• Process time went down to 25% of the original time for foam insulated panels (order specific).

• Preparation time reduced by 50%.

• Operations now require less labor and significantly less expertise.

• Rework reduced to almost zero.

Lenmak Exterior Innovations Inc., established in 1996, is a global leader in manufacturing state-of-the-art light gauge metals for residential, commercial, and agricultural applications. With a steadfast commitment to innovation and operational efficiency, Lenmak specializes in cutting-edge manufacturing processes.

While Lenmak's automated sheet punching and bending systems were high performing, they identified room for improvement in the foaming station of their insulated panel production line. The foaming process, although automated, still had elements of manual operations and required specialist knowledge, adding to the overall production time. Their goal was to streamline this process further.

Lenmak partnered with Negmax Industrial Innovations Inc., known for its exceptional prowess in CNC technology. Negmax proposed a comprehensive solution that included upgrading the outdated CNC control system, designing a streamlined CAM solution for panel patches, and creating a deterministic model to tackle the irregular behavior of foam expansion.

Negmax implemented the proposed solutions meticulously. The control system of the CNC machine was upgraded to accommodate new technologies and maximize hardware utilization. An application-specific CAM system was developed to handle panel patches efficiently. Finally, a near-deterministic mathematical model was created for the foam formula, based on testing numerous panel sizes against their optimal foam volume. This was then integrated into the CAM calculations.

Post-implementation, Lenmak experienced significant improvements. Manual operations were replaced, and preparation time was halved. The process could now be completed with significantly less expertise, thanks to the new system's ability to predict the foaming volume. Full machine utilization was achieved, reducing the process time to 25% of the original time, depending on the order. The rework rate was almost zero, demonstrating the robustness of the new system.

"Despite investing millions in high-end machinery, the true game-changer has been Negmax's remarkable expertise. Their ability to integrate and optimize our systems was the missing link in fully unlocking our production potential. It goes to show that machines are just tools - you need a great brain to make them work optimally together." 

This collaboration between Lenmak and Negmax is a testament to Negmax's commitment to delivering tailor-made solutions that enhance productivity and efficiency. By integrating smart technology and custom solutions, they helped Lenmak overcome a significant production bottleneck, setting a standard for future projects. The successful outcome reaffirms Negmax's ability to deliver outstanding results for their clients.