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Published Editorial The benefits of automation are plain to see at TPSM
A combination of investment in automated processes and providing a high level of quality and service to all of its customers has led to the consistent year-on-year growth of Teparay Precision Sheet Metal. Its latest purchase will help to continue that trend.
Founded in 1986 by Terry Belcher Snr. and now run by his two sons, Terry and Ray, Teparay Precision Sheet Metal (TPSM) has seen significant expansion resulting in it currently employing 80 people in its 80 000 ft2 facility in Hainault, Essex. This growth is a result of TPSM working closely with its customers across industries as diverse as furniture, storage, shop fittings, lighting and HVAC, to develop ideas and turning them into products that can be manufactured efficiently. As a result of this philosophy the company has also been quick to invest in manufacturing technology, particularly where it can automate the process.
Over recent years it has taken delivery of four automated turret punch presses, a laser, five press brakes and three state-of-the-art panel benders. This is in addition to investment in a new powder paint facility, an 8m by 3.5m box oven, shot blasting and robot welding. This level of automation highlighted one area that still needed to be addressed, that of deburring and surface finishing.
"By automating all these processes it left that one area, grinding, as a manual operation," says Jon Grainger, TPSM's Technical Sales and Marketing Manager. "It was at this time that our Managing Director, Ray Belcher visited the Kuhlmeyer factory in Germany as a guest of Ellesco and saw the ZBS twin-belt grinding machine demonstrated. He could see that it would fulfil the task in hand."
The Kuhlmeyer ZBS portal-type, twin-belt grinding machine is capable of working on fabrications up to 3 m in length and continuous grinding belts that allow roughing and finishing in the same setup, making it a highly productive machine. The open operating environment makes loading and unloading a straightforward operation and once loaded, components can be easily positioned on the motorised axes to achieve the ideal working position, greatly reducing operator fatigue, and presenting any of the five available component faces to the belts for grinding. The operator then applies pressure using shaped hand-tools or the machine's pressure pad to remove excess material.
TPSM saw the advantages of this system and after further discussions with Christchurch, Dorset-based Ellesco, the decision was taken to purchase, with installation taking place in summer 2008. This installation went so smoothly, with the machine proving itself almost immediately without any problems, TPSM could see that it would soon be working to capacity. Therefore, after just a couple of months the question was put to the management at TPSM, should they buy another ZBS machine to provide additional capacity and back-up? Or, do they look at other areas to develop?
"The answer," says Jon Grainger, "was to return to Ellesco and investigate the potential of a Kuhlmeyer BKK machine that is designed to dress weld on the corners of sheet metal boxes. This particular machine complements the ZBS machine as it is ideally suited to heavier weld removal, and would relieve the pressure on the ZBS machine, creating extra capacity for the more detailed finishing work."
The Kuhlmeyer BKK machine features a table with magnetic supports to hold components with the grinding belt moving vertically across the weld, while the table swivels through 90 degrees to ensure full contact with the welded corner. The machine's control unit automatically recognises the height of the workpiece and ensures that the cycle is kept to a minimum.
Both machines are now in full production and they have proved to be the missing link in TPSM's quest to create a more automated work environment. The level of automation is helping to eliminate operator fatigue, which in turn is improving consistency and eliminating some issue surrounding manual intervention in the deburring process. The technology employed ensures that components cannot be damaged by over enthusiastic use of abrasive materials while reducing cycle times.
"This programme of investment has been key to TPSM's success in recent years and has allowed us to develop better relationships with our customers," confirms Jon Grainger. "We now have the added productivity, improved quality and flexibility of production that enables us to work with customers to take products from concept to manufacture, something that is becoming part of our day-to-day business.
"It is reassuring to know that we have the back-up and support of suppliers such as Ellesco, who installed the Kuhlmeyer machines and had them in production in under a week. These machines now form part of our factory tour for customers and it is reassuring to hear their responses, some have never seen equipment like this, others are simply impressed by what they are able to do."
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