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Sawing: Selecting a Material Handling System
Adding a material handling system can improve the safety and productivity of the sawing process
- April 11, 2011
- Article
- Fabricating
It is becoming more important than ever for today’s fabrication shops to incorporate a coordinated material handling system into their production sawing environment. Companies that can effectively and efficiently move material around their facility and into their sawing process reduce saw wait time, creating a competitive advantage.
In addition, safety, which likely is the most important and least appreciated aspect of the manufacturing puzzle, can be improved dramatically.
“I have seen companies invest in material handling for both safety and productivity reasons,” explained Behringer Saws President Richard Klipp. “From a safety perspective, the less you transport, pick up, and jockey materials by crane or forklift, the safer the environment is that you are creating.”
A far more commonplace justification for an investment in material handling equipment is based on productivity and efficiency improvements.
“If material can be moved in and out of a saw with the push of button, then you are spending less time waiting for the availability or loading and unloading from a crane,” said Klipp. “The high costs and slow speeds associated with operating cranes and forklifts are very quickly offset by the investment in an effective material handling system.”
Types of Material Handling
The types of material handling system that can prove beneficial to a sawing operation range from a simple roller conveyor to an advanced loading/unloading/sorting system.
Nonpowered Roller Conveyor. The simplest material handling system available is a nonpowered roller conveyor. These are most effective when coupled with an automatic saw, which can pull the material into the machine.
Powered Roller Conveyor. Powered roller conveyors allow material to be moved both on the input and output side of a machine. These are most commonly utilized with a semiautomatic machine, when material must be manually conveyed to appropriate length.
Advanced Load/Unload System. These types of systems have multiple options for both the input and output side of the saw. On the input side, a lift and carry conveyor, chain drag conveyor, incline magazine, or flat magazine all can be utilized depending on the needs of the shop. On the output side of the saw, pushers, sorting units, and stillage areas are common with this level of automation.
“The best way for a customer to determine what system is best for their needs is to review the entire process flow, to and from the saw,” said Klipp.
By understanding the size and types of materials to be transported and what the pre- and postsawing operations are, shops can choose the correct material handling system.
The decision whether to automate should not be based on how big production runs are because small and midsized shops with varying production can take advantage of the benefits as well. According to Klipp, material handling can help any size of shop gain efficiencies.
“It is more a question of how sophisticated a system you may need, and what sort of ROI can be generated from that system,” explained Klipp. “The justification process is a key component of making a good investment decision. But unequivocally yes, any operation can benefit from some level of material handling.”
For more information, visit www.behringersaws.com.
Understanding Laser Length Measuring
To enhance productivity further, shops can use laser-based measuring systems with pre- and postcut material handling equipment. For example, the BSI laser length measuring system from Behringer Saws saves time and reduces waste by confirming material dimensions prior to cutting to maximize material usage by creating more accurate, consistent cuts.
“The laser system is a highly accurate means of measuring and verifying cut component length,” said Behringer Saws President Richard Klipp. “Most production sawing facilities have either an automatic feeding system or a length-measuring system to generate the proper part lengths. Smaller or older facilities, however, still rely on the operator’s ability to measure and mark the component correctly prior to sawing.”
Designed for use on sawing systems that have handling components to move materials into the work area, the laser length measuring system employs laser technology to verify the length of the material to be processed. The laser automatically detects the material and transmits the dimensions to the control panel. The operator can then move the material with a powered roller conveyor to the correct length for cutoff.
Once reset to zero, the readout on the operator’s control will measure the length of the part being moved forward toward the laser via powered rollers or some other type of conveyance system.
When the part is at the correct length, the operator closes the vise system and begins the operation. The laser system eliminates time-consuming manual measuring, which often leads to deviations in production runs and wasted materials due to human error.
“This laser system helps reduce scrap and waste by ensuring parts are cut to the exact length specified, within +/- 0.10 inch,” said Klipp. “You are able to reduce scrap by eliminating cutting pieces too short and reduce the waste by having them too long. Productivity gains are made in some cases by eliminating the tedious and slow process of measuring via tape measure and marking of the part.”
The laser also can be tied into a computer for the purpose of printing out production sheets verifying the cut length of a part. This report can be included in the bar code process or shipping documents.
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