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At EMI, we’re proud of the impact our machines have on our customers’ businesses! From increased output to lower labor costs, to greater profitability we’ve seen first hand how the right equipment can revolutionize a fab shop. But don’t take it from us! Read on for a specific example of how our CNC tube plasma cutting systems helped a handrail manufacturer boost their bottom line.
Several years ago, we received an inquiry from a company that specialized in manufacturing handrails for farm equipment. Initially, they outsourced the fabrication of their handrails—but they ultimately encountered several challenges that led them to rethink their approach.
Challenges to outsourcing handrail production included:
- Long lead times of 4 to 5 weeks
- High minimum order quantities
- Rust issues due to prolonged storage
- Excessive material handling
To solve these issues, they invested in a brand-new CNC pipe bender. And while this machine significantly improved their bending operations, their cutting and preparation processes remained manual.
These manual workflows included:
- Cutting pipe to length using a bandsaw
- Coping with a hydraulic press and 90-degree die
- Manual milling for 30° and 45° copes
- Drilling holes using custom fixtures on a manual drill press
- Final assembly and welding using dedicated fixtures
Although their bending and welding processes were efficient, the cutting and coping stages of their workflow became bottlenecks. It quickly became clear they needed a more integrated solution.
Ultimately, the shop invested in one of our TPC 2444 CNC Tube Plasma Cutting Machines. This turned out to be a game-changer for their operation.
Improvements thanks to CNC tube plasma cutting system:
- 30% improvement in material yield thanks to advanced nesting capabilities
- Setup time reduced from 30 minutes to just 2 minutes
- Automated material loading, reducing risk of injury
- No more die maintenance
- Lead time dropped from 4 weeks to 20 minutes, enabling just-in-time production
- Labor reduction of 33%
The switch to the TPC 2444 not only improved their efficiency and flexibility—it also allowed them to offload parts from traditional machining, freeing up valuable capacity on other machines. And ultimately, they were able to load the machine to 80% utilization, which supported a 1-year ROI.
Looking to Boost Your Bottom Line?
If you’re looking to gain a competitive advantage when processing tube and pipe, consider a CNC tube plasma cutting system! Our team is standing by to help answer your questions and determine if an EMI machine will help your business improve efficiency, output and profitability. Contact us today to learn more! We look forward to hearing from you.
