• Customer fulfillment time slashed by 50% from 2 days to 1 day.

• Engineering time for parts preparation saved by 70% - 90%.

• CNC operator's time reduced by at least 50% through automation.

• Full automation achieved for the plasma cutting system, improving efficiency and safety.

• Significant reduction in the expertise and risks associated with the process.

Metal Supermarkets, a leading franchise in the small-quantity metal supply industry, prides itself on speed, variety, and convenience. Offering an array of metals and value-added services, the company recently decided to add Plasma cutting capability to its operations in Edmonton and Manitoba. This addition aimed to bolster Metal Supermarkets' competitive edge through improved speed and convenience. 

The company was seeking to improve their competitive position by increasing productivity, reducing manual tasks, and enhancing lead times. However, the complexity of overhauling the process flow, system hardware, and software, and replacing them with a more efficient system, represented a significant challenge.

The solution involved implementing a cutting-edge Linux-based control system integrated with high-end electronics. Other features included the addition of an ATC and touch option as hardware, improved CAM software, streamlined operational processes, and the provision of parameterized, ready-to-cut programs straight from the CNC.

The implementation process began with defining the project scope that concentrated on the main issues in the CNC process. This was followed by hardware upgrades, where a Linux-based control system along with an ATC and touch option were installed. Parallelly, software enhancements were conducted on the CAM software, which included a host of new features such as automated advanced nesting, easy adjustments to the starting position, and kerf compensation. Following this, ready-to-cut programs were created for a variety of shapes to expedite the production process. 

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.

The implementation of the project at Metal Supermarkets Edmonton significantly transformed its CNC cutting process. With the introduction of a top-quality CNC controller and a more efficient THC & Ohmic sensor, the process was streamlined, reducing manual tasks and lead times. The new CAM software facilitated intricate cutting patterns, increasing productivity, and the scope of possible outputs. The prepared machine programs sped up production, enabling faster responses to customer orders. Comprehensive machine maintenance and wiring upgrades extended the equipment's lifespan while ensuring operational stability. Additional features like precision drilling and part marking added customer value through enhanced product detail. Improved GUI resulted in easier software use, leading to faster adoption and reduced downtime. The project not only optimized operational efficiency and output quality but also boosted employee productivity and customer satisfaction.