Genesis. Industrial Equipment. Material Optimization Technology for Cold-Formed Steel Manufacturing

Transcription

1 Genesis Industrial Equipment Material Optimization Technology for Cold-Formed Steel Manufacturing

2 Roll Forming Industrial Automation and Integration for Optimized Light-Steel Framing The Material Optimization Technology (MOT) is a proprietary manufacturing process that has been developed by Genesis LSF industry professionals. This process combines highly flexible cold-forming equipment with advanced material handling, conveyance and assembly technologies into one unique integrated solution. This platform allows the manufacturing of C and U section profiles used for structural wall, floor and roof systems, while eliminating the need for material picking, manual handling or large material inventories. The Genesis Enterprise Manager (GEM) software sequences, communicates and tracks the entire production schedule of cold formed steel material for every project via the MOT platform through one central control. Specifications of light steel panels sub components are communicated seamlessly via the MOT Programmable Logical Controller (PLC) to the applicable roll-forming machines. The machines then automatically and simultaneously produce a complete set of components of specific profiles and dimensions, called kits. These kits are conveyed through the preparation area to be either: Assembled through the downstream panelized process within the Licensee s factory Bundled for shipping to a Genesis Solution Provider (GSP) Bundled for shipping to a jobsite for stick framing

3 The MOT platform is a revolutionary production concept in the Light-Steel Framing industry. The central driver to the process is overall cost reduction and this is achieved through the optimization of material and labor. Material Optimization MOT produces material on demand by communicating with the Genesis Enterprise Manager (GEM) which provides the system with all the detailed requirements of every subcomponent of every wall, floor or roof panel/truss. Each sub-component is then accurately produced to the necessary gauge, size and length. The unique advantage of the MOT lies within its ability to guarantee the most optimal use of material. Depending on the MOT model selected, an intelligent use of multiple sizes and gauges available on each roll-forming machine allows for the optimization of material by reducing overall steel consumption in any type of building structure In some designs this material optimization concept can generate more than 30% savings in steel costs. Labor Efficiency The MOT produces trade friendly components for plant or jobsite assembly. The material is automatically identified, marked, pre-punched, notched and sheared to allow for easy assembly into panels, floors or roof trusses by a minimum number of employees. A complete array of Smart features is included in any MOT model, eliminating time consuming and inefficient direct manual labor typically associated with custom cutting and pre-assembly tasks. Material Handling Elimination Every MOT model comes with a fully automated conveyance system which is connected directly to the roll-forming equipment. A single operator running five, six or seven rollforming machines produces all the components called upon for a given kit. These components are automatically collected at the end of each roll-former and are transferred by the conveyance system seamlessly and ergonomically as complete kits to the assembly area. This system eliminates the need for sorting or searching through bundles of standard material and manual maneuvering of material to the assembly area. Smart Stud with bent tab Bridging Channel Clip Angles Pre-Insulated Column/Beam (2-Ply) Smart Track Smart Lintel Stud Smart Sill Track Pre-Insulated Column/Beam (3-Ply) MEMBER Column/Beam (2-Ply) Top Stud Sub-Assembly

4 Quality CSA, UL & CE certified, industrial safety-compliant Oversized shaft design for increased durability, preventing any bending or deforming over time Custom hardening process, extending the roll tooling lifetime by reducing friction, wear galling, sticking, and potential heat damage Heavy duty hydraulic packages on all punch and shear tooling Beam and joist welding with patented technology eliminating the need for galvanized painting Maintenance-friendly design providing easy maintenance access to machinery components without tear down or dismantling Coil Inventory Management 2 Quick & Easy Change Over 2 Roll Forming Kit Preparation Coil-to-Jobsite Product Traceability

5 Flexibility Product manufacturing versatility in each machine: up to 4 leg heights or flanges, 4 web depths/widths and 4 material thicknesses Coil and tooling change over in less than 20 minutes Compact, Modular and Portable machines, that fit into standard shipping trucks or containers, easy to install, re-arrange, move and re-locate if required Quick interchangeable tooling cassettes for service and anchor holes Compact Modular Portable Features Dual sided heavy duty de-coiler (4,000 lb coil each side) with adjustable brake Coil traceability and consumption tracking Stress monitoring on roll tooling Auto-gaging (no material thickness change over) Dedicated Human Machine Interface (HMI) on each machine with start-up procedures, production status and fast troubleshooting prompt screens Individual output of m per minute Combined output of more than50 panels per 8-hour shift Available length, from m up to m All material identified according to the ICC standard for complete traceability Fully automated production of pre-packaged kits, ready for assembly: Service holes pre-punched, fully customizable in size and shape Anchoring holes pre-punched, for hold-down bolts Connection locations pre-marked for accurate, easy and fast assembly All material cut-to-length with the highest accuracy: +/- / mm Multiple tooling can be purchased as an option

6 Based on the aimed market penetration, three MOT models can be implemented. They can be upgraded as the business evolves. The following tables provide a description and comparison of the three models. Turnkey Industrial Equipment Customizable and Scalable to Your Evolving Market Needs Steel Consumption Optimization 2 Storey 4 Storey 6 Storey Affordable Housing, Single Family Homes, Duplexes and Townhouses, Commercial Plaza -storey, Restauranst, Windbearing Walls Market, Wall Kits Market, Roof Trusses Market Multifamily Dwellings up to 4 storey Multifamily Dwellings 4 to 6 storey, Villas and Custom Homes, Commerical Office Buildings up to 8 storey Walls 90-95% 90-92% 88-90% MOT5000 Flat Trusses Roof/Floor * 00% 00% 00% Common/Scissor Roof Trusses ** 00% 00% 00% Floor Panels (Concrete Topping) *** 55-00% 55-00% 55-00% Floor Panels (Plywood/OSB Topping) **** 6-00% 6-00% 6-00% Walls 96-00% 96-98% 95-96% MOT6000 Flat Trusses Roof/Floor * 00% 00% 00% Common/Scissor Roof Trusses ** 00% 00% 00% Floor Panels (Concrete Topping) *** 55-00% 55-00% 55-00% Floor Panels (Plywood/OSB Topping) **** 70-00% 70-00% 70-00% Walls 00% 00% 00% MOT7000 Flat Trusses Roof/Floor * 00% 00% 00% Common/Scissor Roof Trusses ** 00% 00% 00% Floor Panels (Concrete Topping) *** 90-00% 90-00% 90-00% Floor Panels (Plywood/OSB Topping) **** 00% 00% 00% Each ratio expresses the amount of steel utilized versus the amount of steel the optimum design requires (i.e. leanest LSF design for structural integrity) * 8-8 m span mm concrete (DL=3.0 kpa 62.5 psf, LL=.9 kpa 40 psf) or 3/4 20 mm plywood/osb (DL=.2 kpa 25 psf, LL=.9 kpa 40 psf) spacing ** 6-8 m span mm concrete or 3/4 20 mm plywood/osb spacing *** 5-7 m 6-23 span mm concrete (DL=3.4 kpa 7 psf, LL=.9 kpa 40 psf) **** 5-7 m 6-23 span - 3/4 20 mm plywood/osb (DL=.0 kpa 20 psf, LL=.9 kpa 40 psf)

7 MOT Models Model Number Description MOT 5000 MOT 6000 MOT 7000 Roll Forming Equipment CTPMOT-SS086 Custom Wall, Roof & Floor Stud Roll Former CTPMOT-SS04 Custom Wall, Roof & Floor Stud Roll Former 2 0 CTPMOT-SS24 Custom Wall, Roof & Floor Stud Roll Former CTPMOT-ST04 Custom Wall, Roof & Floor Track Roll Former CTPMOT-ST24 Custom Wall, Roof & Floor Track Roll Former 0 0 CTPMOT-BR-CL Custom Bridging Channel and Clip Angle Roll Former CTPMOT-ROC Automated Dump and Run-Out Conveyor System 2 CTPMOT-CLD Coil Lifting Device Unit Kit Preparation Equipment CTPC4-LNP Lintel Notching Press and Die CTPC4-PRWA Pre-Weld Accessories Package CTPC4-PWJ Pre-Weld Dual Jig & Clamps Kit CTPC4-APW Automated Pre-Weld Machine (UPGRADE OPTION) MOT Specifications Feature MOT 5000 MOT 6000 MOT 7000 Material Thickness Min: mm Max: mm Min: mm Max: mm Min: mm Max: mm Material width/depth 3 standard Sizes Up to mm 4 standard sizes Up to mm 5 standard sizes Up to mm Floor Span at Full Optimization 2 4' 4 m 8' 5.5 m 24' 7 m Maximum number of storeys at Full Optimization Operational Metrics (one shift) Total Production Floor Space sq. ft. 65 sq. m 7375 sq. ft. 670 sq. m 8050 sq. ft. 735 sq. m Number of dedicated Employees per shift Daily Production Output 4 25,000' 38,000 m 5,000' 46,000 m 76,000' 54,000 m Yearly Production Output 5 30,200,000' 9,200, 000 m 36,223,000',040,000 m 42,237,000' 2,874,000 m Design Material Thickness, actual material thickness can vary + 5 to 0 % 2 Optimized use of steel for designs matching or under this specification. The system may provide means of design in a structurally sound product for higher specifications, but the use of steel may not be fully optimized. 3 Manufacturing, Loading & Storage Minimum Floor Space 4 Shift of 8 hours, 50-minute break per shift, 90% efficiency 5 48 weeks a year

8 Contact Us The Material Optimization Technology (MOT) is a proprietary manufacturing process that combines highly flexible coldforming equipment with advanced material handling, conveyance and assembly technologies into one unique integrated solution. The key driver behind its design is the elimination of material and labor waste to improve cost For more information, please contact us at: info@genesisworldwide.com Toll Free (North America): Phone: + (905) Keele Street, Bldg. B Vaughan, Ontario L6A 0K6 Canada This document has been published for the purpose of providing information of a general nature only. Further, no guarantee, warranty, or any other form of assurance is given as to the accuracy, currency or completeness of the information provided. Accordingly, any reliance on, or use, by you of any information contained within this document for any purpose whatsoever shall be entirely at your own risk, and any liability to you is expressly disclaimed to the maximum extent permitted by law. All Logos are trademarks of Genesis Worldwide Inc. Copyright 2009 Genesis Worldwide Inc. Reproduction of any part of this document is prohibited, except with the prior written consent of Genesis Worldwide Inc.