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To handle increased business cutting large, 6 m x 2 m sheets of various metals, this Swiss job shop selected a “flying optic” beam laser system to deliver speed and precision. DFSA, a subcontracting job shop near Lake Geneva, Switzerland, has earned an enviable reputation for quality and innovation in the fabrication of sheet metal components. Numbering more than 100, their customers include industries ranging from building construction and transportation to machinery and chemicals. Aluminum, steel, and stainless steel components fabricated by the job shop include housings, guards, brackets, machine frames, windowsills, wall claddings, and even part sections for railway cars.
On the shop floor, every customer part has an identification number, enabling a record of everything that has been produced for each customer since the system went on-line in 1994. All materials — even bolts, screws and other hardware — have identification code numbers assigned to them and tracked by the computer system. A computerized log is maintained for all work done by everyone involved in each job. On completion of a job, a certificate indicating type of material used and a variety of other information is given to the customer together with an adhesive identification code sticker that is affixed to the part. With this expansion in workflow came the need — and opportunity — to upgrade the company’s manufacturing equipment. Due to the quantity of sheet metal being fabricated into customer parts, DFSA decided to acquire a laser cutting machine that would be able to handle 6 m x 2 m material, the shop’s preferred sheet size. Ultimately, the Frachebouds decided to install a 3,000 W IMPULS 6020 laser processing center from Strippit/LVD (Akron, NY).
Another factor, Daniel points out, is the machine’s optical system. The IMPULS features the “flying optic” design, whereby the sheet remains stationary on the table while the cutting head travels over the X-, Y-, and Z-axes. In addition, the machine’s two programmable shuttle tables, featuring a high-speed changeover time of 13 seconds, ensure high productivity in the busy shop. The laser operator is able to unload parts and set up a new sheet on one table while the sheet on the other table is being cut. Set-up downtime is reduced significantly and often eliminated. Material Handling Is Critical to High Productivity Daniel Fracheboud also is an enthusiastic fan of Strippit/LVD’s CAD/CAM (computer-aided design/computer-assisted manufacturing) system. Called CADMAN L for laser machining, the system features part programming, automatic nesting, DXF/IGES/MI (digital exchange format/international graphics exchange/manufacturing information) file format conversion, and common-line cutting. It enables off-line program preparation and interfacing with other programming systems within DFSA’s LAN. The IMPULS is now well into its second year of operation at DFSA. During the first year, the IMPULS processed 2,710 plates of 6 m x 2 m material, producing 2,833 individual part configurations. Daniel reports that DFSA is now much more competitive, eliminating much of the subcontracting they previously had to do, while taking on more customers and a greater variety of precision fabricating work. To handle the large amount of inventory needed to provide customers with just-in-time service, DFSA set up a unique, computerized material storage and retrieval facility just outside their main plant. Four levels deep and 15 levels high, sliding sheet and plate bins hold stacks of aluminum, steel, and stainless steel stock with various thickness. Each bin is coded for fast electronic access. Conveyor carts on rails enable delivery of the material through sliding doorways directly to the laser machine, press brakes or other fabricating and preparation areas. Dedication to optimizing productivity is a major factor contributing to DFSA’s success among their customers. “The final factor in selecting Strippit/LVD for the laser,” Daniel concludes Daniel, “is that they treat us as part of their family and not just another buyer of machine tools. We found that to be true with the Strippit/LVD press brake that has seen many years of service here, and it continues with the IMPULS. The people are always ready and willing to discuss our requirements and help us with solutions. They have become friends; as I said, like a family.” The brothers agree that, at DFSA, integration of technology and innovation will never end. To keep succeeding, they insist, they must keep moving forward to be the best they can be for their customers. This business philosophy is practiced around the clock at DFSA and bears witness to their close “family” relationship with Strippit/LVD and to the enviable reputation they have earned in the fabricating industry. Strippit/LVD Company - March 2001 |
The company, founded in 1971, is currently run by four sons of the founder. Daniel Fracheboud is the general director of the business, while Maurice heads up research and development, Stéphane oversees quality assurance, and Julien handles vendor relations. Since 1994, the company has operated with a state-of-the-art, fully computerized, local area network (LAN) system. Part prints are sent to customers for verification via fax modem. Changes, if needed, are made quickly and efficiently.
According to Daniel Fracheboud, several factors figured in their decision. First, the laser source: the IMPULS machine features the proven GE Fanuc laser resonator with an integrated CNC (computer numerical control) and digital AC drives, also from Fanuc. The laser’s electronic excitation ensures a highly stable beam for exceptional cutting performance in all types of materials. At DFSA, the IMPULS cuts aluminum up to 10 mm thick, steel up to 20 mm, and stainless steel up to 15 mm, quickly and accurately. The problems normally associated with the laser beam expanding over large table areas have been virtually eliminated by the patented beam delivery system.