- Wiedemann NC Turret Punch Presses (Motorum 2044 EZ, Motorum 2048)
- Accurpress Press Brakes (6’, 8’, 10’)
- Autodesk Inventor
Bartco Lighting (Huntington Beach, CA) is a manufacturer of spec-grade linear fluorescent and LED lighting fixtures supplying the world’s hospitals, colleges, museums, retail stores, office buildings, and similar institutions. Recently the company launched a comprehensive Lean Six Sigma program designed to improve manufacturing speed, efficiency and productivity.
Turret Punch Press Programming
“Previously jobs were nested only with like-parts,” “Recently customer demand has moved to more requests smaller lot sizes. Therefore, auto-nesting of mixed part lots makes a lot of sense for us.”
Director of Operations,
A study revealed 40% of current Work Orders were for 20 pieces or less – an ideal scenario for mixed Work Order nesting. At the same time Bartco had been using the same programmer (the metal shop supervisor) for several years. When this person became less available, the company had to utilize a second resource for the task.
SimTrans was identified as the solution. SimTrans is an online transaction manager bridging SigmaNEST and Material Requirement Planning (MRP) systems, order entry or other management software solutions. It was decided that Bartco would use SimTrans to mix nests with multiple Work Orders rather than continue to schedule like-products on dedicated blank sizes. Similarly, the automated part programming feature of SimTrans/SigmaNest within a nest eliminated the need for a traditional NC programmer.
Today Bartco is in the early stages of SimTrans implementation. Future plans include the complete integration of MRP, bending, programming, and automatic nesting.
Press Brake Programming
Bartco launched a Single Minute Exchange of Die (SMED) initiative to reduce tooling change-over time. A primary component of the project involved moving offline as many operations as possible with programming representing the most significant opportunity for improvement.
The exercise allowed Bartco to better understand, control, and gain press brake capacity. The next move was to schedule to press brake capacity and then back schedule the turret presses. The company did not try to schedule to turret capacity, but rather allowed the brake schedule to pull in production from the turrets.
SigmaBEND software was a key component to the project’s success in reducing setup time from 25 minutes to 5 minutes or less. Implementing SigmaBEND, combined with an ability to schedule to press brake rather than turret presses improved on-time completion in the Metal Shop from 20% to a staggering 95%.