Increase Throughput on Your Rollforming Line Now!

by Mark Robins | 3 April 2023 12:00 am

Why is it sitting idle? Perhaps it is a finicky machine that is time consuming to set up to get a good profile. Another delay could be the time it takes to load and thread the line with the coil. Maybe it is the time spent packaging the product. There are options to consider that will help increase your throughput.

New Equipment

Investing in new equipment can increase your production. Replacing your single-mandrel uncoiler with a double end will bring coil changes down to a few minutes. Switching your stationary shear to a flying shear will increase your panel line production. Consider an inline shrink wrapper for finished packs or a stacking system that can discharge the stack of panels out of the way faster, allowing your rollforming line to continue to run. Unfortunately, purchasing new equipment isn’t always in the budget and won’t happen quickly. Lead times on new manufacturing equipment have never been longer.

Let’s look at production-increasing options that tend to get overlooked but can be implemented in a few weeks or even days. Upgrading your controls is a beneficial option. If your operators spend extra time entering each order at the line, it may be time to upgrade your control system. Multi-batch controls can display multiple orders and allow the operator to make changes at the rollforming line. If the control system is networkable, orders can be downloaded from the office ERP or design software directly to the machine, saving production time and minimizing the chance of clerical errors since the data is entered once. When downloading order information to the line, additional data can be sent that allows an integrated printer to produce packing lists and bundle tags at the production line for completed orders.

How much of your production downtime is caused by maintenance issues or breakdowns? With the labor shortage, many companies feel forced to minimize or eliminate maintenance departments, pushing that responsibility on the operators. The cost of downtime and emergency technician trips can be expensive. Maintenance programs or contracts from the OEM can be a great way to perform preventative maintenance and keep the machine running in top condition.

Typically, these contracts are less expensive than paying technicians to travel on demand because they can be scheduled in advance and at regular intervals. While at your facility, it’s a great opportunity for the technician to train new operators, refresh the knowledge of your existing staff, and review your spare parts inventory to recommend any new parts that may be a problem due to supply chain delays.

Increasing production from your existing line does not necessarily mean purchasing newer, faster equipment. It may be a new streamlined process or rethinking how you maintain your equipment. Reach out to your OEM or controls manufacturer to find out how they can help … now.

Matt Werner is senior manager of global marketing and sales at The Bradbury Co. Inc., Moundridge, Kan. To learn more, call (620) 747-0810, email matwer@bradburyco.com[1] or visit www.bradburygroup.com[2].

Source URL: https://www.metalconstructionnews.com/articles/increase-throughput-on-your-rollforming-line-now/

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