With manufacturing plants around the world, commercial-vehicle seat manufacturer Isringhausen can choose where to undertake key aspects of production. This means that group companies such as Isringhausen (GB) in Wrexham have to look at all options to improve their productivity and performance.

Following a strategic review, the Wrexham plant decided to reduce its reliance on the sub-contract supply of ‘manipulated tube’ used in the manufacture of seat frames. It reckoned that by bringing this work back in-house, work flow could be better organised and the stock levels to meet customers’ just-in-time requirements could be dramatically reduced, plus the change would release floor space for the next phase of its expansion and development plans.

The starting point of the project was the installation of an Elect 42 all-electric multi-stack CNC tube bender from BLM Group UK Ltd, Ampthill, Bedfordshire (www.blmgroup.com), as the centrepiece of a purpose-built tube manipulation cell.

Isringhausen (GB)’s operations director, Geraint Thomas, said: “Buying this machine was a strategic decision and one that would form part of the company’s longer-term plan, so we had to make the right choice. We needed a machine that would be productive, accurate and reliable and would deliver the quality of product that our customers demand of us.

"We also had on eye on the environmental impact of bringing production back in-house. The fact that the BLM Elect 42 is an environment-friendly all-electric machine was a major benefit for our own production environment; it also opened up the possibility of grant support from the Welsh Government, through its Funding For Innovation scheme.”

Environmental credentials

The grant approval came as a result of the machine’s environmental credentials, with electric motors replacing the hydraulic system, the reduction in transport miles due to the work not being shipped in from the UK and Europe, and also the fact that the new tube manipulation cell would create at least 10 new jobs in Wrexham (these materialised within one month of the machine being installed, with new positions being created throughout the factory thanks to changes in working practices and the increased production generated by freeing up space that previously had been given over to storing seat frames).

With its nine axes of movement, the Elect 42 is ideal for Isringhausen (GB)’s complex, multi-shaped, tubular components, which often feature little or no straight lengths between bends. The productivity of the machine installed at Isringhausen (GB) is enhanced by the BLM 3-D visual programming software (VGP3D) which, via the use of quick and easy steps, reduces set-up times dramatically and ensures the highly cost-effective production of small to medium-size batches.

Further savings are made by virtue of the set-up data being stored with the piece-part program — plus the fact that advanced working cycles within the VGP3D software increase productivity by as much as 40%. Once the operator has input the bend co-ordinates, the software generates a cycle simulation, highlighting any potential problems or collision points.

This also results in a real-life cycle time being generated, allowing production costs and component pricing to be calculated accurately, while component feasibility is assessed without the need to physically bend a part or manufacture prototype tooling.

Ease of use

The Elect 42’s ease of use was evident when it was delivered in early February. Steven Moss, Isringhausen (GB)’s IMS manager, says: “The installation process was seamless, and we were bending our first tube within five hours of the machine being offloaded. We had undergone some training prior to the machine arriving and had some programs ready and waiting.

"The control system is so simple compared to what we had used previously, and the initial training was enough to get us into production very quickly. The two operators will complete the more-detailed training in stages, as we progress with increasing throughput.”

Mr Thomas says there has been a noticeable increase in consistency and overall quality of the seat frames being produced since the Elect 42 was installed at Isringhausen (GB). “We are achieving 100% conformity, which we are extremely pleased with from an unfamiliar machine.

"We are also seeing lots of interest in the machine from existing customers of our seating systems. They can see the benefits of what we can achieve now and are asking if we can supply them with other tubular product. In one day alone, I received over 50 requests for a quote.”