On this blog, we often talk about the ways investing in advanced sheet metal manufacturing technology can help improve productivity. However, machinery is only half of the equation in the manufacturing industry and the human element is often overlooked as working on employee productivity tends to be a lot more complex than simply upgrading your machinery. Despite this, if you can get it right, improved worker productivity can have a significant impact on your bottom line and also help improve both  job satisfaction and morale. This week, we look at some of the ways sheet metal manufacturers can improve worker productivity.

Examine existing workflow

The first step in improving productivity is to identify inefficiencies in the workflow. To do this, you need to evaluate the processes, technology and of course the people required to produce your product. When focusing on employee productivity, look closely at things like procedures, communication tools and channels and resources to see if there is room for improvement. From there, value mapping can be an effective way to identify and monitor process improvement to see the impact on the workflow.

Anti-fatigue matting

Anti-fatigue matting can play an important role in boosting productivity as it enables workers to perform for long stretches of time without any pain. Anti-fatigue matting improves posture and blood circulation, reduces body aches, helps preserve energy levels and helps workers feel physically comfortable and supported throughout the day.

Invest in employee education

In an industry that is constantly evolving both in terms of technology and procedural processes, there are plenty of opportunities for employees to advance their professional skillset which ultimately adds value to your business and ensures you remain up to date with the latest specialist technologies.

Foster a team environment

Although it’s made up of separate stations, a manufacturing floor is most productive when everyone is united and working towards the same goal and lag, waste and conflict is kept to a minimum. Creating a co-operative environment requires a dual approach of running regular team building exercises and working with employees individually to ensure they feel comfortable and see themselves as part of the team.

 

ACRA are proud to provide Melbourne sheet metal manufacturers with a comprehensive range of quality new and used sheet metal machinery and accessories including anti fatigue matting. To learn more about our capabilities, please don’t hesitate to get in touch with us by calling 03 9794 6675.

Endlessly variable and hardworking, ironworker machinery simplifies many difficult metal fabrication tasks. This week, we look at how you can improve the productivity of this already invaluable piece of machinery.

Ironworkers have a punch, but don’t throw away your drill

Ironworkers tend to be limited in the hole sizes they can punch relative to the thickness of the material and cannot be used to punch a hole smaller in diameter than the material thickness.

More is better when it comes to throat depth

Throat depth should be deep enough for most of your work and be able to punch your largest part. Remember, you can’t add it later and if there is a special job, a drill can do the work instead.

Think carefully about the ironworker table

If you plan to use your ironworker for pipe notching or bending, it’s important to choose a table where the die holder is attached in a user-friendly way. Die holders can be attached with T slots, drilled holes, or tapped so it’s important to closely inspect before investing.

Die holder positioning is also important

If you need to punch close to the web, get a die holder where the die is near the edge of the holder rather than in the centre, as this can inhibit punching ability.

Different types of angle iron shear have different pros and cons

The slug-type angle iron shear is the best choice for those seeking a good cut quality, but it does cause some material loss and shimming. It also requires blade changes. If you need to cut a large piece of iron and want to avoid wasting materials however, the cropoff shear is the best choice, although it produces a lower cut quality.

The flat-bar shear is great for fabricating base plates, but quality varies

Different ironworkers offer different quality levels at this station and the rake angle in particular, can have a significant impact on the resulting cut quality. Broadly speaking, the higher the rake angle, the more distortion the drop piece has causing the material to roll or bow.

 

Acra stock a dynamic range of new and used sheet metal manufacturing machinery including ironworkers. To learn more about our capabilities, please don’t hesitate to get in touch with us by calling 03 9794 6675.

 

In the sheet metal manufacturing industry, laser cutting remains the gold standard in terms of speed and precision but did you know this futuristic technology was first theorised about over 100 years ago? This week we uncover 10 surprising facts about the history of laser cutting technology.

 

1. The relationship between energy and the frequency of radiation was first deduced by physicist Max Planck in 1900 who said energy could only be emitted and absorbed in chunks.

 

2. This theory was extended by none other than Albert Einstein in 1905 with his paper on the photoelectric effect. In 1917 Einstein presented his theory on stimulated emission, the process which makes lasers possible.

 

3. However, it would be 40 years before scientists would be able to prove Einstein’s theory in the lab. This was done in 1954 by Charles Hard Townes with the help of Herbert J, Zeiger and James P. Gordon.

 

4. Originally the strength of a laser was measured in ‘gillettes’ which refers to the number of razor blades a laser beam can cut through. Today, the strongest laser is as powerful as a hydrogen bomb.

 

5. Laser is an acronym which stands for Light Amplification By Stimulated Emission of Radiation. The term was coined by Gordon Gould in 1959.

 

6. Ruby laser technology was first used in a cutting context to drill holes in diamond dies in 1965.

 

7. In 1963 Kumar Patel developed the first Carbon Dioxide laser, which was more powerful and less expensive than the ruby laser previously used. A CO2 laser was the first to be used as for cutting metal in 1967 when it was used alongside oxygen jet cutting to cut through a 1mm thick sheet of steel.

 

8. The Being Company was the first to use laser cutting technology in a manufacturing context in 1970, it invented multi-beam laser cutting technology and used it to cut through ‘hard’ materials such as titanium.

 

9. 3D laser cutting was pioneered in 1979 and employed a 5 axes rotation system.

 

10. Laser cutting is renowned for its accuracy and indeed laser measuring is accurate to just over a nanometre (a billionth of a metre).

 

Acra stock a top of the range laser cutter from leading sheet metal machinery manufacturer Durma. To learn more about our capabilities, please don’t hesitate to get in touch with us by calling 03 9794 6675.

 

 

 

 

 

 

For most sheet metal manufacturers, investing in a new press brake is not usually at the top of their priorities list. For a long time, press brake technology has lagged behind other sheet metal machinery in terms of automation. As a result, most companies have a manually operated press brake that requires a substantial amount of programming on the floor and as a result, is unable to keep up with the other machines speed of production. However, over the past couple of years press brake technology has evolved substantially to the point where many functions are automated and modern machines have uptime comparable to other sheet metal technologies. This week, we look at exactly what those technological advances are and the impressive impact they can have on productivity.

Repeatable press brakes

The most common upgrade choice for businesses is the repeatable press brake which draws from material databanks to automate press brake moves and limit the amount of manual calculation required.

 

Software that adapts according to material behaviour

The software behind press brake technology has also become substantially more sophisticated. One exciting innovation is the software’s ability to adapt to material behaviour in real time. Using internal sensing and external laser sensing, this software can account for material variations including crowning and deflection.

 

Adaptive bending

Many new press brakes not only make it easy to calculate spring back and deflection before bending, but can also account for varying tensile strengths and adjust both deflection and calculation errors during the bend. This deflection adjustment is achieved through either mechanical or hydraulic means on the lower beam. Some systems also continuously monitor tonnage throughout the cycle and if an adjustment is required, the crowning cylinders are engaged whilst the cycle continues.

 

Offline programming

Offline programming eliminates manual programming on the factory floor and thus enables the press brake to remain in constant production. Whilst previous offline program technologies struggled to manage variables such as the bend radii of the available tooling, the newer breed of offline programming develops the press brake program directly from a 3D drawing, but before the blank size is determined. This way the properties of the press brake can be quickly programmed in by the operator to ensure accuracy.

 

ACRA are establishes suppliers of quality new and used sheet metal machinery including press brakes. To learn more about our range, please don’t hesitate to get in touch with us by calling 03 9794 6675.