More processing capability

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Derby-based Eggleston Steel can now take on larger jobs, reduce turnaround times and be more competitive thanks to new laser cutting and forming machines.

The family-owned stockholder has invested in a 6kW LVD Phoenix fibre laser sheet metal processing system with a 4m by 2m capacity and automatic nozzle changer, along with a 220t 4m Easy-Form press brake and a 6mm capacity guillotine.

Eggleston Steel was founded in 1809 and has grown significantly since it moved to its current site 16 years ago. It now employs 56 people and has a turnover of around £8m, with customers typically in the fabrication, construction and DIY markets.

“We grew rapidly following our move to the new site,” says Managing Director Richard Hewitt.

“A lot of that was down to increased efficiencies, more space and better buying, but one of the most important factors has been the company’s move into processing – profiling and bending – in addition to its traditional stockholding activities.”

Operations Director John Ready adds: “Processing is our special skill, and along with short lead times that is where we tend to win work. Our customers tell us we are much quicker, more reactive, flexible and will take on the jobs that the bigger guys don’t want to do. We have general steel products and we have the laser so a customer can purchase a beam from us with the end plates and cleats all delivered on the same day on one vehicle – that certainly gives us an advantage.”

John explains: “The three customer demands we always have to meet are quality, lead time and price – and usually in that order. That means we need machinery that has the repeatability and accuracy to be able to do that, and the efficiency in terms of energy usage, consumables, etc, to make sure that we can compete on price.

John says that on the Phoenix laser the key talking points are speed, accuracy, quality and running costs. Not only is it twice as energy-efficient as the fibre laser it replaced, but the speed of cutting can make a big difference to cost and lead times too.

“The increase in cutting speed and decrease in running costs allow us to be much more competitive in a fast-paced and sometimes very tight market. Having the Phoenix allows us to compete with much larger national steel companies.”

He says that on some jobs they can now take three or four hours off the processing time This would typically be a project for a portal frame building which would involve numerous base plates, cleats, connecting plates and so on, in materials from 3mm to 10mm thick and with lots of bolt holes. Previously that would have been a nine or ten-hour job, which could now come down to five or six hours. That can make a big difference to the price.

Eggleston Steel has seen the big benefits on the new LVD Easy-Form press brake too.

Previously there were problems with accuracy and repeatability, which led to multiple handling and cutting extra blanks to ensure the job could be completed. Now every bend is right first time with no need for re-bending or adjustment and no need to cut extra blanks for test bends.

“The operator just enters the desired bend angle in the machine and we know that when he takes it out it will be right. This has allowed us to produce more accurate parts first time and reduce the amount of rejected parts by a significant amount,” says John.

“By the nature of the business we are often doing two or three-offs, so getting it right first time without having to scrap any is very important. The LVD machine allows us to produce more work than we have ever done previously.”

LVD’s CADMAN B offline programming software has also helped increase productivity and produce more accurate complex parts says John.

“The offline software means we can simulate tricky parts on a PC using our actual press brake configuration and tooling and check for errors that may occur due to clashes. Previously we would have cut parts to test on the press, meaning other jobs going through would have to stop until those test parts were completed. That has definitely made a difference to us.”

https://egglestonsteel.co.uk

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