TRUMPF Express V2/11

Vol. 2/11

SpecialFABTECH Buyers Guide

Ride-along Safe, safety workers

Road warriors Tankers keep the country moving

Two friends at work An exceptional situation

Functional beauty Traditional handiwork, modern design

Magazine for Sheet Metal Processing in North America

Best in classAhead of the curve

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8

MAKING A DIFFERENCE

12 Riding in the fast lane Public safety workers benefi t from cutting-edge technology.

PROFILE

14 Rules of the road Tanker trucks are more than the cargo they’re carrying.

CUSTOMER FOCUS

25 Roots of success A strong work ethic leads to success at EMJD.

FABRICATING

28 Steel instead of stalls Love at fi rst sight means business.

CRAFTSMANSHIP

30 Artistry, craftsmanship and versatility Old World meets New World at Ferra Designs.

A former public school teacher turned sheet

metal fabricator successfully leads his company

through a fi re, then through a recession.

PORTRAIT

The wise guys

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343435

TO THE POINT

PANORAMA

PERSONALITIES

STORIES IN SHEET METAL

CREDITS

CLOSING POINT

STANDARDS

TOPICS

25

12

30

EXPRESS VOL. 2/11 FEATURE

CONTENTS

Gaskets made from 1 millimeter thick copper, cut on a TruLaser 5030 fi ber.

Special Page 17

FABTECH Buyers Guide

33Express Vol. 2/11

From the executive offi ces of large, global manufacturers to the fl oors of family-owned job shops, I repeatedly hear, “Th ese are the toughest times we’ve ever seen.” Th e economy is indeed sputtering along in fi ts and starts, and manufacturers of all stripes are struggling. But in what period of time would you want to live? In the 14th century, when the Black Plague that claimed more than 200 million lives peaked in Europe, and the uncertainty of daily survival created a mood of despair and hopelessness? Or 82 years ago, when the stock market crashed, which led to the Great Depression and virtually halted manufacturing around the world? Whether we like them or not, these are our times. Th ese are the days in which we’re living. And in spite of the economic uncertainty, there is success to be found. Last fi scal year TRUMPF Inc. experienced the second-highest sales revenue in its history—on the heels of a two-year, economic roller coaster that included a recession of epic proportions. But there are obstacles when it comes to achieving and sustaining such success, and they are roadblocks faced by the entire manufacturing industry. For example, it has been diffi cult to increase production to meet post-recession demand. We’ve had to ramp up very quickly, but procuring supplies and components, and fi nding skilled employees have presented signifi cant obstacles for us.

Th ere is also a mismatch between the jobs manufacturers have available and the qualifi cations of those applying for them. As a remedy, we have taken the same serious approach for training our customers to achieve maximum productivity with our machines and extended that principle to our employees. If—and “if ” is the qualifying word—a job candidate is motivated, willing to work hard, reliable, and interested in what we do, then TRUMPF will train them even though they have no industry experience. But this is simply a short-term solution to a problem that the industry—and society in general—must fi gure out how to correct in the long term. Th e problem is a systemic one that involves a sort of complacency. Long-time fabricators have retired and the younger generation’s focus has shift ed to training for other types of careers. However, as we continue to move manufacturing forward in this country, we must do what we can to excite people to obtain the skills necessary to work in our industry. Another obstacle to success speaks directly to the current generation of manufacturers, especially those of the baby boom era, who aren’t always comfortable when it comes to tweeting, webinars and eBlasts. But opting out is not an option. We have to learn to navigate them in order to keep the lines of communication open with each other, with our customers and with the next generation of manufacturers. Th ose who are reluctant to embrace electronic and social media might be motivated to change their mind when they view them as tools that lead to innovative new business opportunities. One example is www.mytrumpf.com, an online initiative that TRUMPF has launched to help customers manage their business in a more streamlined fashion. With so much change and so many unknowns defi ning our society, one thing remains constant: we must remain tireless and fl exible in our pursuit of success and innovation. We must continually invent and re-invent. In fact, TRUMPF’s TruMatic 7000, a combination punch-laser machine, is a tangible example of the innovation and fl exibility to which I’m referring. I invite you to stop by the TRUMPF booth at FABTECH to see, fi rst-hand, how this machine combines the advantages of punching and laser processing into one cost-effi cient package. Even though the times are challenging, remember that they are our times. And as diffi cult as they may be, history has shown us that it is possible to achieve success by embracing the obstacles in our path.

This is our time

Rolf Biekert, President and CEO

TO THE POINT

3Express Vol. 2/11


PANORAMA

Big Blue Dog

Industry speak

An 8-foot Blue Dog by Cajun Artist George Rodrigue sits in the artist’s New Orleans Studio.

Don Begneaud comes full circle

FMA develops defi ning source

> Additional information: www.thefabricator.com/glossary

> Additional information: www.begno.com www.georgerodigue.com

If you think the term “bad edge” describes the guy who’s operating the machine next to you, you may want to check out the Fabricators & Manufacturers Association’s (FMA) comprehensive new industry glossary.

Th is defi nitive dictionary for the metal forming and fabricating industry currently lists almost 600 terms, and plans are to expand it to more than 3,200 entries. Th e goal for the glossary is to be the largest and most comprehensive available

online in the industry. And in case you’re wondering what the glossary has to say about “bad edge,” here’s the defi nition:

bad edgenoun

Defi nition:A defect of the outside edge of metal on a coil. It happens

during the rolling of metal onto the coil. Th e rolling process causes a deformation of the steel; if the slitter knives are not

aligned perfectly, the slitting process will produce a slightly broken or torn edging of the metal.

He owns a precision sheet metal fabricating business respected for its technological advancements and state-of-the-art equipment. Don Begneaud’s company, BEGNEAUD Manufacturing, serves sophisticated industries, such as aerospace, oilfi eld, automotive and medical, for example. So it might be a little surprising to hear that the Lafayette, Louisianan went and got himself involved with a legendary Blue Dog that has its roots in a Loup-garou—or the rougarou, as it’s known by some. Both words are used interchangeably in southern Louisiana, where stories about the rougarou, which describe a werewolf-like creature, are common. In a way, Don has come full circle. As a kid, he created metal sculpture of tiny fl owers using a propane torch he bought with S&H Green Stamps. Th ese days, his multi-million dollar precision fabricating company also creates metal sculpture for artists such as Cajun “Blue Dog” creator, George Rodrigue. Known throughout the world for his series of paintings that feature a blue-hued, ghostly-

looking terrier-spaniel mix pup, the Blue Dog was inspired by the artist’s deceased dog Tiff any and infl uenced by the Loup-garou legend. When Mr. Rodrigue decided to make the biggest Blue Dog ever, it was BEGNEAUD Manufacturing, owned by his good friend, Don, who fabricated the 800-pound, 16-foot aluminum masterpiece for the artist to paint. BEGNEAUD Manufacturing was already fabricating Blue Dogs for the artist in smaller sizes, such as 4-foot and 8-foot heights.

Th e second anniversary of the sculpture’s installation, which is located at Veterans Memorial Boulevard and Svern Avenue in the New Orleans suburb of Metairie, was celebrated this summer. Th e Blue Dog has become part of the city’s culture and serves as a symbol of its recovery post-Hurricane Katrina. It appears throughout the City of New Orleans, in both two-dimensional and three-dimensional formats. By the way, the Blue Dog metal sculpture isn’t just blue. It all depends on your perspective—literally. You see, there are three sides to the artist’s work, and while Mr. Rodrigue always paints a Blue Dog, there are two more dogs in the same piece of sculpture that are painted other colors, such as red and yellow, or even some other-worldly hues that you’d never even dream of.

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> As the FMA’s new leader, how do you defi ne your mission for the organization?

FMA’s mission is to champion the metal forming and fabricating industry. I’m honored to be the steward of that mission. Moving forward, FMA will be focused on those activities, products, services, events, and information tools that answer the question, “Does this improve our members’ businesses?” The more times we can answer yes to this question, the better we will serve our industry. As an organization, FMA represents over 2,000 members and serves nearly 200,000 subscribers throughout the U.S., and we have not yet capitalized on our critical mass to raise our industry’s profi le and importance in the consumer media and Washington. When joining the industry four years ago, I quickly discovered that the men and women who work in the metal fabricating industry are incredibly innovative, bright, hard-working, and, most important,

tough. My goal is to see that we get our industry – as well as all of manufacturing – recognized for the vital industry it is. I’ll put the creativity and resourcefulness of the professionals who work in the metal fabricating sector up against any industry.

> What is the single most important thing fabricators and manufacturers should know about you?

I grew up in the heart of the auto industry – Michigan. My father was a tool and diemaker at Fisher Body, then General Motors. He is my personal hero, and I believe my fi rst-hand knowledge of the value of manufacturing to families and communities will serve me well in leading FMA. In my offi ce I have his retirement plaque that has the Fisher carriage on it along with his toolbox. Both serve as reminders of the three components that people who work in manufacturing have: capable hands, clever minds, and, most important, heart.

PANORAMA

TRUMPF Inc. presents 2011 awards to distributors

Left to right, Mike Pinchot (Fabricating Machine Technology), Craig Summers (TRUMPF), Gary Budzik (Fabricating Machine Technology), TRUMPF’s VP of Sales and Marketing Burke Doar, and Dave Nichols (Fabricating Machine Technology).

Top award to Fabricating Machine Technology

> Additional information: www.us.trumpf.com

Two questions for FMA’s new leaderThe Fabricators & Manufacturers Association, Intl. (FMA) has appointed Edward S. Youdell as the organization’s new president & CEO. He succeeds Gerald M. Shankel, who has announced his retirement but will remain with FMA during the transition as President Emeritus. TRUMPF Express caught up with Mr. Youdell shortly before he assumed his new position on October 1 to ask him two questions.

QUESTIONS

2

TRUMPF Inc. recently presented 2011 awards of sales achievement to Fabricating Machine Technology LLC, Metalforte and Mid-Atlantic Machinery at their annual distributor meeting. Fabricating Machine Technology (Cleveland, OH) was presented with the Outstanding Distributor Performance Award in recognition of their exceptional performance in selling TRUMPF products during the past fi scal year. Th e Sustained Excellence Award was presented to Mid-Atlantic Machinery (Harrisburg, PA) in recognition of their consistent performance in selling TRUMPF products. In recognition of their dedicated and successful eff orts to increase the sales and support of TRUMPF products during the past fi scal year, Metalforte (Monterrey, Mexico) was presented with the Most Improved Performance Award.


PANORAMA

premier medical facilities in the Northeast, led them to TRUMPF Medical Systems. “Several of our surgeons had seen TRUMPF’s innovative products at tradeshows and said ‘those are the surgical tables and lights we want’,” according to Robert J. Falaguerra, St. Francis’ Vice President of Facilities, Support Services and Construction. When the new tower opened in January 2011 it featured 17 state-of-the-art operating rooms, including hybrid and cardiac rooms - as well as dedicated ORs for the Connecticut Joint Replacement Institute – all featuring TRUMPF Surgical Tables, LED Lights and ceiling-mounted Equipment Management Systems. Beyond its innovative products, TRUMPF’s real contribution may well be in the new perspectives on effi ciency it off ered the St. Francis team. TRUMPF executives, from both TRUMPF’s Farmington, CT machine tool headquarters and Charleston, SC-based medical systems, off ered St. Francis a new take on effi ciency, gathered from their combined, diverse industry experience. TRUMPF’s ideas have enabled St. Francis to directly improve patient throughput while maintaining safety and allowing it to continue providing the highest possible levels of care.

St. Francis Hospital and Medical Center’s new $184-million John T. O’Connell Tower in Hartford, Connecticut has been designed to accommodate the very latest innovations in “green” construction, medical technology advancements and cutting-edge telecommunications. Th e management team’s objective, to position St. Francis as one of the

Patients benefi t from TRUMPF’s innovation

Mack Molding receives honors

St. Francis Hospital is one of the premier medical facilities in the Northeast

Prestigious international award given to Vermont company


TRUMPF surgical table

Earlier this year Mack Molding, a leading custom plastics molder and supplier of contract manufacturing services, was recognized for having redefi ned the company as a major North American manufacturer in the new millennium. Mack, a user of TRUMPF equipment, specializes in plastics design, prototyping, molding, sheet metal fabrication, full-service machining, and medical device manufacturing. Th e company was named a winner of Managing Automation Communications’ prestigious 2011 Progressive Manufacturing 100 Award. A decade ago, in the midst of a recession that drove major technology OEMs to off shore manufacturing, Mack craft ed a new business model that would expand its position as both a contract manufacturer for the medical market, as well as a custom plastic molder of super-large parts. With great strides being made on both of those fronts, Mack has been concentrating on the third leg of the business model – big, bulky, complex products – that diversify its markets beyond medical and emphasize its services in addition to injection molding. “Th is aspect of our business model drives us toward products that are too large to be manufactured effi ciently overseas and too complex

to be confi dently and expediently managed from off shore locations,” explains Jeff Somple, president, Mack Molding Northern Operations. Mack was honored along with a list of blue-ribbon manufacturing companies from around the world, including Caterpillar, Chevron, Coca-Cola, Dow Chemical, Ford, Honeywell, Lockheed Martin, and Nestlé—all companies that have demonstrated an ability to rethink their businesses and apply advanced technologies in innovative ways that manufacturers everywhere would be well served to emulate.

> Additional information: www.mack.com

In the little town of Pinckard, Alabama is MAHA USA, LLC, a small company with big ambition. Operating in a 90,000 square foot cutting edge production facility, MAHA USA is a leader in the automotive engineering industry, providing superior

vehicle lift products for vehicle testing and maintenance for both automotive and heavy duty markets. Subsidiary to the 40 year old MAHA Group, located in Southern Germany, MAHA USA has founded its reputation on quality, service and advanced technology. Investing nearly $2 million over the past 18 months in new equipment and machinery, including a 5,000 watt, 14 foot TRUMPF Laser Cutting

Machine, “MAHA is ready to tackle the future,” Managing Director Wolfgang Raffl er says about their newest state-of-the-art equipment. “Our greatest investment however, remains with our dedicated workforce. In

the midst of the recession, MAHA USA was fortunate enough to continue growth, expanding our team to over 50 employees. We are one of the few companies able to gain employees instead of decreasing workforce,” Raffl er continues. In 2010, MAHA introduced the Wireless Mobile Column Lift , the only wireless operated lift on the market with proven ball screw technology. With the addition of this exclusive product line, MAHA USA strives to advance market shares in the United States and worldwide.

Floor by fl oor, one a week, New York’s new landmark at Ground Zero is rising toward the sky. Work on “One World Trade Center – 1 WTC” has been ongoing since April 2006. Th e antenna tower will rise an impressive 1,776 feet into the sky as an ever-present symbol of renewal and hope for the future. Designed by architect David Childs, 1 WTC will be the tallest structure in the United States. It comprises a transparent glass tower standing on a pedestal almost 200 feet tall. Th e glass elements are edged with a stainless steel frame. Th e design’s architectural elegance results from the peak being turned by 45 degrees in relation to the square base, so that the tower appears to taper and rotate as it rises. Th e structure’s complex façade elements, manufactured in Germany, are made with high-quality sheet steel produced by Th yssenKrupp Nirosta in Krefeld. Th e material is created by using a special rolling and heat treatment process at the company’s Dillenburg mill. From this material, Th yssenKrupp’s sister company, Christian Pohl GmbH in Cologne, shapes the stainless steel panels for the outside corners of the building. Th e individual façade elements, made of corrosion-resistant chromium-nickel-molybdenum, measure one by four meters each and have a total weight of 250 tons. TRUMPF’s TruPunch 5000 was used to help create the steel panels. Th e machine was well-suited for the job, which came with very special challenges. One of the challenges was to guarantee that the material

would remain fl at, even when it was exposed to strong winds and in spite of it being very thin. Th e Port Authority of New York and New Jersey have a website that features extensive information on the World Trade Center project. According to a statement on the website, “Th e new World Trade Center embodies a bold vision: To remember, to renew, and to rebuild the future.” A live camera shot of 1 WTC can be found here: http://www.panynj.gov/wtcprogress/live-camera.html.

Quality counts

New York icon

MAHA grows forward in Alabama

One WTC grows tall

PANORAMA

77Express Vol. 1/11

> Additional information: www.maha-usa.com

A symbol of renewal and hope



PORTRAIT

Ed Leventhal, (left) president and owner of Valco Industries, and Dave Montgomery, the company’s general manager.

8 Express Vol. 1/11

99Express Vol. 2/11

Ed Leventhal, president and owner of Valco Industries in Springfi eld, Ohio, readily admits that he’d like to shave a few years off his driver’s license. “I wish Dave and I were both 20 years younger,” he said, sounding a little refl ective during a recent interview with TRUMPF Express. Dave is Dave Montgomery, Valco’s general manager. “We’re both committed and excited about manufacturing, and we’re committed to the long term,” said Ed. “I don’t know what the long term will be, but we’re excited about what we’re doing and we’re excited that we can provide jobs to people.” Valco Industries, which Dave described as “halfway between a job shop and a contract manufacturer,” has ongoing relationships with a number of companies in the metal cabinetry business, the electronic chassis business, and the agricultural, transportation and trucking industries. “We’ve got a pretty well diversifi ed group of customers,” said the GM, who is originally from Dayton and was educated at the University of Cincinnati as an electrical engineer—before he headed east for more schooling. “I was lucky enough to get a scholarship to Harvard Business School, and there I ran into the fact that everybody wanted to be on Wall Street and nobody was really interested in manufacturing.” So Dave took the road less traveled and went to work for his family’s machine tool business—which he ran for about 35 years until the business was sold. “I thought I might retire,” he said. “But I guess I’ve got manufacturing in my blood.”

Full circleIt was about 11 years ago that Ed, who taught in the Cleveland Public School System in the late 1960s and early 1970s, joined Valco Industries as plant manager aft er his family sold its 55-year-old business, Vining Broom. “For awhile, we were the largest broom and brush manufacturer in the country,” said Ed. “But that became much like the largest buggy whip manufacturer in the United States,” he joked. Aft er the company sold, Ed stayed on for about a year-and-a-half. He then did a little personnel consulting and became director of the Small Business

Education, experience lead the

way at Valco Industries

The wise guys

PORTRAIT


PORTRAIT

One of the heartwarming things to come out of Valco’s fi re is that several of their customers visited the facility while the building was still burning. “Th ey wound up opening their doors to some of our employees,” Ed said. “Th ree companies provided work opportunities for our folks, so we didn’t have to lay anyone off during the fi re. Th is provided a much closer working relationship with these customers. It was very benefi cial because our employees saw where the parts they were making were going.” But there is much more than simply good fortune and business savvy involved in Valco’s ability to successfully overcome the odds associated with the fi re. Th ere is also goodwill. “Ed wouldn’t mention this,” said Dave, “but two things are really important. First, this [outpouring from the community] probably wouldn’t have happened if Ed hadn’t been so much of a giver back to the community. I think this was as much a gesture of appreciation for what Ed puts into the community as anything else. “Th e other thing that I would say is that Ed’s philosophy is to put money back into the company to make it competitive. We continue to make signifi cant reinvestment to stay ahead of the curve. Th ings change rapidly; it’s diffi cult competing with foreign markets. Th e only way to do it is to have really good people and the best aff ordable technology.”

Investing in dependability“Th e machine building pretty much burned up, as much as a metal building can burn,” said Dave. Fortunately, Valco Industries was well insured and able to replace the TRUMPF laser and other high-tech equipment lost in the blaze. In fact,

Development Center in Springfi eld. When a good friend of his, a co-owner of Valco, was looking for a plant manager, Ed joined the company. And just one year later Ed bought into the business. Seven years ago he became sole owner. Today, Valco is located in the very building where the Leventhal family business operated for more than half a century.

Catching fi reUnfortunately, a major fi re hit Valco Industries in 2007, and it was by pure coincidence that Valco relocated to the building where Ed’s family business operated for years. Th e space was perfectly wired for big machine tools, and although there was some concern about the confi guration of the building, Valco was able to move in quickly—which was a big plus. A major catastrophe was averted, and in spite of the fi re and subsequent move, not to mention the recession, Valco Industries continued—and continues—to catch fi re. “Just as a sort of benchmark,” said Dave, “throughout the recession, certainly on an annual basis, we were profi table. We were able to kind of reel things in, and in spite of the fact that we didn’t lay anyone off we did remain profi table during that period.”

”We continue to make signifi cant reinvestment to stay ahead of the curve.”

Valco’s General Manager describes the business as “halfway between a job shop and a contract manufacturer.”

1111Express Vol. 2/11

PORTRAIT

Ed and Dave credit the TruLaser 5030, with its ease of operation and dependability, for helping them put the company back together--quickly. According to Ed, “Th e fact is that the fi re happened in February, and we were running our new TRUMPF laser in April.” And as business expanded, it became clear that Valco needed additional laser capacity. Being relatively small and certainly frugal, the company’s GM kept his eye on the used market. “We spotted a TRUMPF in Chicago for a song,” said Dave, explaining that it was an older model. “I went up to take a look at it; it wasn’t running and the owner said it needed a new resonator, but it looked like it was a fairly decent machine, so we took a fl yer on it.” Although the company faced the prospect of spending a considerable amount of money to have the resonator repaired, that all changed when the rigger’s technician —and here’s where the story gets interesting—who drove their new, old laser from Chicago to Springfi eld, off ered to do the repair work. “He asked me, ‘How do you feel about gambling?’” recounted Dave. “We rolled the dice and said, ‘OK, give it a shot’. And would you believe that 1996 laser’s been running ever since with the original resonator?” He laughed as he explained, “Th e guy was a very unique individual and taking a chance certainly paid off for us, but I don’t know that I would ever recommend him to someone else.” Ed added, “We’ve run that old laser a lot more than we ever anticipated; in terms of durability and so on, TRUMPF came through again.”

The heart of the matterDuring the recession, Valco Industries worked with the local community college and the State of Ohio to obtain signifi cant training dollars for its employees. Th e company made a decision not to lay off any workers and went into a fairly extensive training program, both on-site and at other locations such as TRUMPF. “We did a lot of blue print reading classes, measuring device classes and a variety of things like that to try to improve our skills knowledge,” said Ed, the former school teacher and current member of the Springfi eld Public Schools’ Board of Education. “We felt at some point that things would start bouncing back and we would be better positioned with our personnel.”Aft er all, he pointed out, “Th ere are a lot of companies that have lasers and press brakes and welders, but we think the real diff erence is people.”

Who: Valco Industries Inc., Springfi eld, Ohio. Established in 1972. www.valco-ind.com

What: Valco bills itself as fabrication’s fi rst responders that can take your part from design to prototype to production.

How: TruLaser 5030, TruLaser 2530, TruLaser 2030, TruBend 3120

Valco Industries Inc.

Valco Industries suffered—and survived—a devastating fi re in 2007.

Some 20 million Americans work from their car, and Havis rides right along with them. Its products are used by workers in the mobile workforce, with the company’s primary focus on the public safety and utility markets. In fact, “comfort, safety and quality” is Havis’ motto. Th e company is best known for supplying fi rst responders such as EMS workers, fi remen, law enforcement personnel, and others who are part of the mobile workforce—including those in the military—with mission-critical equipment. Even police dogs benefit from Havis technology. Founded on a family tradition of supporting public safety, the history of Havis dates back more than 75 years. Developed under the banner of Havis-Shields, the brand has grown to include LEDCO-CHARGEGUARD’s world

class mobile computing solutions, Collins-Dynamics emergency lighting and a number of other companies. Today, Havis is the largest designer and manufacturer of mobile workforce equipment in the industry. The company employs more than 200 people at primary locations in Warminster, Pennsylvania, which is site of the company’s headquarters, and Plymouth, Michigan. TRUMPF Express sat down to talk with Havis’ Pete Spera, Director of Operations, about this interesting company. Havis competes with four or fi ve others in its industry, but it is the largest of the equipment providers for the mobile workforce. How did Havis get its start?Pete Spera: Havis-Shields was founded in 1928 by Dan Havis and Jim Shields. It was just two

Havis is serious about safety

guys in a garage, a very humble beginning. Originally we built fi re trucks, but eventually got out of that and began making lighting fixtures for emergency scenes, and from there we added consoles and motion devices, transport solutions, docking stations and power management solutions to the product line. Currently, Havis is owned by Jim Shields’ great-grandsons, Joe and Mike Bernert. It’s always been a family business, which is something the company is very proud of. A search of Havis’s website highlights many products. Can you please tell us about a few of the company’s key products?Pete Spera: We manufacture consoles, computer-docking stations and other equipment for a variety of vehicles. These consoles mount between the front seats and


Riding inthe fast lane


they house the radios, modems, light switches, etc. And of course, everyone needs to put their coff ee somewhere, so our consoles have cup holders, too. Our computer-docking stations, also mounted in vehicles, allow you to install a computer in your vehicle, where if not properly anchored becomes a dangerous projectile in a crash. Havis solves that problem with the most rugged line of docking stations that the market has to off er. Add to that our motion devices and you can provide a convenient, ergonomic solution to both the driver and the passenger. Anyone from a utility company service technician to a state highway patrolman to a storm chaser can enjoy a safe and comfortable “mobile offi ce” experience, and they can do all of this while printing receipts, issuing e-tickets and capturing video from a laptop docking station. On top of that, we provide a number of power management solutions that help to reduce vehicle emissions, improve fuel economy,

increase battery life and prevent vehicle downtime. As an example, when you see police vehicles by the roadside near where a utility crew is working, Havis makes equipment to monitor the car battery charge. Our power management device “Idle Right” can turn the car off and on to maintain all electrical systems while conserving fuel. Lastly, we off er a wide range of transport solutions that provide safe passage for canine units and prisoner transport. TRUMPF Express readers, by and large, seem to be

dog lovers, so everyone will be curious about the products Havis makes for K9 transport.Pete Spera: Canine units are an important part of our product portfolio here at Havis. These protective canine enclosures keep police dogs safely stored and transported. Havis has its own powder coating operation, so we powder coat our canine products to protect the dogs and to make clean-up easier. Raw aluminum will damage a dog’s fur, but powder coating the products avoids this. Th ere’s also a temperature control system, which will turn on a fan and lower a window in the police vehicle if the temperature becomes dangerous for the animal. We also off er “step-in” options to reduce the wear and tear on a dog’s hips as it enters and exits police cruisers, trucks and vans. Since we care about the offi cers and the dogs, these enclosures have options such as remote release, so if an offi cer is away from his car and needs canine help, he can simply press a button to open the door to the canine unit, providing him with some four-legged back-up.

Can you explain your “Build versus Buy” philosophy and how TRUMPF’s TruMatic 7000 fi ts into that?Pete Spera: Havis processes one-and-a-half-million pounds of aluminum and steel every year. We’ll do runs of 10 to 50 diff erent parts with quantities that range from 10 to 500 at a time. By designing and fabricating our own products, we are able to maximize our designs around manufacturability. Havis was the fi rst manufacturer in the U.S. to have the TruMatic 7000. Aft er a visit to TRUMPF’s Farmington facility, it was obvious that TRUMPF continues to drive technology into their products, which is something we want to take full advantage of. We have found that the TruMatic 7000 with SheetMaster, SortMaster and Auto-Indexing of every tool has shown an increased consumption of Raw Material over our traditional equipment, as well as vastly improved edge quality. Th at said, our success isn’t owed exclusively to machines. It all starts with good programming, and I’ve been told by those in the know that Havis has one of the best programming, operator and maintenance teams, in the country. How do you stay current in your industry? Pete Spera: It starts with our engineering staff . We’ve got a group of 10 people that are constantly involved in R&D, and Havis has an advantage in that our Michigan facility is 20 minutes from Detroit, which allows us to regularly communicate with the Big Th ree. So GM, Ford, Chrysler, and then companies like Panasonic and Dell on the IT side… these companies recognize Havis as an expert in the mobile workforce and they involve us with upcoming projects and products. In addition, the CEO of Havis is involved in the National Fleet Management Association, which allows us to stay on top of the needs and trends of the industry.

MAKING A DIFFERENCE

Who: Havis Inc., Warminster, Pennsylvania. The company dates back more than 75 years. www.havis.com

What: Delivers comfort, safety and quality to the mobile workforce

How: TruMatic 7000

Havis Inc.

Canine units are an important part of the product portfolio at Havis.


Customization is a distinct advantage

Rules of the road

As the fi rst rays of morning sunlight glisten off a sleek, stainless steel tanker truck streaking down the big slab, which is trucker talk for the interstate highway, chances are the driver is on his way to deliver some type of liquid such as bulk milk to processing plants, gasoline to fi lling stations, or chemicals, such as bleach, to be converted into everyday items like hair dye or cleaning products. Tanker trailers keep logistics running smoothly for some of the nation’s biggest industries, and it’s likely that the tanker you passed on your way to work was manufactured just off I-44 in Springfi eld, Missouri at ACRO Trailer, which fabricates stainless steel, aluminum and carbon steel tanker trailers for the liquid transportation industry. Founded in the 1960’s to provide for the specialty market of liquid transportation, ACRO Trailer has been an industry leader for more than 50 years. In December of 2001, ACRO was acquired by Semo Tank/Baker Equipment—the company’s largest-ever acquisition—which has resulted in a successful marriage that combines many years of industry experience with exceptional talent. Areas that ACRO Trailer specializes in are building tanker trailers for the crude oil and waste water hauling industries. Th e company also covers a wide spectrum within the food industry, from food grade units to tankers that haul away used cooking oil and grease for processing and disposal. But ACRO is best known for its special expertise when it comes to fabricating units for the chemical manufacturing industry. Th e company’s carbon steel and stainless steel lined units are capable of hauling such corrosive materials as bleach and hydrochloric acid safely and dependably.

More than meets the eyeTh ere’s a lot more that goes into those tanker trailers than the cargo they’re carrying and the metal they’re made of. Each of the industries that ACRO serves requires extensive knowledge concerning governmental and safety regulations, equipment and metal requirements. In other words, there are multitudinous codes and compliances that must be adhered to—strictly. Not only does this custom manufacturer need to learn their customers’ specifications in order to build to build to customers’ business requirements, but ACRO must also be familiar with all of the industry regulations and follow them to a “T,” in order to ensure that each tanker is built to satisfy government and industry regulations. It can all seem a bit complicated to those outside of the industry. For example, Department of Transportation (DOT) 412 refers to code specifi cation in federal regulation for cargo tanks authorized to transport hazardous materials, and each DOT-412 cargo tank must conform to general and specifi c requirements. Fortunately, because of ACRO Trailer’s technical expertise and years of experience within the liquid transportation industry, every unit the company manufactures is up to code and built to last.

(It’s noteworthy to mention that all DOT 412 units that ACRO builds and maintains hold a “U” stamp through the American Society of Mechanical Engineers, which designates the company as being a certifi ed ASME repair and build facility.) ACRO employees like Chris Foshe, the company’s General Manager, who has 14 years of experience in design and engineering under his belt, help ensure that everything comes off without a hitch. “Our fi rst and foremost goal is that the customer gets the tank he is expecting—from equipment layout to the quality,” said Foshe. He explained the streamlined process in place at ACRO: Clients fi rst work with sales staff to discuss their requirements. A quote is then built with specifi cations based on information gathered from the customer, the type of metal alloy required and the equipment needed. The specs then go to engineering for design and review of code requirements, and at this point clients usually work one-on-one with the engineers. Once the engineers sign off , the order goes into the production schedule and then Engineering and Production work closely together to deliver to the customer the tank they are expecting. ACRO’s customer support extends to on-site DOT training as well as DOT regulation assistance, providing customers with documentation and regulatory information as needed.

A return on investmentIn the last couple of years, there has been signifi cant growth at ACRO when it comes to investing in new machinery to aid production. “Everything is done in-house as far as manufacturing goes,” said Chris

PROFILE

PROFILE

15Express 2/11

Chris Foshe and Chris Schwalls of ACRO Trailer.


Schwalls, the company’s Maintenance and Equipment Manager. He explained that the process—which begins with flat metal sheets—is intense. Every piece is manufactured and processed on the production fl oor. Flat plate material gets processed fi rst by a burner in order to cut the required pieces. Th e end caps or heads are cut on the burner as fl at circles, which then go to the head bumper, giving the heads a contoured shape. Th en a barrel roller does just what the name implies by taking fl at sheets and rolling them to form the barrel of the unit. Aft er several stages, the various components for the main tank are complete, leaving all of the outriggers, hose trays and walkways to be built and assembled. According to Chris, quality control inspects every inch of the unit throughout production by hand and is always present on the manufacturing fl oor. Chris said that TRUMPF’s TruTool Shears are considered a valuable asset on ACRO’s shop fl oor when it comes to assisting in the forming of insulated materials. “Th ey help us achieve maximum effi ciency and productivity, which are key components of any successful manufacturing operation,” he said. “Th e old hand shears we used to depend on were slow and could only cut straight lines. But the TruTool C 250 slitting shears allows us the ability to make intricate cuts quickly, with ease, and they have required no maintenance.” ACRO’s Maintenance and Equipment Manager also credits the TruTool TKF 1500 beveller with increasing productivity at ACRO by leaps and bounds. “In the past,” Chris explained, “production used to use a seven-inch grinder to grind material by hand. One plate would take you a good hour to hour-and-a-half to grind it, slowing us way down. Now with the TRUMPF tool we have streamlined the process for grinding four sides and have gone from an hour-and-a-half to about 15 minutes.” Chris Foshe and Chris Schwalls pointed out that ACRO’s ability to provide special fabrication in-house gives them a distinct advantage by preventing down time. Also, most repair work performed on ACRO manufactured tanker trailers is on equipment between 18 and 30 years old, the men said, and

replacing outside components is essentially the only repair required on these older units.

In addition, the company fabricates special parts for clients who have trailers from other manufacturers

that may have either gone out-of-business or no longer supply the necessary parts.

Staying on top of the gameWhen General Manager Chris Foshe’s three draft smen began their careers at ACRO, he insisted that they start on the production fl oor, which gave them a unique perspective of what they were accomplishing with the draft ing and design process. Th e company also ensures that quality and craft smanship do not get lost with new hires by having senior staff with 10 to 15 years of experience work one-on-one with them. ACRO Trailer’s ties to the industry include membership in the Truck Trailer Manufacturers Association, which is currently working toward the standardization of manufacturing and governmental requirements for the industry. Th e company is also a member of the National Tank Truck Carriers organization, which represents the gamut of professionals in their specifi c segment of the trucking industry. A commitment to excellence, to the industry and to their customers keeps ACRO’s tanker trailers successfully rolling down the roadways. So the next time you’re out on the road and spot one of those big steel drums on wheels, you can turn to the person seated beside you and mention there’s a very good chance that the tanker trailer was manufactured right off I-44 in Springfi eld, Missouri. In the meantime, 10-4, and keep the shiny side up and the rubber side down.

PROFILE

Acro Trailer

Who: Acro Trailer, Springfi eld, MO, Established in 1960 www.AcroTrailer.com

What: Provides the liquid transportation industry with high quality tank trailers.

How: (2) TruTool C 250

FABTECH Buyer’s GuideThe Power of Choice—(and right at your fi ngertips)

TRUMPF at FABTECH 2011 Booth 1100

The Poower of Choice—(a

The possibilities in business are limitless, and every manufacturer

has a unique set of business requirements. That’s why At

FABTECH 2011, held November 14-17 in Chicago, TRUMPF will

feature products that empower fabricators by offering them

choices in cutting edge technology.

yyour fi nggertips)and righht at

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And TRUMPF puts useful information about its machinesand

services right at your fi ngertips. Stop by the TRUMPF Café

in the TRUMPF booth, and learn about MyTRUMPF.com, the

company’s customer portal to useful, streamlined information

on machines, products and services, such as E-Shop Spare Parts.



FABTECH 2011

TruLaser 1030Working range: 120 x 60 in.Laser specifi cation: TruCoax 2500Max. power: 2500 WMax. sheet thicknessMild steel: 0.625 in.Stainless steel: 0.314 in.Aluminum 0.25 in.

TruLaser 5030 fi berWorking range: 120 x 60 in.Laser specifi cation: TruDisk 3001Max. laser power: 3000 WMax. sheet thicknessMild steel: 0.8 in.Stainless steel: 0.625 in.Aluminum: 0.625 in.Copper: 0.25 in.Brass: 0.25 in.

The Power of Three.The Power of Choice. TruLaser 5030 fi ber. TruLaser 1030. TruLaser 3030.

At this year’s FABTECH show, TRUMPF demonstrates its broad array of

2D laser cutting capabilities with three laser cutting machines and three

different laser resonator technologies. With the power of three, fabricators

now have more options than ever before.

TruLaser 5030 fi ber

This fi ber-guided, solid state laser lowers cost of parts by up to 20 percent.

Sheet metal fabricators who cut parts out of thin sheet material will fi nd

the TruLaser 5030 fi ber, with its fi ber-guided TruDisk solid-state laser, able

to achieve feed rates up to three times faster than the CO2 version—due to

fusion cutting of stainless steel up to 0.16 in. thick. This reduces the table

time up to 45 percent, and signifi cantly decreases the cost per part.

The TruLaser 5030 fi ber cuts not only mild steel, stainless steel and aluminum

cost-effectively, but also non-ferrous metals such as copper and brass.

The core of the TruLaser 5030 fi ber is a fi ber-guided TruDisk solid-state laser

with an output of 3 kW. With the 2D laser cutting system, users can process

sheets measuring 10 feet x 5 feet. To keep processing time as low as possible

and to increase the fl ow rate of parts, the TruLaser 5030 fi ber has features

that have already proven themselves in the CO2 laser version including the

single-cutting head strategy and automatic nozzle changer.

TruLaser 1030

A machine with extremely low investment and operating costs and an

operating principle that is revolutionary in its simplicity, the TruLaser 1030

offers the ability to easily add laser cutting to in-house services—opening

the door for fabricators to pursue new business opportunities. And now

there are multiple options within the TruLaser 1030 product line that

empower manufacturers to make choices depending on their individual

preferences and business requirements: The TruLaser 1030 with TruCoax

2500, featuring 2.5 kW of power, and the TruLaser 1030 fi ber with TruDisk

2001 solid state laser and 2kW of laser power.

The TruLaser 1030 is available with a light barrier for a fully automated

pallet change.


TruLaser 3030

With its reliable and time-proven TruFlow CO2 laser, TRUMPF’s TruLaser

3030 offers fabricators high process dependability. Available with up

to 6 kW of laser power and TRUMPF’s RotoLas tube cutting option, the

TruLaser 3030 with single cutting head strategy sets the standard for

the future with features the increase productivity and fl exibiliy when

cutting sheet thicknesses up to 1 inch.

The result of the innovative technology found in the TruLaser 3030 is

that a greater number of parts can now be cut in the same amount

of time. Another result is that the power usage per part is reduced,

making the TruLaser 3030 an excellent example of energy-effi cient

productivity.

The pallet changer can be installed on the TruLaser 3030 parallel or

perpendicular to the machine. This allows ideal space utilization and

requires 20 percent less installation space. Another advantage of the

perpendicular positon is that the operator has a view of the entire

process from the control panel.

TruMatic 7000:The Perfect Combination

TRUMPF’s new combination machine, the TruMatic 7000, sets the bar

for the industry. The TruMatic 7000 combines the best of both words:

scratch-free punching and laser processing. With this machine, sheet

metal fabricators now have a highly dynamic solution.

Reliability and versatility are at the heart of this TRUMPF innovation.

The machine features 4 kW of laser power for the highest cutting

dynamics, along with productive punching with a maximum stroke rate

of 1200 ipm in the medium format, 1000 ipm in large format.

The TruMatic 7000 is effi cient and powerful. Single cutting head

strategy and fast nozzle changer facilitate unattended operation over

multiple shifts, and an active die for extending forming capability

allows for larger, higher forms and an active upward forming stroke.

A SheetMaster designed to cater to the top-notch performance of

the TruMatic 7000 offers an extremely dynamic, reliable and versatile

option. Achieve high productivity with its dynamic operation and

simultaneous unloading of up to four parts, maintain superior process


TruMatic 7000Working range: 100 x 50 in. 120 x 60 in.Laser specifi cation: TruFlow TruFlowMax. laser power: 4000 W 4000 WMax. sheet thickness: 0.314 in. 0.314 in.Max. stroke rate punching: 1200/min. 1000/minMax. stroke rate marking: 2800/min. 2800/min

TruLaser 3030Working range: 120 x 60 in.Laser specifi cation: TruFlow Max. power: 6000 WMax. sheet thicknessMild steel: 1 in.Stainless steel: 1 in.Aluminum: 0.625 in.

TruLasa er 3

With i

30


reliability with its versatile suction positioning and additional laser axis, and

operate in unmanned shifts by using the single cutting head strategy and

automatic nozzle changer.

TruMark Laser Marking Systems: Beauty, Versatility, Speed and Precision

With high quality laser marking systems equipped with every available type

of marking laser: YAG, vanadate, and fi ber, TRUMPF meets your application

requirements.

TruMark 6030

The TruMark 6030, designed for high pulse energy and superior pulse-peak

power to create crisp and high contrast marks, is particularly noted for its

versatility.

This laser marking system enables users to perform any marking process

quickly and with a high level of quality, including annealing, engraving,

color change, and foaming. The selection of materials is just as fl exible. The

TruMark 6030 performs on metals, ceramics and plastics. This diode pumped,

Nd-YAG laser operates in the infrared range of 1064 nm.

The TruMark 6030 laser features a considerably shorter mark time when

compared to other products in the TruMark Series 6000. TRUMPF has

increased the output of this marking laser by 35 percent, reducing cycle

times by the same percentage.

TruBend Series 5000 and 7000:Many options, much fl exibility

What do you require of your press brake? Whatever your bending

requirements may be, TRUMPF continues to put the power of choice in

manufacturers’ hands by providing innovative, industry-leading products to

meet any challenge.

TruBend Series 5000

TRUMPF’s TruBend Series 5000 family of press brakes are known for their

versatility, and productive processes from programming and tool set up, to

the bending procedure itself.

FABTECH 2011

TruBend 5130Press force: 141 tonsBending length: 127 in.Rapid approach & return: 520 ipmWorking speed: 24 – 36 ipmInstallation height: 24 in.Stroke 17.5 in.Throat depth: 16.5 in.

TruMark 6030 Wavelength: 1064 nmLaser medium: Nd: YAGPulse repetition frequency: cw, 1-120 kHzMax. marking fi eld: 11.4 in., F=16.5 in.


This hydraulic press brake system is able to handle a wide variety of

precision bending of parts in various sizes, types of materials and

material thicknesses, and features 4-cylinder technology and ACB

(Automatically Controlled Bending) to ensure that the fi rst part is a

perfect part.

Available with a press force ranging from 55 to 353 tons and two, six

axis back gauge solutions, the TruBend Series 5000 press brakes are

equipped with a visual setup and positioning aid comprised of an LED

light bar integrated in the cover of the upper tool clamp. During tool

setup the visual set-up aid indicates the positions where the bending

tools should be loaded. The operator inserts the tools at the location

of the LED lights rather than having to read the setup sheet and then

locate the tools according to the scale on the machine. Productivity

during the bending process is further increased by the visual

positioning aid. It clearly identifi es the next bend location, eliminating

mistakes and constant reference to the control or setup sheet.

TruBend Series 7000

High-speed bending of smaller parts from thinner materials is the

hallmark of the TruBend Series 7000 electric press brake.

The compact TruBend Series 7000 feature ergonomically-correct

conditions for the operator, creating optimum working conditions and

user-friendly operating elements that are integrated into the machine

design. The operator can control the machine while sitting down and

work without becoming fatigued, which helps ensure the quantiy and

quality of the fabricated parts. Foot and arm rests can be adjusted so

that every operator can set up his or her workplace individually.

Typical applications of the TruBend Series 7000, which provides high-

quality, effi cient solutions for the production of small bent parts

up to 40 inches, include sheet metal parts used in the production

of vending machines and electrical equipment, as well as in the

telecommunications and aerospace industries. Optional TRUMPF

LED lighting illuminates the area in front of and behind the beam,

ensuring correct lighting conditions precisely at the bend, without

heat radiation.

g g g p

at radiation.

TruBend 7036Press force: 40 tonsBending length: 40 in.Rapid approach & return: 520 ipmWorking speed: 24-59 ipmInstallation height: 12 in.Stroke: 4.75 in.Throat depth: 6 in.

This hydraulic press brake system is able to handle a wide variety of

precision bending of parts in various sizes, types of materials and


TruFlow

Over many years, TruFlow CO2 lasers have become well established in laser

materials processing, and are known for their reliable and robust beam

sources. Tens of thousands of beam sources worldwide have proven this

laser consistently dependable as a universal cutting and welding tool.

TruCoax

Diffusion-cooled CO2 lasers are impressive due to their compact and

lightweight design. And with a high beam quality, they are optimal for

thin sheet processing.

TruDisk

With laser outputs of up to 16 kilowatts and beam qualities starting at 2

mm*mrad, disk lasers offer unrivaled robustness - for highly productive

thin sheet cutting as well as for welding.

TruDiode

The diode direct lasers are extremely energy effi cient and particularly well

suited for welding and brazing applications.

TruFiber

Fiber lasers are impressive due to their high processing speeds in the lower

output range. With laser outputs between 200 and 400 watts in basic

mode beam quality, they are ideal for precision processing.

TruPulse

With short high-energy pulses at a higher pulse output, pulsed solid-state

lasers are ideal for spot or seam welding as well as cutting.

TruMicro

Short and ultra-short pulse solid-state lasers are being successfully used in

micro production and photovoltaics for structuring, material removal, edge

stripping, cutting, or boring.

TruMark

With beam sources in all relevant wavelengths (infrared, green, ultra-

violet), marking lasers mark metals, plastics, glass, ceramics or organic

materials - at a high quality level that lasts.

One size does not fi t all

Optimization of diverse applications requires different laser technologies

and TRUMPF offers the largest application and service network in the

world as well as the broadest industrial portfolio of any manufacturer.

TRUMPF’s full range of laser technologies is up to your challenge.

FABTECH 2011


TruTops Software

TRUMPF software products and solutions provide idea support for

all of your sheet metal processing needs. In addition to solutions for

sheet metal design, programming systems and proposals for complete

production control, we offer custom products to match your specifi c

requirements.

Design Software

With numerous functions geared toward sheet metal processing,

TRUMPF design software is a time-saver. Integration of TRUMPF

bending factors ensure precise production and the modular principle

results can be adapted to your needs. It also coordinated perfectly

with TruTops programming systems.

Programming Systems

The perfect mix of productivity and process reliability gives

you complete control of part processing. It features a seamless

modern operating concept focused on ergonomics and effi ciency.

Programming systems are integrated into the total TRUMPF concept

from design to production planning.

Production Control

With TRUMPF production control software you have a constant

overview of your production situation enabling quick response to

interruptions. Production sequences and processes are optimized,

which assists in controlling costs.

TruTops Software:machine intelligence

With TRUMPF software products you benefi t from ideal interaction

between machine, control system and production software—because

nobody knows TRUMPF machines and technology as well as we do.

2424 Express Vol. 2/1124 Express Vol. 1/112424 Express Vol. 2/11

Shears/Double Cut Shears

A complete line of shears that is ideal for cutting jobs where material loss

through chips must be avoided.

Nibblers

TRUMPF nibblers are easy to guide and cut distortion-free through a

variety of thin and thick (0.375 in. in mild steel) materials including stainless

steel and aluminum.

Fasteners/Seam Lockers

Facilitate production of standing and angular seams at tight angles, as well

as closing Pittsburgh Seams.

Bevellers

Provide clean, accurate edges that help guarantee good weld quality;

TRUMPF bevellers can start a bevel at any point with no structural damage

to the material.

Chamfer/Deburr

TRUMPF chamfering and deburring machines create cuts with excellent

surface quality, which is important for large visible welded edges.

Slat Cleaner

Removes slag build-up on support slats without interrupting production.

It is a simple and cost-effi cient alternative to manual slag removal or

complete slate replacement.

oduction.

moval or

TRUMPF’s Portable Power Tools:the right choice for the job, hands down.

More than three-quarters of a century of experience in designing rugged,

precise portable power tools for the HVAC, metal shop, construction and

other related industries.


The owners of EMJD prove that

home is where it’s happening

Roots of success

“You can’t go home again” has become woven into the fabric of American speech ever since author Th omas Wolfe penned a book by that title back in 1941. Th e phrase generally implies that once you leave home, you can’t return and fi nd success there. But Scott Noyes and his business partner Jeff Madsen are two guys who’ve put an end to that whole notion. Both men, who grew up in Littleton, Colorado and have been great friends since their late teens, left the area, and then returned. Th ey now own EMJD, a successful, precision sheet metal company that has some of the most cutting edge technology found anywhere in the country. In fact, EMJD was TRUMPF’s fi rst 4000 Watt laser customer in the Rocky Mountain region back in 2002, and ever since then Scott and Jeff have generously opened up their shop fl oor to prospective TRUMPF customers—even to friendly competitors—who are interested in learning more about TRUMPF technology.

The team at EMJD opens their doors to friendly

competitors.


CUSTOMER FOCUS

Diverse industriesEMJD has an interesting and diverse customer base. For example, the company fabricates enclosures for the safety and security industry. One component they fabricate is stainless steel faceplates with holes that house electronics (think of the touch pad on your home security system). EMJD also manufactures enclosures for high end audio and computer equipment including mixing boards for a customer that sells equipment to radio stations. Remember Dr. Frasier Crane, the radio psychiatrist on the television sitcom Frasier? Dr. Crane was working on mixing boards from EMJD, who fabricated them for its client who puts electronics behind the boards and then sells them to about 80 percent of the country’s radio stations.

Another industrial market EMJD serves is the automatic and manual car wash industry. Th ey manufacture a variety of items from the track the cleaner travels on as it rolls back and forth over a car during the wash cycle, to the entire enclosures that your vehicle passes through when you pull into your neighborhood touch-less car wash. Since taking the helm at EMJD in 2001 aft er purchasing the company from Scott’s father, Don, the business partners have continued to grow the company by about 20 percent annually, which is no small feat given the economic challenges of the time.

Family mattersIt makes sense that Scott is leading the sheet metal fabricating company his parents started. Aft er all, he was earmarked as the sibling—the one out of Don and Dorothy Noyes’ four children—who seemed to have a natural aptitude for the manufacturing business. An older brother now works at EMJD as the company’s programmer for laser and punch, a sister is an aeronautical engineer for the defense industry, and another brother is a pilot for United Airlines. Th at all four of the Noyes kids are successful in their own right is not accidental. Jeff said that much of their success is owed to lessons learned on EMJD’s shop fl oor, where they cut their working world teeth. Th eir father, Don, founded EMJD in 1970 aft er he’d spent 12 years in manufacturing in Santa Clara, California working as a foreman for a company called EMJ. He moved to Colorado to satisfy customer demand, and added the “D” to create EMJD. Don, “who built the company from basically nothing,” said Scott, did sales during the day, and then fabricated the orders at night. Dorothy, Scott’s mother, handled the accounting end of the family operation. “Th ey kept a clean balance sheet and never utilized a line of credit,” said Scott.

Scott Noyes and Jeff Madsen of EMJD.


Th is was the kind of work ethic that he and all four siblings grew up with, but it was Scott who demonstrated a talent for manufacturing and running a company. “I’d sit back there with my brother and check panels until we were blue in the face,” Scott recalled of his fi rst job at EMJD. He was about 14 at the time. When they reached the age of 16, according to Scott, his father would let the kids step up to sanding. “So I moved into de-burring,” said Scott. “Basically, that’s really where you start to learn the manufacturing business. Everyone spends time there. Aft er you’ve mastered sanding, tapping and a little bit of machine work, from there, if you can look at prints and read them, then opportunities open up and you can move into other areas.” Scott attributes his early success in manufacturing to aptitude. “If you look at something and can kind of fi gure out how it’s made and visualize it in your head, I think that’s a key. I could look at it and I just had a good feel for it.” Aft er he obtained his undergraduate degree, Scott admitted that he wanted to light the world on fi re, and working in his father’s business wasn’t really where he wanted to be. So he ventured out instead, into a very successful career in the fi nancial industry. “My Dad said he’d love for any of us kids to come into the business, but if none of us chose to he’d just sell it,” Scott explained. “It was never like, ‘One of you guys has to take over this business.’” But in the early nineties when his father lost his long time foreman, Scott returned to Englewood to help out. Aft er awhile though, he realized his father was still not ready to completely release the reins of the business, so for a second time, Scott again ventured out . “Th ere were things I wanted to do diff erently, but at that time it was still my Dad’s way or the highway, and EMJD was his baby.” Th at was in 1991. “I had this opportunity with Th e Boeing Company that fell into my lap,” he explained, so Scott headed to Seattle. But on his way out of town, he stopped to tell his good friend Jeff , who was becoming his father’s right-hand guy at EMJD, to, “Hang out, and take care of my Dad. It’ll all play out and I’ll come back and we’ll buy this thing.” Unlike Scott, who was raised in a manufacturing environment, Jeff ’s manufacturing background was formed when he went to work for EMJD. Before that, he’d worked as a bouncer at a bar in his late teens, before heading to Hawaii for a few years to run a wholesale business—eventually

returning to Englewood. Jeff followed his friend Scott’s advice to go talk with Don at EMJD to see if there might be a job for him there. Jeff was hired as EMJD’s shipping manager in 1988. However, “It didn’t take my Dad long to fi gure out that Jeff had an aptitude for more than working as shipping manager,” said Scott. While working at EMJD, Jeff started taking classes in mechanical engineering and worked his way up in the company. Eventually, Scott said that Jeff was doing 90 percent of everything, including preparing quotes, and his Dad was doing less and less. “When my Father was ready to retire,” said Scott, “Jeff and I sat down and talked with him, then put together a deal and bought him out.”

Exception to the ruleWhen it comes to doing business with friends, Jeff said that he and Scott, “Don’t seem to have any problems. We are the exception to the rule.” However, he added that as friends, “We spend less time together outside of the offi ce than we used to. It’s less frequent than it was 20 years

ago, because we end up talking about work.” But that’s not the only thing that’s changed over the years. According to Jeff , “Ten years ago, 80 percent of what we fabricated was repetitive and 20 percent was new.” But that’s shift ed, and today 80 percent is new and only about 20 percent is repetitive. As the business partners refl ected on the changes they’ve seen at EMJD during the past decade, Scott said, “We’ll sometimes say to each other, ‘What happened to the days when we used to hang out and laugh about things?’ Now it’s completely opposite from that.” Aft er pausing for a moment, he off ered, “But that’s change, and it’s what’s kept us going and allowed us to grow.”

Who: EMJD Corporation, Englewood, Colorado Established in 1970, www.EMJD.com

What: Precision sheet metal fabricators

How: TruLaser 3040 with LiftMaster, TruBend 5230 and TruBend 5230 with BendMaster

EMJD Corporation

CUSTOMER FOCUS

”If you look at something and can kind of fi gure out how it’s made and visualize it in your head, I think that’s a key.”


Pretty as a picture postcard in the Black Forest. But instead of cattle, there’s a TruLaser 1030 in the barn at the Krämer farm. Working with his wife Sabine, Martin Krämer takes care of both the farm and metal manufacturing operations.

FABRICATING



The TruLaser 1030 clearly survived the journey to the remote farm. Working in ten-hour shifts, the company primarily works construction steel from one to twelve millimeters thick. Familiarization was no problem for Krämer’s team. “It’s almost as easy to use as a coff ee maker,” Martin Krämer notes. Only three days of training were necessary to make a full-fl edged entry into the laser business. On a normal workday the boss will also be in the shop, in his overalls, while his wife takes care of paper- work in the offi ce. Th e family fully

supports the project wherever possible. Even granddad helps wherever he can. Almost eighty years of age, this former farmer stands entirely behind his son’s company, even though the cows had to give way to the machinery. In spite of the fact that business is good, Martin Krämer has not yet thought about expanding. In the near future he wants to try his hand at cutting stainless steel. For this father of three, working at home is ideal. It’s no surprise that he intends to stay right there on the family farm. It makes sense enough. Who would want to abandon such an attractive workplace?

Who: Krämer Brennteile in Hofstetten. Founded in 2001, 5 employees. www.kraemer-brennteile.de

What: Laser-, fl ame- and plasma-cut parts, bent components

How: TruLaser 1030

Pitching in to work sheet metal

Some truck drivers have their doubts as they wind their way over country roads to Krämer Brennteile. Th e idyllic countryside surrounding the farm in the Black Forest is more reminiscent of a vacation area. But you would search in vain for a hotel — or cattle, for that matter. Instead you will fi nd a substantial manufactory for sheet metal processing. In addition to construction steel and a fl ame cutting machine, a TruLaser 1030 has found space in the outbuildings. In spite of a classic vocational education in agriculture, Martin Krämer did not work as a farmer for very long, “because there just wasn’t enough money in it,” he recalls. As a result he started doing odd jobs at construction sites, had a job in advertising, and fi nally worked his way up to production manager in a sheet metal processing shop. Nine years ago he decided to hang out his shingle. In my positions I had always assumed so much responsibility. And at some point I realized, ‘You can do this yourself!’” No sooner said than done! Th e farm equipment was cleared out in 2001 and Krämer invested in a fl ame cutting machine.

A partner Th is daring initiative paid off . Krämer Brennteile grew quickly, even though the company’s founder never did any active advertising. “On the fi rst day in business I called up a few companies I knew and told them I had opened my own shop. Th at’s all.” A down-to-earth attitude and professional profi ciency are what make this businessman so convincing. His approach is simple. He turns out short production runs both quickly and reliably. But Krämer’s team is not made up solely of metalworkers. Two ma- sons and two carpenters also work steel on the farm and seven part-timers lend a hand when needed. Th ey all know about fl exibility in their working hours and punching the time clock is out of the question. It’s usually a matter of getting the work out when it’s on hand, day by

day. “Sometimes a shift can last ten or fourteen hours,” explains the boss with a grin. But word of the company’s willingness to pitch in has got- ten around. Today the farm serves 170 customers in the region. Krämer’s clientele is widely diversified. Among them are vehicle builders and mechanical engineering companies, but also small fi tter’s shops and tradesmen. It sometimes happens that a new part is made up based only on a cardboard model or a fragment of a broken machine part. Th e fi rm’s own truck

makes deliveries to customers, mostly small and medium-sized companies nearby in the Freiburg and Off enburg districts. Gradually the company started off ering welding work and coatings, and it soon became apparent that in order to keep customers satisfi ed over the long term, Krämer was going to have to add laser cutting to his off erings. Choosing the machine manufacturer was not diffi cult. “I knew TRUMPF machinery from the past and quality was always spot-on.” Th e problem was the limited size of the barn. All the systems available on the market to date were too large. Th at wasn’t true for the TruLaser 1030, unveiled in 2009. Space-saving, easy to operate and with a good cost-benefi t ratio — this innovation was convincing from the very start. Krämer, the fi rst customer in Germany to purchase the TruLaser 1030, bought the machine during the Blechexpo trade fair. Th e timing turned out to be perfect. When orders lagged in 2009 the employees rebuilt the former cow barn to make space for the machine. Th e remodeling was completed just in time for delivery in June 2010.

It was love at fi rst sight. Martin Krämer and the new TruLaser 1030 were destined for one another.

The job shop owner bought the machine “right off the lot” when it premiered in Stuttgart, Germany

at the end of 2009. Today that laser cutting machine is located in what used to be a cow barn.

Steel instead of stalls

“The TruLaser 1030 is almost as easy to use as a coffee maker.”

FABRICATING


CRAFTSMANSHIP

Like many recent college graduates today, when Robert Ferraroni, owner of Ferra Designs, thinks back to when he completed his degree in industrial design at Pratt Institute, he remembers his expectations did not correlate with the job market. “I was twenty-two and looking to be exposed to exciting, new ideas. I quickly found there was a shortage of industrial design opportunities and what was available, was not inspiring.” Fortunately, his education combined with the handcraft ing skills imparted by his father, a European cabinet maker, began to earn him freelance opportunities in furniture building and interior work for night clubs in New York. By 1989, “I found I was fi lling a niche with the freelance work, designing and building,” and he decided to pursue it full time. Armed with a credit card, welder, a few hand tools and a newly rented studio in the Williamsburg neighborhood of Brooklyn, New York, Rob launched Ferra Designs. Initially, his focus was privately commissioned furniture designs for prestigious clients in the area, but by the end of the nineties, the company had off set furniture design with architectural metal work. In 2000, Rob met Jeff Kahn, co-owner of Ferra Designs, through mutual friends in Brooklyn, New York. Th e partners met during a time when the city was experiencing an increased demand for

Founded in tradition

Artistry, craftsmanship and versatility

Jeff Kahn, standing, and Rob Ferraroni of Ferra Designs.


CRAFTSMANSHIP

contemporary blacksmithing work, a mutual interest of the two designers. In addition to being a sculptor, painter, and photographer, Jeff ’s status as a skilled metalworker made him a perfect fi t for the growing company. Th ey decided to collaborate.

Embracing technologyTh e partnership between Jeff and Rob resulted in a paradigm shift in the culture of the company from a technical standpoint. While the business had been grounded in traditional, handcraft ed production, the growing popularity of the internet at this time required Ferra Designs to become more resourceful, faster at expediting the fi nished product, and more competitive. “Building by hand had become too complicated and competitive in a city such as New York. Jeff believed in technology and was the real catalyst in moving in that direction,” explains Rob. So, with Jeff came the decision for Ferra Designs to invest in metalworking technologies. They moved their shop to a ground fl oor location in the Brooklyn Navy Yard and began to purchase water jets, CNC milling and precision welding equipment. A TRUMPF CNC press brake was also added; an integral tool in Ferra Designs’ recent development. With the new technological capabilities, the company has been able to take on projects that combine creative design and functionality with a production aspect that makes designs reproducible. Th e technology has been advantageous in wine cellar design, a particularly exciting area for the designers. While traditionally there is limited metal work involved in wine cellars, Ferra Designs’ has been groundbreaking in the design of metal embellishments, doors, wine bins, and other display concepts for Dalst Wine Cellars. “Customers are as passionate about their wine cellar as we are about the design.” Rob explains, “Th ey become excited about our work and really embrace our eff orts.” By staying current with technology, Ferra Designs is able to meet diffi cult customer demands without compromising on quality or aesthetic expectations. “Prior to the TruBend 5170, we lacked modern bending capability. Th e machine opened up a whole new design direction, with particular inspiration for the complex shapes and bends common in the fi eld of architecture.” Th e designers are excited about the challenging new projects that are possible because of the fabricating technologies, including stylish restaurants such as Dressler in Brooklyn, New York, trendy residential properties, and even Brooklyn Bowl, a Zagat rated “top music venue,” which redefi nes the concept of a bowling alley. “We also really enjoyed working on staircases for PS90, a public school built at the turn of the century.” Having once been under complete disrepair, a developer recognized the character and potential of the space for high-end housing in the up-and-coming Harlem.

Design and product development Now, these cutting edge industrial artists are looking to take advantage of reproducible results by starting their own product lines. “Last year, we added additional space in the Brooklyn Navy Yard; exclusively for design.” As Jeff explains, “We are introducing our own product lines to incorporate areas where we are individually passionate about into the business.” While Rob has been getting back to his roots, developing products in furniture design and architectural lighting, Jeff has embraced his deep-rooted fervor for music and art. Jeff has been working with audio engineer Jeff rey Jackson of Experience Music, Inc. to produce high-end, semi-customized audio equipment which integrate vintage circuit designs with modern technologies. “Th e early cinema sound systems introduced by Western Electric were able to produce sound that was simply phenomenal. Over the years, consumers have pushed for sound equipment to become smaller and more compact, but we are going the other way and moving away from digital audio and achieving extraordinary sound.” Ferra Designs then captures this sound with the equally beautiful chassis body, speakers, and preamplifi ers. Th e combination of traditional handiwork with contemporary design is a thread that runs deep throughout Ferra Designs. While investing in technology has opened the door to new and exciting opportunities, Jeff and Rob continue to off er custom metal work for top architects and maintain the extensive blacksmithing operation on a historic farm in Denver, NY. Whether produced manually or with state-of-the-art technology, the attention to artistry and quality craft smanship is fundamental to Ferra Designs.

Who: Ferra Designs Inc., Brooklyn, New York. Established in 1989. www.FerraDesigns.com

What: Precision architectural metal fabrication

How: TruBend 5170

Ferra Designs Inc.

A wine bin by Ferra Designs, created with the help of TRUMPF’s TruBend 5170.


PERSONALITIES


Jared Szechy has a talent for fi guring things out

Sheet metal overhaul


PERSONALITIES

Jared Szechy is profi cient in several languages that are Greek to most people. Th ey’re the kinds of languages that English Lit majors seem to envy: C/C++, C#, Java, VB, Verilog, VDHL, PHP, SQL, and HTML. A recent college graduate, Jared has a degree in computer engineering from the University of Dayton, where he was awarded the school’s prestigious Presidential Scholarship. With a left brain that’s been in perpetual motion ever since he can remember, Jared, who was born and raised in North Royalton,

Ohio, near Cleveland, recalls creating some hair-raising moments for his family as he was growing up. “Oh, yeah,” he said when asked about his penchant for lift ing the hood on the car, taking a screw driver to household appliances, trif ling with electrical sockets, and other antics well-suited to a curious kid with an inclination for learning how things work, “I can remember my Dad saying, ‘If it’s not broke, don’t take it apart.’” But that’s all changed. Th ese days, when Jared drives over from Dayton to visit his family, they have a project list ready and waiting for him. Th roughout his college years, Jared had the perfect summer job for someone with his set of skills. Family friends who own Acromet Metal Fabrication, located in his hometown of North Royalton, brought Jared on to the shop fl oor where he was assigned to help out with and eventually operate TRUMPF’s TruLaser 3530. He remembers the fi rst part he ever cut with the machine: it was a garden fairy.

“I’m fascinated by technology,” said Jared. “It’s always fun using the TRUMPF laser, and the stuff it can do is incredible.” But as much as Jared enjoyed working with the TRUMPF laser cutter, there was one small hiccup. “Unless you work with sheet metal every day, it’s hard to memorize the thickness of the material,” he explained. “Sheet metal thickness is on a gauge scale. Th is scale is diff erent for diff erent materials as well. Needless to say, unless you have a table handy, it is diffi cult to

remember the measured thickness for each gauge material.” However, with his talent for fi guring out things, Jared decided to develop a sheet metal application for the Android market that would solve the problem. “I just hard coded the tables for aluminum, stainless and carbon steel, and have them displayed in a tabbed list view,” he explained. “Aft er ponying up the $25 to publish to the Android Market, my app was live. And aft er a couple hundred installs, I added some additional features per users’ requests, such as sheet weight and tolerances.” When he created his sheet metal app, Jared was one of the only employees at Acromet with an Android phone—so his co-workers didn’t have much feedback for him. However, he received plenty of advice from the Android community, and in late summer of this year he fi nished a complete overhaul of his sheet metal application. He said that he “completely ditched” his initial version, which was more of a prototype. Version 1.0 of Jared’s

sheet metal app was offi cially launched August 13 of this year. According to Jared, with the initial version he received complaints about the lack of sheet dimension settings. With the new version, a feature has been integrated right into the details page. Dimensions can be easily changed, and the weight and tolerance information dynamically updates. “Th ere is no need to change screens, or open menus,” Jared said, and added, “Th e sheet sizes are also saved for each material type.” Jared’s sheet metal app features tables that list the thickness of aluminum, carbon steel, and stainless steel sheet metal. It also calculates the corresponding weight and ASTM tolerances of each sheet. As far as Jared knows, his is the fi rst sheet metal app ever created for the Android marketplace. He said those who will benefi t the most from the app are new to sheet metal fabricating, and also established fabricators who work with many diff erent sizes and types of material. Defi nitely not an “Android-only” kind of a guy, though, Jared has an iPod that he loves. But when asked if he thought about developing a similar sheet metal application for the iPhone, Jared said probably not. Sheet metal apps for the iPhone already exist, he explained. “I’m not into duplicating apps; if it’s already out there, I wouldn’t want to do it.” Th is young computer engineer from Ohio views his sheet metal app as a “stepping stone into Android programming.” Jared Szechy is always looking for the next big project. “I’m always developing something,” he said. In the meantime, he still has work to do on his current sheet metal app. “I still need to get my hands on the ASTM aluminum standards so I can add tolerances for aluminum as well.” Jared’s sheet metal app for the Android is free-of-charge and may be downloaded here: https://market.android.com/details?id=com.goliathonline.android.metalgauge

“Dimensions can easily be changed, and the weight and tolerance information dynamically updates.”


CREDITS

TRUMPF Express 2/11Magazine for Sheet Metal Processing

Published by

TRUMPF Inc.

Farmington, CT 06032

www.us.trumpf.com

Responsible for the content

Sheila LaMothe

Editor-in-Chief

Melanie McMillan

860-255-6112

[email protected]

Editorial Staff

Mike Gordon

Susan Grohs

Sheila LaMothe

Taryn Murphy

Nathalie Reuster

Design and production

John Mik, MIK Advertising & Design

Printing and assembly

Paladin Commercial Printers, LLC

Contributors

Keri Bailey

pr + co. gmbh, Stuttgart

Photographs

Steve Adams

Biel Photographic

BEGNEAUD Manufacturing

MRC Medical Communications

Cheryl Heath

Rockafellow Photography

EMJD

Ferra Designs

STORIES IN SHEET METAL

Anyone who has experienced a win at the slot machine will tell you that that distinctive clattering of coins is music to one’s ears… and it’s all made possible by metal. Metal currency was first minted in 7th century BC coastal Greece. Gold, a precious metal thought to be valuable since the beginning of time, was a popular choice for the original metal coins. Most were made from the natural alloy called electrum, a diluted mixture of gold and silver. Eventually, the ancient Greek

kingdom of Lydia began manufacturing purely gold coins, which became the offi cially issued coinage of Greece. Soon aft er, silver coinage was introduced and became a widespread trend throughout the region. In fact, up until the 20th century, silver was the most popular metal used for the production of coins. Th e fi rst coin to ever achieve international standard status was the tetradrachm, a silver coin used commonly for all kinds of transactions in the Grecian world. Th e coin was stamped with popular Greek iconography: the head of the goddess Athena on one side, and the images of an owl, an olive sprig, and a crescent moon on the reverse.

Around the same time, The Persian Empire was collecting taxes in gold and minting gold coins, which the corrupt Persian kings would stockpile. Following the invasion of Alexander the Great, the hoarded coins were put into circulation, eff ectively causing the fi rst known infl ation event. Th e Persians were also responsible for minting the dinar and dirham, gold and silver coins that were ultimately adopted for use by the Islamic world.

Not to be outdone, ancient Rome was also busy at the mint. Two coins important to the era were the aureus, made up of gold alloyed with silver, and the solidus, a smaller coin of mostly gold. Th e Republic of Venice to the north was thusly inspired to create the renowned ducat – a popular coin for years used for trade throughout Europe, originally made of 100% solid gold. So the next time you’re jingling the coins in your pocket on the way to the vending machine or hearing that happy jangle while fi lling up your piggy bank, remember the ancient origin of our nickels and dimes.

There’s a story behind that

penny in your pocket

Metal matters

Two coins found in ancient Rome.


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Building a coliseum

In 1914, the first bowl shaped stadium in the country was built at Yale University in New Haven, CT. More than a National Historic landmark, it is a coliseum built on tradition, where young Ivy League football stars and other athletes have become heroes. So, when renovations needed to be made to one of the “true

treasures in American sports,” they turned to ES Metal, a Connecticut job shop, for help producing dist inct ive ra i l ings with unique dimensions. Fabricated from raw sheet, they were manufactured with the TruLaser 4030 with the same commitment to excellence and dedication as the athletes on game day.

Documents

TRUMPF Express V2/11