This week will see the completion of Alpha Manufacturing’s’ latest machinery installation as final programming and testing of the new TruBend 7000 Bend Cell takes place.

Purchased alongside a new TruBend 5000 machine as part of a £1 million investment by the precision sheet metal fabricator, the fully automated robotic bend cell will dramatically increase Alpha’s folding capacity. The TruBend Cell allows a new level of flexibility through its high automation and offline programming. Extremely fast and accurate processing speeds allow maximum flexibility, particularly in small batch work.

Key Features:

• X2 faster output than conventional bending cells thanks to synchronized processes
• Automated Load Master Bend loads sheets while production is underway
• Reduced downtime through offline programming
• Automated tool changer makes order processing extremely flexible, particularly when working with small batches
• 6-axis back gauge ensures maximum part flexibility

The 7000 Project

The actual installation of the TruBend Cell has been relatively short having only taken around 3 weeks from early June 2017. However, the project surrounding the new machine has been ongoing for months, while the original strategic plan which lead to its purchase was established years in advance.

Alpha announced this latest investment; £1 million to purchase the TruBend Cell 7000 and TruPunch 5000s12 back in December 2016, shortly after the installation of a TruLaser 3030 Fibre and STOPA Storage machine. Since then, wheels have been in motion at Alpha in preparation for the arrival of the 7000.

An expert with experience of operating the TruBend Cell was needed to program and operate the machine and so Joey Verueco joined the team a full two months prior to its installation. Since then, Joey has worked on pre-programming parts so that there will be no delay in the machine becoming fully operational once installed. He has also spent time co ordinating with Alpha’s existing programming team to ensure that parts are optimised for the machine. Once the machine is operational, Joey will be responsible for all offline programming for the 7000 and will begin to train other team members on its operation.

The two new installations have also had a major impact on the shop floor and Alpha’s design department were busy back in January 2017 re-drawing the entire factory layout to accommodate. Careful consideration was given to machine position to ensure that workflow through the factory was optimised. Existing machines have either been repositioned or in the case of our Pullmax 720 machine; sold to accommodate the latest additions.

Long Term Plans

Although this latest installation clearly offers plenty of immediate advantages in terms of production capacity, it represents something much more significant for the Midlands based manufacturer. The TruBend 7000 Cell installation is a key step in a phased strategic development plan which was set out back in 2015 and has been at the forefront of Alpha’s operational planning ever since. This ambitious plan outlined a set of targets to be achieved by 2020, one of which was the complete automation of Alpha’s manufacturing facility.

The realisation of this plan began way back in July 2016 when Alpha signed off on the purchase of a STOPA automated storage system and Trumpf TruLaser 3030 Fibre machine at a combined cost of £1 million.

The STOPA storage system offers fully automated material handling and material flow with full integration into processing machines. Raw material is loaded into the STOPA storage system and is then picked by a longitudinal moving picker crane and delivered to processing machines as required.

This allows for ultimate efficiency in material handling and stock management, as minimum re order levels can be set and materials automatically replenished as required.

Speaking at the time, Alpha’s Operations Director Paul Clews:

“This installation is the first stage of an automated system which will eventually run the entire length of our factory. By 2020 the majority of our processing machines will be automatically fed by this system. This will not only include our punch and laser machines, but also all folding and panel bending processing will be fully integrated. This will enable all strategic WIP to be managed by the push of a button, maximising efficiency.

The installation will take us away from the conventional tower system which we currently use, as do many of our competitors, allowing long term full management of sheet metal all the way through to complete manufactured parts.”

How the 7000 Cell fits in.

The Trubend 7000 machine was purchased not only because of its complete automation and offline programming capability but also for its ability to easily integrate with the STOPA system. Long term, the STOPA system will run the entire length of Alpha’s factory and will feed all processing machines. The 7000 machine has been strategically positioned so that it can easily be integrated with the STOPA when the time comes for it to be extended. This will mean that the entire process of folding using the 7000 will be offline and automated, from material storage, picking, loading, processing and re-storing.

More than just a new installation, Alpha’s TruBend Cell 7000 project is a landmark moment in a long-term plan set out in 2015 and a clear indication of the direction in which the company will be heading in the coming years.