Client Background
Aluminium profile fabrication plant
Project Challenge
A cutting operation in a profile plant needed to be repeatable, guarded and positioned within an existing line rather than run as a standalone bench operation.
Customer Pain Points
- Cutting length varying between operators
- A manual step sitting inside an otherwise continuous process
- Guarding and access that had grown around the operation rather than being designed
- Material handling before and after the cut
- No consistent record of what was produced
Our Solution
What We Built
A cutting unit built on a pedestal frame and positioned within the profile line. The unit is designed for the section being processed, with the cutting position, the support and the guarding laid out together so the routine tasks can be done without defeating a guard. The photograph on this page shows the unit installed in the plant.
Manufacturing Process
How the Machine Was Built
Operation study
Section, cut specification and line position recorded from the customer's actual process.
Layout
Unit laid out against the existing line, including material approach and removal.
Design
Mechanical, control and safety design carried out together.
Build
Manufactured and assembled at the Vaughan facility.
Try out
Cut proved on customer material before shipment.
Installation
Installed into the existing line and commissioned with the customer's operators.
Supply Chain Coordination
Sourcing and Build
Frame, drive and guarding components are selected against the section and the duty. Contact surfaces are specified non marking where the profile carries a finish.
Quality Control
Checked Before Shipment
- Cut position and length repeatability measured and recorded
- Material support checked through the full cut cycle
- Guarding and access verified against the routine tasks
- Continuous run on customer material before shipment
- Safety functions verified and recorded
Final Result
What the Machine Does Now
The cut happens at a designed position within the line rather than at a bench beside it, with guarding that allows the routine work to be done as intended.
Customer Benefit
Why It Mattered
A manual step inside a continuous process was replaced with a designed unit, and the guarding stopped being something operators had to work around.
Customer identity, section specifications and production figures are not published. Technical discussion is available on request.
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Questions
About This Project
Can you tell us who the customer was?
Customer identity, section specifications and production figures are not published. Technical discussion is available on request.
Could you build the same machine for us?
Not identically, and that is the point. The machine was designed around one customer's part, rate and floor space. The same approach applied to your part produces a different machine.
How long did the project take?
Project duration depends on scope and the build schedule at the time. We are happy to give you a realistic schedule for your own requirement once the scope is defined.
What was proved before the machine shipped?
The checks listed in the quality control section of this page, run at the Vaughan facility. Customer witnessed try out before shipment can be arranged.
How do we start a similar project?
Email [email protected] with the part drawing, the operation and the rate. That is enough for a concept and a defined scope.
Talk to an engineer
Have a Similar Operation
Send the part and describe the step. We will tell you what the same approach would look like applied to your line.