Our new Mazak FMS system is up and running!

Advanced Laser Cutting FMS system

Flexible Manufacturing System by Mazak added at Noble Industries

The Mazak FMS system has a material storage tower that can hold 10 different sheet metal material.  It also has a pneumatic load system to accurately position the sheet on the laser and automatic unload capability.  Laser cutting jobs are loaded into the computer.  While both lasers are cutting the parts of the material already loaded, the FMS system automatically locates the material for the next job and has it waiting.  Once the machine has finished laser cutting the parts on the laser, it will call for the FMS system to unload that sheet and load the material for the next job.  The FMS system continues to get the material ready for each job while the machine cuts metal parts.  This allows the same number of operators to run twice as many lasers at one time.  It can also be scheduled to run parts in the “lights out” mode so that employees can go on a lunch break and machines continue to run.

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Metal Fabrication Case Studies – Retail Point of Purchase Freestanding Display

Metal Fabrication Case Study

Customer:   Retail Point of Purchase

Product:  Freestanding Display

Type of Fabrication:  Laser Cutting, Welded Wire Mesh Grid, Press Brake Metal Forming, Welding, Powder Coating

Problem:  Taking a new design from the concept to production

Noble Industries solution:

Noble Industries has several customers who design all types of store fixtures for the retail industry.  Many things are considered before a prototype is scheduled.  Our customers will send conceptual drawings or models with all the factual information included such as the material they wish to use, dimensions, views from the front, back, side and top, specific hardware requirements, what powder coat color or colors they want and much more.

Our process engineers will review the design for manufacturability and give any comments or concerns to the customer.  If everyone agrees on the concept, then our customer will detail each individual part.  For this particular metal fabrication case study, we had a project to fabricate for Point of Purchase during the holiday season.

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Designing for Manufacturability (DFM) in Metal Fabrication

Successful metal fabrication job shops know that in order to maximize production time, it has to start with the design.  The best way to do that is by designing parts for the way it is going to be fabricated or by DFM.  This starts with a cooperative effort between the customer, the manufacturing engineer at the job shop and the operations team.  When they all 3 work together, the outcome should be developing the most cost-effective production design. 

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Metal Fabrication Case Study – Automotive Aftermarket Metal Brackets

Metal Fabrication Case Study

Customer:  Automotive Aftermarket

Product:  1/4 Plate Metal Bracket

Type of Fabrication:  Laser Cutting, Press Brake Metal Forming, Powder Coating

Problem:  Taking a new design from the PPAP to production

Noble Industries solution:

Noble Industries has an automotive aftermarket customer that will periodically change the design of one of their metal brackets based on the vehicle design changes.  As an ISO 9001:2008 metal fabricator, when a design change is made, we will provide the customer with test metal parts and their PPAP documentation.  After the customer tests the brackets they will place an initial supply of the new custom metal bracket.  For this particular metal bracket we made 3 test brackets.

Once the customer completed their testing they placed an initial production order of 750.  This specific part is made out of HRPO (Hot Rolled Pickled & Oiled) .25 X 60 X 120 sheet metal.  This material is also known as HRPO ¼ plate material.   Purchasing order sheet metal in the size of 60 inches by 120 inches because that is the sheet size for our Mazak Lasers.  To produce these parts, we have estimated that laser cutting will be performed at 35 parts an hour with 1 set up.  Our Virtek will inspect the first article part before the remaining 749 are laser cut.  After the parts are laser cut, the job folder and flat parts will go to the Press Brake area for metal forming.

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What does Custom Metal Fabrication mean?

The word “custom” can mean a conventional way of doing things or a common standard or practice.  For custom metal fabrication it means almost the opposite.  Custom metal fabrication means that someone wants to make something unique or specific to their needs.  It may mean they want to make 1 piece or a very small number of metal parts.  Custom metal fabrication can also mean large productions or medium size production run of between 100 – 2500 parts at a time. 

 Whatever your specific meaning, Noble Industries is the company that can provide all your custom metal fabrication needs!  If it is a project where you need to cut metal into specific sizes we can do that through the use of saws, lasers & punches.  If you need tubular parts, we can saw cut one or 1,000 at a time with the use of traditional saws or our CNC Dutch saw which allows us to saw cut bundles of tube or pipe quickly along with deburring the ends.  If you need sheet metal parts cut with a countersunk hole our 6 axis laser cutting equipment can handle that easily.  If you have a need for metal wire straightened and cut to length, we can do that as well.  Whatever custom metal cutting means to you, we can handle it.  We commonly cut aluminum, stainless steel, carbon steel.  Our equipment includes Mazak Lasers, Amada Punch Presses, Salvagnini Panel Punching, CNC Shearing, Piranha Iron Worker, Dutch Saw, Band Saws, Cold Cut Miter Saws, Wire Straightening and Cut off equipment and much more. 

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