With the most innovative processing

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Dayna Goodwin
6 years ago
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[ Experience] is part of Finluc Group whose various businesses are active in the market of boiler manufacturing, heating system construction and sheet processing for third parties.

by Fabrizio Garnero Automation and laser are the key words With the most innovative processing technologies for laser cutting and welding, is currently responsible for large scale semi-processed

1 [ Experience] is part of Finluc Group whose various businesses are active in the market of boiler manufacturing, heating system construction and sheet processing for third parties. In particular, Verona Lamiere was established in 1989 as a company mainly dedicated to sheet cutting and bending. by Fabrizio Garnero Automation and laser are the key words With the most innovative processing technologies for laser cutting and welding, is currently responsible for large scale semi-processed parts orders made from metal sheets. This definition implies that we don t just manage the cut and bent sheet, but we also cover the entire production process for semi-processed parts explains Mr. Remigio Lucchini, owner of Verona Lamiere. For example, we are starting to manufacture a very important order to make 60,000 doors that we will supply already finished to customers. So, we are talking about laser cut, formed and assembled parts in metal sheets, and we also manage varnishing and gluing of the glass with outsourced partners. Therefore the customer receives the finished product, packaged, labelled and ready for the storage warehouse. For us, this means being responsible for the order: or rather also managing the outsourced activities, interfacing with the client to follow and support him in all his needs, both in terms of service quality and goods management; in short, coordinating every single task. A supporting element of the philosophy followed by the company is in fact based on the specialisation in various processing stages, the reason for which it avails of collaboration with trustworthy partners who ensure professionalism and a quality product for the production of accessory or complementary parts. In this sense, a series of business partnerships were set up with companies working in the Veronese hinterland to complete the service offered to customers. Valid support already at design phase The concept of partnership that also, and particularly, extends to its customers, to ensure valid support already in the design phase, serious attention to qualitative requirement specifications and the study of optimal technical solutions to minimise production costs, as well as joint analysis to determine an optimal quality/cost ratio based on specific needs. We are working a lot to create ever-closer contact between our technical office and that of our customers explains Engineer Gaetano Carcano, General Manager of the company also because it is now fundamental from a strategic point of view, especially for those is currently responsible for large scale semiprocessed parts orders made from metal sheets MAY 2006 No. 127

The laser cutting cell with the Platino system installed in. companies without internal skills in metal sheet processing and that ensures our experience and our contribution gives guaranteed success.

and optimise the design based on the actual feasibility with our machinery.

2 The laser cutting cell with the Platino system installed in. companies without internal skills in metal sheet processing and that ensures our experience and our contribution gives guaranteed success. In some cases, in fact, we get rough, general drawings, with instructions on how the part must be made but it is up to us to industrialise it, or rather, analyse it from a technical/economic aspect and optimise the design based on the actual feasibility with our machinery. Recently, for example, we designed a line of ad hoc cabinets from scratch for a customer; in this case, we got a general sketch from the planner used as the basis for the actual design and production. Differentiation for end markets The main end markets for processes are the boiler, vending machines, office furniture, white goods in small quantities and the production of semi-processed structural parts for operating and industrial machinery sectors. With such a wide-ranging market explains Mr. Lucchini again our strategy is to favour orders characterised by medium to high quantities. Having seriously invested in automation and laser technology, it is best to have as little machine downtime as possible, the reason for which our batch limit is one hundred parts. Given today s low profit margins, it is fundamental to always have the laser cutting systems moving; this is why we prefer big batches, even if we are always willing to work with smaller quantities. The various end sectors for also includes that of small quantities of electrical appliances, intending for example kitchens for communities with thousands of pieces per year or machines to distribute beverages and coffee. Another important sector is heating because ICI Caldaie, also part of Finluc Group, passes all its boiler processing and heating system orders to. Another interesting sector for us - recalls Carcano is industrial machines such as forklifts or the transport sector, where we work for leading companies on the market. In this case, high strength steel sheets such as Domex and Weldox, even if we generally work more with carbon steel. However, we process all types of sheets, from polished to galvanised to stainless steel and aluminium and we always purchase high quality materials, since we consider this an important part of our successful processes. In the workshop, twelve automatic lines process the sheets is convinced the key unbeatable if you want to be competitive on the subcontractor's metal sheet processing market is the continuous modernisation of the systems park and technological innovation. For this reason, as previously mentioned by Mr. Lucchini, The 3D Rapido laser system by Prima Industrie installed in Verona Lamiere. F O R M I N G MAY 2006 No. 127

[ Experience] Automation of the processes and laser technology are the characterising elements of Verona Lamiere business.

the automation of processes and laser technology are the characterising elements of the company s business which found in the Prima Industrie Platino and Rapido laser cutting systems two reliable

However, it is best to Flash Being responsible for an order not only means we manage the cut and bent sheet, but fully manage the production procedure of the semi-processed part.

3 [ Experience] Automation of the processes and laser technology are the characterising elements of Verona Lamiere business. The most automated part of the company is definitely cutting, a division with 12 automatic lines installed for sheet processing, including punching cells and laser cutting systems. the automation of processes and laser technology are the characterising elements of the company s business which found in the Prima Industrie Platino and Rapido laser cutting systems two reliable systems enabling concentration on certain cutting and cutting/welding activities. However, it is best to Flash Being responsible for an order not only means we manage the cut and bent sheet, but fully manage the production procedure of the semi-processed part. proceed in an orderly manner and give a general framework of how the company is organised in terms of production. In fact, the workshop is organised into four macro-divisions: a division dedicated to cutting operations, which works over three shifts; the bending division which works over two shifts and mainly in manual mode despite having a robotic bending cell; an assembly division, which conducts typically manual operations such as punching and works over one shift; the moulding division, with presses installed up to 500 t and working, according to the work load, over one or two shifts. The most automated part of the company - explains Carcano is definitely cutting and panelling, a division with 12 automatic lines installed for sheet processing, with punching cells, laser cutting systems and panelling systems. Despite the high level of automation however, our philosophy is to avoid, as feasibly possible, working completely unstaffed; since we have 12 automatic machines, having at least two or three operators present seems justified Being responsible for an order also means managing the outsourced activities, interfacing with the client to follow and support him in all his needs, both in terms of service quality and goods management MAY 2006 NO. 127

The Platino flat laser cutting system installed in specifically for cutting average thicknesses, i.e. 8, 10 and 12 mm.

The moulding division has presses installed up to 500 t that work, based on the work load, over one or two shifts.

This is the reason why having one or two operators always present in production is justified.

if, thanks to the Rapido system the company was also introduced to the laser welding market, but we'll get back to this later.

4 The Platino flat laser cutting system installed in specifically for cutting average thicknesses, i.e. 8, 10 and 12 mm. The bending division works over two shifts and mainly in manual mode despite having a bending robotic cell. The moulding division has presses installed up to 500 t that work, based on the work load, over one or two shifts. because if there are faults or malfunctions they can ensure extremely fast reaction times and reduce risk of loosing precious hours of work. This is the reason why having one or two operators always present in production is justified. Laser, winning and revolutionary technology As we have seen, one of the technologies assisting 's business is laser technology, which is mostly applied by the company in cutting processes, even if, thanks to the Rapido system the company was also introduced to the laser welding market, but we'll get back to this later. What is however important to highlight is the strategic aspect that the introduction of this laser technology has had on the company. Laser in fact - explains Lucchini has allowed us to increase operational flexibility and reach the famous 50 parts that we referred to before and especially to create more complex products to give added value to the company and the imagination compared to what is feasible with more traditional processes such as punching and shearing. Overall, this expands our reference market also thanks to the possibility avails of an assembly division, where typically manual operations are conducted over one shift. F O R M I N G MAY 2006 NO

[ Experience] takes advantage of the positive features of each machine while trying to orientate it and direct it to the applications that best adapt to specific peculiarities and potential.

The purchase of each machine is due to a specific requirement A particular aspect of is that the machinery installed is fairly wide-ranging both for the type of machinery and the names of the

5 [ Experience] takes advantage of the positive features of each machine while trying to orientate it and direct it to the applications that best adapt to specific peculiarities and potential. of helping the customer to make his product more appealing. The purchase of each machine is due to a specific requirement A particular aspect of is that the machinery installed is fairly wide-ranging both for the type of machinery and the names of the machinery manufacturers. Even if machines today are all fairly similar, they always have different characteristics, whether good or bad, from one another. Since we have quite a lot of machinery, because there aren t that many sub-contractors in Italy with twelve automatic systems to process sheeting, from the very start we have always tried to take advantage of the positive features of each machine, trying to orientate it and dedicate it to applications that best adapt to its specific peculiarities and potential says Mr. Lucchini. Based on contingent needs when making the purchase, chose the most suitable machine indicated to meet specific requirements, independent of the manufacturer and from that moment the machine will be mostly dedicated to a precise application. Rather than an initial, precise choice, that of dedicated machinery, it is a philosophy matured over time explains Carcano. When an order is launched, it is decided where to manufacture it, also based on the various machine loads, but we are always careful to ensure that certain types of material go on certain systems for which they are more or less dedicated. Therefore, all thin sheets are always on one type of machine and all stainless steel on another system, and so on. Among other things, we realised that such management leads to more regular system wear. In fact, if for example a machine is dedicated only to stainless steel, this will definitely be a less worn machine compared to one used to cut carbon steel, since the cutting process for stainless steel is decisively cleaner. Experience cannot be bought and must be gained over time Installation of the Prima Industrie Rapido threedimensional system is exactly what this philosophy is about. In this case - recalls Lucchini there were two reasons for our purchase: firstly, a request by one of our important By simply assembling the welding head set up by Prima Industrie, Rapido allows you to even meet welding requirements on profiled parts MAY 2006 No. 127

Laser welding requires templates that guarantee an extremely precise approach to the parts to weld Flash Given today's extremely low profit margins, it is fundamental to always have the laser cutting

customers, but especially our willingness to evolve and start diversifying our business which was purely flat cut based.

6 Laser welding requires templates that guarantee an extremely precise approach to the parts to weld Flash Given today's extremely low profit margins, it is fundamental to always have the laser cutting systems moving; therefore big batches are preferred, even if we never refuse smaller quantities. customers, but especially our willingness to evolve and start diversifying our business which was purely flat cut based. It also often happened that the work conducted using the Rapido contributes to increasing the work of the other machines because three-dimensional processes are a great sales pitch. Another aspect, but none the less important, is that the Rapido, by simply assembling the welding head developed by Prima Industrie, allows us to also meet welding requirements on profiled parts. We would like to work more with this sector, since it is extremely fertile ground with enormous potential, but there is still a lack of culture and mentality and laser welding is frowned upon. One limitation is definitely costs given the process requires templates to guarantee an extremely precise approach of the parts to weld and that, therefore, require certain willingness to invest. We are however convinced that laser welding will play an important role in the future, especially to increase the added value of orders. The objective is therefore to saturate the Rapido system with other cutting activities but especially welding. For over a year now, we have been working in the professional sector of laser welding where the aesthetic appearance of the bead is important. The HOW welding unit enables welding from a distance over 100 mm, thereby avoiding interference with equipment. F O R M I N G MAY 2006 NO

[ Experience] For over a year has been working in the professional sector of laser welding where the aesthetic appearance of the bead is important.

compared to that of other competitors. Even though the other manufacturers were serious and reliable, I am fully convinced that experience cannot be bought and has to be gained over time.

7 [ Experience] For over a year has been working in the professional sector of laser welding where the aesthetic appearance of the bead is important. Lastly, I would like to add - interjects Lucchini that the choice of 3D laser made three years ago favoured Prima Industrie particularly due to their experience already in this type of system compared to that of other competitors. Even though the other manufacturers were serious and reliable, I am fully convinced that experience cannot be bought and has to be gained over time. Welding at a distance over 100 mm from the surface The HOW welding unit, the name of the head developed by Prima Industrie, enables welding at a distance over 100 mm, thereby avoiding interference with the equipment. It is particularly suitable for welding in sections (stitch welding) and is easily inter-changeable with the cutting unit. The HOW unit includes a coupling flange on the machine head, an air and gas connection, a mirror (with focus length 200 mm) to focus the ray on the part to process and cross-jet protection of the optics. A removable tube enables coverage gas adduction and plasma elimination and can be assembled in four different positions, based on the advancement direction. The HOW unit also Flash The objective is therefore to saturate the Rapido system not with other cutting activities but especially welding. We have been working for over a year in the professional sector of aesthetic laser welding. The HOW welding unit assembled on the Prima Industrie Rapido system MAY 2006 NO. 127

10 and 12 mm, and the Platino, while also cutting higher thicknesses, seemed most suitable for this operation thanks to the excellent mechanics, as well as the machine with the best quality/price

8 One of the reasons why the Platino system was chosen is the possibility of accessing the machine work area from the front. Flash To be competitive on the sub-contracting, sheet processing market, you need a continuously updated systems park and technological innovation. 10 and 12 mm, and the Platino, while also cutting higher thicknesses, seemed most suitable for this operation thanks to the excellent mechanics, as well as the machine with the best quality/price ratio. Another reason that influenced the overall choice was the possibility of having front access to the work area of the machine because, even though the machine has a vertical sheets warehouse, the sheets often have to be loaded manually, especially when making slightly profiled parts. In this case, we need to supply them by hand because when just a few parts are being manufactured automatic loading and unloading is pointless. This is definitely a big convenience and one of the reasons why we preferred the Platino to other similar systems. The Platino system installed in is equipped with a vertical warehouse. includes self-learning programming equipment. A reliable flat laser system specifically for medium thickness cuts The second Prima Industrie system continues Mr. Lucchini was instead installed simply because we needed a reliable flat laser system specifically for medium thickness cuts, i.e. 8, F O R M I N G MAY 2006 No

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