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No. 2 - 10/2004
INSPIRED FOR TUBE
UK
THE TUBE PROCESSING TECHNOLOGY
Contents
INSPIRED FOR TUBE
Also available in pdf format on:
Contents
www.blmgroup.com
INSPIRED FOR TUBE
4
Bending & Endforming - Automotive
Specialists in innovative
tube working
6
Lasertube - Furnishing
8
Bending and Endforming - Heating
“The Finishing Touch”
The heat is up!
10
Laser Sheet & Tube - The Sub Contractor
From client perception to prototype
12
Cutting - Forming
A battle won
14
BLM GROUP UK - The Group
Hello BLM GROUP UK!
INSPIRED FOR TUBE
Edited by:
2
Public Relations Division
BLM GROUP
Emanuela Colombo
Antonio Farese
Cristina Guzzetti
e-mail: [email protected]
tel: +39 031 7070 200
Produced by:
BLM GROUP
Via Selvaregina 30
22063 Cantu (CO) Italy
www.blmgroup.com
Number
No.2 10/2004
Inspired for Tube
Graphic Design
Studio Grafico Page
Vincenzo Rosa
Fabrizio Santini
Printed by:
Arti grafiche maspero
Fontana & c SpA
Cermenate (CO)
Photography:
BLM GROUP
DMM srl
Marchesi & C
Baender Blech Rohre
Reproduction of all or part of articles or
illustrations published in this edition cannot be used without prior authorisation.
Gian Maria Gros-Pietro, economist, has recently been
appointed Director of the Department of Economic
Science and Trade of the Luiss University in Rome.
He has been a Director of the Institute of Research
and Development for over twenty years. The Institute
is the most important centre of the National Council
for Research in Economics.
He has been a consultant to various Italian Government Ministries, especially in the field of industrial politics, since 1970.
In 1994 he became a member of the Committee for
Global Consultation and Guarantees for Privatisation.
In 1997 he was nominated President of the IRI with
the task of privatisation of companies and closure.
In 1999 he became President of ENI to oversee transition to a free energy market within Italy.
In 2002 he was nominated President of Autostrade,
a completely private company, and from December
2003 he was also President of Federtrasporto.
He has been an economic consultant to UCIMU (The
Italian Machine Tool Trade Association), since the early 1980’s and has worked with the BLM GROUP for
many years; he is Vice President of ADIGE SALA SpA
and a Director of BLM GROUP UK Ltd.
INSPIRED FOR TUBE
industry. The market, therefore, is not overwhelmed
by fashion, not even by technology; it is dominated
by those companies who find the best method of
satisfying their customers - the more this is true, the
more stable is the company. Fashion and sophistication only prosper for a while, true growth - and
dependability - is built over time. And what can
we say about the supposed difficulties of these family concerns competing in developing markets?
Wal-Mart is owned by the Waltons. The richest man
in the world, Bill Gates, maintains
sole control of Microsoft; the same
applies to his arch rival, Larry Ellison,
the Oracle owner. In Europe, the
most successful automotive group,
BMW, is owned by the Quandt family, and the most famous tyre company in the world - Michelin - is also
owned by a single family. In India,
industrial dynasties are competitors
in economic development rivalling
the Chinese. It is possible to continue with these examples; there are
many. What is the unique strength
these family groups possess? Dedication over a long time. These are
words missing from a strict definition of somewhat
impersonal capitalism. Economic growth creates
worldwide well-being but is also creates problems.
The biggest of these is the need for conservation
of natural resources which should be for the benefit of all. A more correct response must be to develop technologies appropriate to each specific
need. Then those highly competitive companies
can unite and harness their capacity to accommodate the skills of a diverse population.
Gian Maria Gros-Pietro
Vice-President ADIGE SALA S.p.A.
Head of Department of Economics and Business
LUISS University, Rome
No. 2 - october 2004
Opinion
If one looks at the ranking of the top 100 American companies today, more than half did not exist
twenty years ago. This simple observation says two
things. Firstly, the American economy is the motor
that drives the rest of the world as it is the most dynamic and has the capacity to subject itself to continual reflection and renewal. Secondly, it can be
considered that, as the economy is always changing rapidly, there is also always room for companies
to climb up the table. For example, in Europe, Ireland has been a catalyst for a spectacular increase in growth in recent
years. When they joined the European Union, they were one of the
poorest in the Community; today their
output per capita is superior to that
of the United Kingdom. Naturally, if
one wishes to see the most astonishing growth phenomena one must
look towards Asia. The largest and
most populated continent in the
world is also the most ancient and
complex. Their people did inherit their
extraordinary capacity for evolution.
Consider China. Their influence on
overall world trade is limited, even
compared with the UK and Italy, and is relatively
static. But, in dynamic terms, their contribution to
the world economy between 2003 and 2006 will be
equal to that of Japan. If its contribution to the growth
in world imports is considered over the same period, China is superior in net growth to the United
States and the Euro zone put together with a value nearly three times that of Japan; from this perspective, China is easily number one. Turning to the
American ranking, it can be noted that, with all the
talk of technology, the highest turnover company is
a commercial company in the food industry: WalMart. In the leading group, there is a small number
of companies in the medium technology sectors
such as petroleum and refining and the automobile
3
The Daimler-Chrysler Group and its subsidiaries is S.M.A.
INSPIRED FOR TUBE
Automotive
Metalltechnik’s most important client.
Specialists in innovative
tube working
Klaus Liehr.
“We are German and we want to stay in Germany”
is explained firmly by Klaus Liehr from his bright
glass walled office in S.M.A. Metalltechnik in Backnang. Herr Liehr is the Managing Director and
clearly shows that the company has no nervousness of foreign competition in their own planned
future development.
Over 210 employees, including 10 apprentices,
are helping the company achieve its strategic objectives. Tubing and tubular systems for the automotive industry are produced on this site and,
as the giant poster of a Mercedes at the entrance
indicates, Daimler Benz Group and its subsidiaries
are its most important clients.
Complex tubular components
On our tour through the plant we can see a large
number of bending machines, with varying levels of automation, producing complex tubular
components - one on small batches for the Maybach, the largest model in the Daimler-Chrysler
range. Klaus Strobel, the Production Manager, told us “We purchased our first BLM bending machine in 1997 - a MULTIPLA.
Since then we have bought a further ten DYNAMO machines and, in July this year, a SWING
tube bending machine was delivered for tube
up to 35mm diameter, with both left and right
bending capability”.
S.M.A.’s speciality : Connections without brazing for automotive clients.
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Automotive
INSPIRED FOR TUBE
Automatic forming line with three robot controlled AST80NC endformers.
The DYNAMO tube bending machine is the perfect example of the reliability and performance
available from BLM machines. “On this machine,
we bend pipe from the air conditioning system for
the Class C Mercedes. We form an extremely
complex aluminium tube with various 180 degree
bends, which it is not possible to do on another
machine”.
Another application for BLM machines is found
in their end forming area at a technical level that
Klaus Strobel defines as “impossible”, involving
a BLM AST80NC multi-station endformer. “It has
been possible to endform and produce very complex tubular components to a very high standard
using multiple tools mounted on the same machine,” says Klaus Strobel.” In fact, because of
this very technology the S.M.A. is able to produce
tube joints, connections and flanges without additional brazing operations”.
A small revolution
There has been a minor revolution, from a technical production viewpoint, in the forming of our
components. This is particularly valid when producing air conditioning pipes without brazing,”
states Klaus Strobel. “What’s specially interesting
is that we have eliminated the use of gaskets.”
Simplification: Reducing complex work processes to simple procedures. This is Metalltechnik’s
speciality.
Note: by kind permission of Bander Bleche Rohre,
September 2004.
Klaus Strobel.
No. 2 - october 2004
Using the machines for top quality
requirements
“In our production process, we use many different machines from different suppliers but we consider BLM machines to be of the highest quality
possible. We can confirm that the balance between price and performance is absolutely correct in regard to BLM machines.
The Italian company was the first to market with
a tube bender with both automatic loading and
unloading as a fully integrated system - at a sensible price (the Dynamic) “Klaus Strobel affirms.
“We are entirely satisfied with the reliability of the
BLM machines especially when you consider that
the bending machines and endformers are operating on a three shift system, seven days a week.
They are extremely robust and their straightforward construction allows us to do maintenance
on them less often than normal”.
5
DMM create custom-designed or standard
ranges with no quality compromise
INSPIRED FOR TUBE
Furniture
“The Final Touch”
“To produce hundreds of pieces of furniture as if
they were individually made, we combine sophisticated manufacturing methods such as laser tube
cutting, with more traditional craft methods such as
end-finishing by hand -the final touch-”. These words
come from Gian Luca Malipiero, who is the Marketing Director of DMM di Montecchio di Sant’ Angelo in Lizzola (PU). The company is an extremely
modern manufacturer but with origins deeply rooted within the craft industry. By preserving its flexibility and attention to detail it has retained the ultimate respect of its clients and product integrity.
Complete-integration is the “secret”
DMM began life as a manufacturer of decorative
metal components for furniture, and this still remains their core business in the furniture sector.
“We produce components and accessories for
the whole furniture industry, the kitchen sector in
particular,” affirmed Signor Malipiero. “In practice, we are able to turn full circle in providing
pieces for kitchens, lounges and dining rooms up
6
to complete bar and shop furnishing.” It’s an extremely comprehensive range of products and
DMM are able to supply their clients with whatever they want in quick time.
The secret? There is complete integration of the
production software with CAD and CAM programming, dramatically reducing lead times. “In
the course of the last six years, for example,” Signor Malipiero relates, “there has been an 80% reduction in design times for our main product
ranges, the process is now completely automated. It must be emphasised that there is no real
standard catalogue - it’s down to client choice with infinite combinations possible for customised
designs or for adaptations from a basic product.”
From design idea to perfect prototype
Designers are always the first link in the chain in
DMM. “This is especially true in the kitchen sector where clients only give us the bare bones of
an idea and basic dimensions,” says Mailpiero
“and ask us to solve all the logistics”.
Furniture
INSPIRED FOR TUBE
Reducing lead times
DMM by investing in the ADIGE Lasertube 651
system have not only added value to the design
aesthetic of their products, but also achieved
massive cost reductions and huge benefits in
the increased productivity and flexibility that the
system offers.
Previously, their process involved several individual traditional operations such as: sawing,
drilling, punching, notching, deburring etc… Now
components can be ‘complete-machined’ on one
machine, fully automatically, to the highest level
of accuracy and repeatability.
Eliminating 5 or 6 traditional processes has cut
lead times significantly- from ten days to four days.
It has also eliminated the touch-time and handling-time between processes and the accumulative error associated with consecutive machining operations.
In today’s, fiercely competitive, furniture industry,
where the difference between success and failure is not measured in hundredths of a millimetre, creating an aesthetically perfect, defect free
product is vitally important. With the technique
and technology of the ADIGE laser tube cutting
system DMM is able to do just this, within the time
and cost the market demands
No. 2 - october 2004
Lasers and furniture solutions
DMM have relied heavily on high technology
equipment to achieve its product strategy. The
pick of these is their laser tube cutting system.
“An ADIGE Lasertube 651 was installed more
than 4 years ago. “continued Malipiero” In the
beginning, we had to adopt new working practices and encourage our designers to fully recognise and completely understand the immense
potential of the new laser tube cutting technology. Freed from traditional manufacturing restrictions, our designers now have an entirely
new ‘plain-sheet-of-paper’ way of designing
frames and assemblies based on best-for-design, best-for-manufacture and best-for-product.
Creative and innovative designs that were previously thought impossible are now practical and
reality with laser tube cutting technology”.
7
A radical review of manufacturing methods and production
efficiency at Worcester Heat Systems
INSPIRED FOR TUBE
Heating
The heat is up!
A radical review of manufacturing methods and production efficiency has seen Worcester Heat Systems, part of the Bosch Thermotechnik Division, Europe’s largest manufacturer of combination gas
boilers, completely replacing a copper pipe manufacturing facility. The new facility includes 4 new
BLM CNC Tube Processing machines, which have
replaced 3 semi-automatic benders, 2 end formers, an automatic saw and a de-burrer. So far,
process efficiency has been raised by over 25%,
scrap reduced and product quality improved to
such an extent that further automation for subsequent manufacturing and assembly processes is
now possible. A vital part of the production is based
around the design, development and forming of
copper tube components, which, thanks to the installation of the new BLM Machines, now occupies
20% less floor space than before.
Producing from Coil
At the Warndon site, UK, Max Hausler, Manufacturing Development Manager and Mike Ross,
Senior Production Engineer described the integration of the new cell, which has been bought
on stream in stages, as the old facility was gradually de-commissioned. “Originally, production
was based on the use of straight stock lengths
of tube, which were cut to the appropriate length
on a saw and then manually transferred and
loaded onto 5 semi-automatic benders. Whilst
this worked reasonably well, we incurred the
cost of scrap and too much manual handling.
To resolve this problem, we decided to switch
completely from straight stock lengths to tube
supplied in coils. This gave us a continuous
stream of material i.e. up to 1.9 kilometres of 6
mm diameter tube on a single coil.
“Cut and break”
The swarf-free “cut and break” system of the BLM
Process and the BLM Planet provides a clean
burr-free cut, eliminating previously necessary
end-finishing operations. The ability to produce
8
PLANET: a continuous straeam of material
from coil up to 1900 m.
bent parts of a consistent quality was critical to
our plans, as we wanted to automate our brazing
procedures. The new BLM CNC Benders have
given us such repeatable bend accuracy that we
have been able to replace the majority of our manual brazing operations with a single automatic
brazing system.
“Stick bending”
“For bending the more complex copper pipes,
we use the BLM Swing CNC Bender, which can
execute both left and right-hand bends in automatic cycle of the same tube. It is fitted with an
automatic loading and unloading system, so can
be left to run for long periods with minimal supervision.
“As well as bending individual components, we
also use the Swing for “stick bending” ie. bend-
Heating
INSPIRED FOR TUBE
AST35NC: to control closely the quality
copper pipes.
of shape and repeatability.
ing a series of the same component in a continuous stick from a single stock length, which we
then cut into individual components. This process
maximises bending output and minimises scrap.
“We can make use of the BLM Swing’s versatility
and flexibility further, by mounting up to four different tooling options at the same time.
Thus we can process four different tube diameters or different bend radii with minimal tool
change, ideally suiting smaller batch sizes. “The
fourth machine we purchased, was the BLM
AST35NC CNC Tube End Forming machine. We
have an extremely wide and diverse range of endforms, from the simple to the very complicated,
and we wanted to control closely the quality of
shape and repeatability.
The feeds and speeds of the AST35NC are set
and controlled by its CNC System, thus guaran-
teeing the highest degree of accuracy, whatever
the complexity of the end-form. Its 6-station rotary head, including one head with machining capabilities, allows virtually limitless end-forming operations to be carried out with minimal tool
change”.
‘Continuous Improvement’
Max Hausler concluded, “We are committed to
‘Continuous Improvement’ in new technology,
people skills and new product development. We
offer our customers the best possible product and
in turn, expect nothing less than commitment and
total support from our suppliers.
The adoption of the BLM machines simply confirms our willingness to undertake radical change
for the better and our determination to maintain
our position as market leaders”.
No. 2 - october 2004
SWING: for bending the most complex
9
A combined sheet/tube laser cutting system enables Marchesi & C
INSPIRED FOR TUBE
The Sub-Contractor
to be quick and flexible in their response to customers’ demands.
From client perception
to prototype
Marchesi & C srl are among the most qualified
manufacturers of low volume automotive chassis in Italy.
The Modenese company has been manufacturing chassis for all the most prestigious Italian cars since 1965 including Lamborghini (from
Miura through to Countach) with whom they
have a very close relationship, BMW M1, the
Lancia Stratos E037, De Tomaso, Pantera, Pagani Automobili, Ferrari and Maserati. They have
constructed over 20,000 chassis either in aluminium or steel, in sheet or tube.
Three dimensional detail of the complex Snow Cat framework.
10
Labour saving and well
researched methods
Today, the field of automotive chassis has been
transformed with a reduction in manufacturing
problems from this increased benefits in more
varied production modern-day solutions.
“The experience acquired, “Signor Marchesi
states,” has put us at the cutting edge, both in
our continued cooperation with the automobile
manufacturers and in the problems they face.
Overall, the most fundamental aspect of our
work is in converting our clients ideas into pro-
The Sub-Contractor
Some Prinoth/Leitner completely assembled chassis.
totypes”. The basis for this is the visual and mental capacity of Marchesi technicians to produce
the most adaptable labour saving methods possible, whilst forming a real design-partnership
with the automotive manufacturers, thereby creating the undoubted benefits in quality and production cost reductions.
promise - in one operation cutting tube and then,
if needed, using the system for cutting sheet.
To us, the ADILAS 2 represents the best possible solution to our particular needs”.
A genuine compromise
Marchesi & C now have two ADILAS 2 systems
installed, processing flat sheet, tube and sections. But how significant to them is it to have
a hybrid system rather than systems, dedicated to tube or sheet.
“It’s a matter of flexibility”, stated Marchesi.
“Looking at it, we see the best possible com-
First experience with “the Cat”
The frame of the “Snow Cat” produced by
Prinoth/Leitner was an important and relevant
production experience for Marchesi. They used
a laser to cut the tubular structure and were able
to achieve real benefits in cutting high precision
profiles.
They had previously faced considerable difficulties in machining thick wall tubes in tough
materials.
Numerous components were either plasma cut
or sawn involving, long cycle times, the cleaning up of each part manually, and poor accuracy and repeatability.
Marchesi & C is an extremely good example of
a company that has integrated high technology applications, in an innovative way, without
losing sight of their production imperative.
“We don’t want to lose our creation of real added
value coupled to our wealth of experience
gained over 50 years of production. The basis
of all our work is to be inventive and to understand and satisfy our customers’ needs.
Air conditioning
ducting produced from
tube and sheet cut by
ADILAS 2
No. 2 - october 2004
Associated with BLM GROUP since 1985
Marchesi & C have had a long relationship with
BLM, employing their laser technology in 1985
when they installed the first laser sheet cutting
system.
This has recently been replaced with an innovative combined laser system for sheet and tube
- ADILAS 2 “This new system has enabled us
to be very speedy and flexible in our response
to our clients, “said Signor Bonara, “also improving the product precision and repeatability, the machined profiles are much more defined
and production time for the chassis are significantly reduced”.
INSPIRED FOR TUBE
Sheet laser cutting with ADILAS 2.
11
The key to UNIVER’s production: combining quality, price and delivery
successfully, to compete with Chinese products.
INSPIRED FOR TUBE
Stampings
A winning bet.
CM601: Cutting two bars simultaneously.
When competing directly with low-value products
from Asia, you cannot make mistakes. The continuing success of Univers Srl, clearly demonstrates
that aggressive competition, from cheap-labour
countries, can be met most effectively by long-term
strategies, technological investment and a demonic
attention to the right combination of quality, price
and delivery in a mature marketplace.
12
Based at Gussago in the Italian province of Brescia, Univers produces valves, flanges and turned
parts in brass. A member of the Bonomi Group,
based in Lumezzane, founded in 1901, it now employs over 230 people and last year’s turnover exceeded €70 million.
Other Group members include famous international companies such as Rubinetterie Bresciane
(RB), Valbia and Vapres. The group specialises
in the production of taps, and ball valves in brass
and steel for water, gas and pneumatic applications for the building, civil engineering and industrial sectors. Univers’s production capacity
and high technological capability are used both
within the group and for sub-contracting. Univers
produces all forms of small turned parts and fittings to customer specification, particularly for the
brass stampings sector, where they have a vast
amount of market experience.
3000 stampings per hour
Remaining highly competitive with low value products is a winner for Univers thanks to intense and
continual investment in high technology and automatic production lines covering every aspect
of their production process. From tube to bar, from
cold stamping to deburring, from metalworking
to finishing.
Stampings
INSPIRED FOR TUBE
this guarantees the quality of our end product.
We also achieve significantly better material optimisation and reductions in final trimming and finishing operations”.
Recent investments have included three ADIGE
CM601 two bar automatic sawing machines, to
complement the two CM501’s and a CM500 saw,
previously installed.
Having the capability of cutting two bars at the
same time on the new CM601’s has now dramatically increased the flow of cut billets to the
stamping presses - each press can produce in
excess of 3000 components an hour.
“We are cutting bar from 25mm to 50mm in diameter, usually in brass. The ADIGE cuts our billets accurately and automatically without burrs,
The search for optimum quality.
Univers runs a two shift production and the reliability and performance of the ADIGE ensures
that overall production is never compromised.
The ADIGE saws are an important strategic element in the continual search for optimum quality which the company rigorously controls and
measures.
These working practices have enabled them to
obtain UNI EN ISO 9001 approval recognised by
SQS (the Swiss Association for Quality and Management).
No. 2 - october 2004
Their clear and firm objective is to combine high
quality with market prices, whilst remaining profitable but highly competitive with their Chinese
opposition.
13
A rapid response to our customers’ needs
and to market changes.
INSPIRED FOR TUBE
The Group
Hello BLM GROUP UK!
BLM GROUP UK, a totally-owned subsidiary of BLM
SpA, was founded almost eight years ago to provide the highest levels of sales support and aftersales service for the UK market, for BLM and ADIGE products. Backed by the global resources,
finances and know-how of an international group,
BLM GROUP UK is structured to respond instantly
to customer demands and market needs in the high
technology sector of the tube processing market.
True market understanding, serious service expertise and in-depth application knowledge are
14
attributes that can only be gained with years of
experience in the industry concerned. The level
of experience and professionalism available from
BLM UK is unique and unrivalled in our industry,
ensuring our customers get the very best solutions, technically, commercially and in all aspects
of after-sales service. Our levels of support extend far beyond the industry-accepted-norms
and one of our committed goals is to ensure our
customers get the highest possible levels of performance and capability from our machines
throughout the machine’s entire working life.
The Group
For example, initially we can carry out a full investigation on your current processes, then put
forward for your consideration the best possible
solution to get the lowest possible cost per component taking into consideration fastest cycle time,
best automation, lowest labour content, quickest
changeover etc… In most cases we would show
you a machine working in a similar factory environment to your own, followed by a showroom
demonstration, where possible, producing your
own components to prove out the process and
cycle times.
Our after sales support service is monitored on a
continuous basis to ensure we meet or beat the
high standards we set for ourselves. Our last survey showed that we were supplying 98% of
spares from stock and 97% of service requests
were carried out within 24 hours.
The team at BLM GROUP UK
Paul Lake - Sales
Jon Curtis - Sales
Wayne Caldow - Service
Bruce Foster - Service
Steve Hayes - Service
Ian Kopec - Service
David Turner - Administration
Karen Smith - Administration
INSPIRED FOR TUBE
Whether for bending tube, endforming, laser cutting or saw cutting, at BLM GROUP UK we are
happy to share our vast level of experience with
our clients.
BLM GROUP UK Ltd
4 Ampthill Business Park
Ampthill
Beds
MK45 2QW
Tel: 01525 402555
Fax: 01525 402312
E-mail: [email protected]
With this level of total-support and the continual
product innovation, BLM GROUP has become
the market leader, respected as a high technology provider. Evidence of customer satisfaction is
reflected in the fact that over 70% of our customers
have bought second machines, we have several customers with seven or more machines including one with twelve!
No. 2 - october 2004
Equally the majority of machines we supply today
have a telediagnostic system so most errors can
be corrected remotely by modem link within a few
minutes with the minimum of lost production time.
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INSPIRED FOR TUBE
TUBE BENDERS
TUBE END FORMERS
CUTTING DEBURRING AND WASHING
CUTTING AND END MACHINING
LASERTUBE CUTTING SYSTEMS
LASER CUTTING FOR SHEET AND SHEET&TUBE COMBINED
MATERIALS HANDLING SYSTEMS
3D MEASURING AND INSPECTION
PRODUCTION CELLS
NON CONTACT MEASUREMENT SYSTEMS
PROCESS CONTROL SOFTWARE
Also available in pdf format on:
www.blmgroup.com
16
Via Selvaregina, 30
22063 Cantù (CO) Italy
tel. +39 031 7070200
fax +39 031 715911
e-mail: [email protected]
Via dei Campi, 4
38050 Novaledo (TN) Italy
tel. +39 0461 720007
fax +39 0461 720214
e-mail: [email protected]
Via per Barco, 11
38056 Levico Terme (TN) Italy
tel. +39 0461 729000
fax +39 0461 701410
e-mail: [email protected]