production space. These benefits, coupled with the increased quality and reliability of robotic welding over manual welding, will give the company an additional competitive advantage within their industry.
The off-the-shelf system is being installed in September and SmartTCP anticipates Waiward will be up and running production parts within six weeks, an extremely quick installation considering the machine size and complexity of the technology to be installed. From benchmarking efforts and experience, the company anticipates that Waiward will be able to weld with two operators what would normally take approximately eight welders to complete. Overall, this will result in greater and more efficient throughput.
SmartTCP is a leading supplier of automatic welding solutions for steel fabrications in small batch production. Their robotic welding solution reduces the need for expert welders, improves time to market, and increases production volume and quality. The gantry welding system is a turnkey solution that automates both the robot programming and the weld production and includes the hardware, software, installation, training and support during and after implementation. www.smarttcp.com
SIEMENS ENERGY & AUTOMATION, INC. (ALPHARETTA, GA) . . .
recently announced that Fryer Machine Systems, Inc. (Patterson, NY) has selected the Sinumerik 840D numerical control, together with the ShopMill and ShopTurn software packages, for its job shop milling and turning machines.
By using these CNC solutions, machine tool end-users benefit from decreased machine setup time, a unified control for both milling and turning machines combined with superior performance. Flexibility and ease-of-use were key factors in the decision to select Siemens. The solution allows end-users to achieve higher productivity through easy and intuitive features and step-by-step, on-screen programming that enable job shops to quickly respond to customer demands by drastically reducing programming, tooling and production times.
Fryer Machine Systems, Inc was established in 1982 and manufactures a diverse line of over 50 models of high quality machine tools in their Patterson facility. Over the years, Fryer has become well-respected for their quality and innovation. In addition their standard line, Fryer produces customized machines for a number of major companies in the aerospace and automotive markets.
"The Sinumerik 840D?s modular design allows us to take full advantage of the superior mechanical features in our machines," said Larry Fryer, president and CEO of Fryer Machine Systems. "This offers Fryer a customizable solution that is critical to effectively addressing the needs of our customers. It allows us to provide features not available from any other control."
"We are proud to extend our relationship with Fryer Machine by providing innovative CNC solutions," says Wolfgang Rubrecht, general manager, Motion Control Business, Siemens Energy & Automation, Inc. www.usa.siemens.com/cnc
(HUNTERSVILLE, NC) . . .
will be the title sponsor of one of the most prestigious sporting events in the country beginning in 2010: the Irwin Tools Night Race at the Bristol Motor Speedway. While the event's new name is unique ? the "Irwin Tools Night Race" ? the summer classic under the lights at Bristol will continue to be 500 grueling laps around the high banks of the .533-mile oval, one of NASCAR's most popular and storied facilities.
A spectacle in sports since 1961, Bristol has had 55 consecutive NASCAR Sprint Cup Series sellouts, dating back to 1982. "We could not have constructed a better partnership than one between Irwin Tools and Bristol Motor Speedway," said Irwin president Neil Eibeler. "Bristol leads the way in innovation, quality and ingenuity among NASCAR venues. We can't wait to see our blue and yellow colors here for years to come. Our employees are thrilled and our customers will be waiting in anticipation to see nearly 160,000 fans in the stands next year for the first 'Irwin Night Race at Bristol,' the most popular NASCAR race of the year."
Irwin Tools takes over the entitlement from Sharpie, a sister company under the Newell Rubbermaid umbrella, which has sponsored the race since 2001. "We're very happy to keep the Night Race in the Newell Rubbermaid family," said Jeff Byrd, president and general manager of BMS, NASCAR's fastest half-mile. "We have gotten to know the Irwin Tools team over the years and their desire is to be the best technological company in the tool business. We feel we have the best facility in our sport, so pairing up the two can only result in success. We look forward to a partnership and future together."
Irwin Tools is a manufacturer and distributor of a broad line of professional hand tools and power tool accessories, including Vise-Grip pliers and wrenches, Marathon saw blades, Quick-Grip clamping tools, Speedbor wood-boring bits, Strait-Line marking tools, Unibit step drill bits and Hanson taps and dies. Irwin Industrial Tools is a part of Newell Rubbermaid's global portfolio of brands. The Irwin Tools name has been a mainstay in NASCAR since 2003, serving as a primary car sponsor for Roush Fenway Racing. During that span, drivers Kurt Busch and Jamie McMurray both won races in Irwin Tools Fords while Busch carried Irwin to the NASCAR Sprint Cup Series Championship in 2004.
"It's been a great ride with Roush Fenway Racing," said Eric Pinkham, Newell Rubbermaid's vice president of sponsorship and event marketing. "They clearly helped us put Irwin Tools on the map, and we appreciate what they've done for the Irwin brand. Now it's time for a new chapter for Irwin, and we can't wait to get started on the Irwin Tools Night Race at Bristol."
The 2010 Irwin Tools Night Race at Bristol will be on Saturday, August 21. www.irwin.com
KSO METALFAB INC. (STREAMWOOD, IL) . . .
recently purchased MIE Maintenance Software, a system designed to help manufacturers prevent failures before they actually occur, from MIE Solutions (Garden Grove, CA).
KSO Metalfab specializes in the prototyping and manufacturing of stampings, machined parts, enclosures and assemblies, and provides comprehensive services, turnkey project management and full engineering support. Their modern facility is fully equipped to handle any project and their quality systems are in place to ensure they meet or exceed their goals by providing on-time, quality products and services.
MIE Solutions is a leading provider of production control software for the entire manufacturing sector. Incorporating MRP, ERP, scheduling, shop floor data capture, barcoding, job costing, quoting and estimating. MIE Trak (formerly known as FabriTrak) is a leading software for sheet metal fabricators, precision engineers and manufacturers that can be adapted to incorporate any manufacturing processes if required and offers a complete solution. Services include training, full product support and on-site implementation.
MIE Maintenance is a full CMMS and work order system designed to be used for an entire manufacturing organization. The system is designed to help by preventing the failure before it actually occurs, which PM and condition-based maintenance help to achieve. It is designed to preserve and restore equipment reliability by replacing worn components before they actually fail. Preventive maintenance activities include partial or complete overhauls at specified periods, oil changes, lubrication and so on. In addition, workers can record equipment deterioration so they know to replace or repair worn parts.
This software helps manufacturers in asset-intensive industries maintain their investments by managing these assets. MIE Maintenance handles both maintenance requests and predefined maintenance tasks to notify maintenance teams to perform work. Maintenance requests can be denied or approved. Once a maintenance request is approved, a work order is created to perform the work. All the work can be logged into the system for historical reporting and fixed asset reporting. www.kso.com
FABRICATORS PLUS (MUSCATINE, IA) . . .
recently unveiled a newly designed website spotlighting their company?s performance metrics and describing their Customizable Delivery System capabilities that raise the bar for JIT delivery practices everywhere. The company has decided there is no better way to demonstrate the measurability of their value-added services than by making public, its own operational results.
The site, www.fab-plus.com , makes specific company performance measures, for instance, quality defect rate, complete and on-time delivery rate, and others, available directly on the newly designed home page. The new site features an overview of the services and benefits the company provides its customers, industry related news articles, company announcements and detailed information regarding their specific JIT Delivery System development capabilities, as well as testimonials from customers.
Fabricators Plus provides customized lean manufacturing solutions to aluminum extruders and metal fabrication customers in Iowa and the Midwest. They manage the entire process, from the procurement of raw material to delivery of well-designed and high quality components and assemblies, often to large OEM manufacturers operating in a variety of industries that include lighting, furniture, construction and appliances.
The company's specialty is designing customizable delivery systems capable of providing dramatic bottom line results for its customers. They have put their combined 150+ years of operational expertise and understanding of lean manufacturing principles to work to develop customized delivery models that are years ahead of others claiming JIT delivery capabilities.
"We are a team of problem solvers. Our dedication to CDI (Continuous Daily Improvement) helps us to provide our customers with real, measurable results. Results that directly impact their bottom lines. Our customers are able to eliminate on-site inventory, increase their inventory turns and free up cash for investing in other areas of their business," said Douglas Buster, president. www.fab-plus.com
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