Allsops Ltd, a leading UK sheet metal manufacturer, is building on more than 65 years of production excellence by installing the latest CNC punch press and laser cutter technology supplied by
Trumpf Ltd. This double investment in the company’s first Trumpf machines signifies a shift away from Allsops’ incumbent supplier of punching and profiling technology, and the new machines are providing Allsops and its customers with a notable gain in productivity, while associated automation systems mean the company can meet ever faster turnround times.
Allsops employs around 150 people at its facility in Honley, near Huddersfield, and has an annual turnover in excess of £10 million. Designing and creating products for some of the best-known manufacturers in the world means the company relies on the latest production technologies to underpin its added-value offer.
Managing director Robert Machon said: “We are a sheet metal company with a difference. Throughout the design and manufacturing process we work closely with clients from industries as diverse as defence, travel, retail, energy, telecommunications and general manufacturing — bringing their sheet metal ideas to life. Our customers choose us based on several factors: our capacity to deliver every stage of the sheet metal production process; rapid turnround times; highly competitive pricing; and dedication to quality and investment in ‘state of the art’ manufacturing technologies at our 84,000ft
2 facility.”
Customer satisfactionTo help ensure complete customer satisfaction, the company regularly reviews its production capabilities. For instance, after experiencing service issues with its supplier of sheet metal manufacturing machinery, Allsops heard positive things about Trumpf and decided to make an initial inquiry. This led to an investment in a Trumpf TruPunch CNC 3000 punch press with descending die and Industry 4.0 automation for loading and unloading.
At the same time, the company bought a Trumpf TruLaser 1030 6kW laser cutter with LiftMaster linear load/unload system and a material buffer tower for unattended shift working. Allsops also invested in TruTops Boost software for both machines. With a single button press, the company uses the software to drive a quicker process from geometry to NC program. It is also possible to achieve better material usage with a shared order pool and the ‘Lean Nest’ nesting processor.
While the TruLaser 1030 provides the company with fast and efficient 2-D laser cutting, the TruPunch 3000 allows Allsops to support its punching requirements with on-machine forming, tapping, countersinking and bending capabilities.
Mr Machon added: “With our new Trumpf machines we are seeing a number of positive differences compared with our previous technology. We immediately noticed that the machines are faster, giving us more output. In parallel with far better service provision, we feel vindicated in our decision to engage with Trumpf, which we recognise as a trusted industry name.”
As a USP, Allsops always puts forward its ability to create a valued-engineered version of the client’s product to help save money. Mr Machon continued: “Our design and new-product creativity skills are proven and established — and now we have the manufacturing technology to match. Faster times are the main advantage passed to customers. In addition, with both Trumpf machines featuring automation, we can run a lights-out facility in support of tight customer deadlines.”
Aided by automatic load and unload facilities, Allsops’ new Trumpf TruPunch 3000 has a maximum working range of 3,070 x 1,525mm and can easily accommodate the standard sheet size of 3,000 x 1,500mm.
Mr Machon added: “We are capable of punching sheet up to 3mm thick with a press force of 180kN and can use between 24 and 200 tools; Allsops also uses Trumpf tooling. The result? We can produce precision components for customers — fast.”
Using its automated Trumpf TruLaser 1030, Allsops processes materials that include brass, copper, zintec, galvanised steel, aluminium, mild steel and stainless steel. To provide an idea of capability, the machine enables the company to cut mild steel up to 25mm thick, stainless steel up to 20mm and aluminium up to 15mm.
Mr Machon concluded: “We monitor the capacity of our new Trumpf machines closely and can confirm that we are already seeing impressive utilisation. This reflects on the assistance provided by Trumpf during the installation, set-up, commissioning and training process, which went very well. It helped us adapt quickly to our new machines and become confident in the speed and quality of their output. Moving forward, we have big growth plans as we look to enter new markets that are ever-changing. With our new Trumpf machines we are all set for the future.”