NTC LASER HELPS ONTARIO STEEL SERVICE CENTER
CHANGE THE RULES OF THE GAME

A powerful new laser, massive worktable and a vision are enabling this innovative steel service center to add new levels of value for its customers.

Today, incremental improvement is no longer enough. Securing a long-term competitive advantage takes vision. That’s a quality that Debro Steel, a division of Premetalco, Inc. of Brampton, Ontario, Canada manifested in abundance when it became one of the first steel service centers in North America to deploy a 7.0 kW laser. This powerful machine, a TLX-1480 three-axis laser system from NTC America—Laser Group, Novi, MI, has not only allowed Debro to cut thicker parts than ever before, and do it with precision and superior edge quality, it has also provided the foundation for dramatic improvements in the company’s overall competitive position.

“This was a calculated decision on the technology,” says Debro president
Gunar Zenaitis. The company had formerly relied on a four-head underwater plasma cutting system. Many of Debro’s competitors, though, had advanced to newer high-definition plasma systems. “Our market is well served with hi-def plasma machines,” notes Zenaitis, speaking of the heavily industrialized belt of southern Ontario from which Debro has traditionally drawn most of its customers. “So when we started looking at upgrading our cutting technology we had to ask ourselves do we want to be one of the pack with a hi-def system that’s just a little bit bigger or newer, or do we want to offer state of the art, high precision cutting with a laser?”

With the TLX, Debro has clearly chosen the latter option. Designed to optimize the cutting of longer and thicker materials, these newly configured high precision 3-axis lasers are fast, powerful and more compact than traditional bridge-type laser systems with comparable work envelopes. The NTC TLX series places the laser and chiller on the system's gantry, providing for a smaller footprint and shorter beam path, which translates into space and labor savings, increased flexibility and greater cutting quality. The cantilever design and redesigned controller both allow for easier loading and unloading of parts.

The TLX Series is the fruit of NTC America—Laser Group’s long experience with laser cutting challenges and opportunities. NTC is a leading manufacturer of three and five-axis laser cutting systems with a lineup that includes the TLM Series of five-axis, three-dimensional laser systems ideal for cutting complex contours and shapes; the ultra-high speed TLZ Series two-dimensional, three-axis systems with flying optics; the TLV Series three-axis hybrid machines for large configurations. Each of the models features high speed and the flexibility and accuracy to accommodate a variety of workpiece configurations and sizes.

When Zenaitis joined the company in 2006, he was given a mandate to revitalize the business. A laser purchase was already being actively considered when he came onboard; however, it was a 6.0 kW laser system with a conventional cutting table. Zenaitis and his team
opted instead for a game changing 7.0 kW laser with a massive 14 by 80 ft cutting table, along with modifications to the building in order to house the new table.

“The large table was a key part of our vision for this new system,” reports Zenaitis. “It opens the door for efficient processing of very large parts and, because of our ability to stage jobs, the faster processing of small parts. This versatility added with reduced part costs adds value for the customers and enhances their competitive position.”

Training and support for a leap into the unknown can be a daunting prospect, but not in this case. Debro negotiated a complete turnkey-style installation, including training, with NTC distributor Paramount Machinery of Mississauga, Ontario. “NTC, Paramount, and our staff worked very hard and very well together in order to get this done so that we could quickly begin to accept our first commercial orders,” explains Zenaitis. “Setting up the cutting library and conditions was done prior to any actual work being performed, and there have been no issues from the standpoint of support.”

He notes that the investment has also sent a good message to Debro’s employees. “By showing that we were prepared to reinvest in the company in tough times it demonstrated that we were in this for the long haul. This was a positive message, and both the challenges and the opportunities presented by the laser have been enthusiastically embraced by our people.”

New economy, new approach

This new production system has enabled Debro to provide new services and court new customers. “In the crane industry, for instance, where the long boom would normally be constructed from several parts using multiple weldments, we can now provide them with a laser-cut 30-foot part saving them both time and money,” notes Zenaitis, citing one example among many. “Similarly, the expansive new table facilitates the production of long-run small parts, increasing our productivity and reducing the cost per part.” The addition of a conveyor system, which Debro installed to help automate the laser’s production of smaller parts, further reduces costs for both Debro and its customers.

“This machine is producing a product that is significantly better than anything on the market ... especially when compared to plasma or oxyfuel cutting,” observes Debro’s general sales manager David Vachon. “The parts the laser is now producing require less work after being cut. This means that we can produce a finished part rather than a semi finished part.”

Zenaitis adds that “Creating added value like this through the elimination of redundant machining, welding, handling, and transportation results in a lower total cost for our customers. Improving our customers’ competitive position is the secret to our long-term success, which means better margins and better profitability for all of our supply partners.” Zenaitis says that creating value in this way is more important today than ever before.

“Our customers are really challenging us to create the complex parts that they need and do so in a cost-effective manner,” he continues. “Since the installation we are seeing new orders and finding new customers that are interested in the long, laser-cut parts that we can produce.”

In the future Debro is looking to add forming capability to its value-added mix and to continue automating parts handling, thus increasing the laser’s beam-on time, boosting productivity and further reducing the cost per part. “We have to be perceived as the best value for the money,” says Zenaitis. “That’s the goal we set for ourselves, and we are reaching it.”

Last month the laser system entered its first full production month following configuration, training, sample prototyping, and testing. Initial customer reaction has resulted in Debro increasing its staffing in order to provide production capacity of three shifts per day. While the learning curve was steep, just by walking through Debro Steel you notice the excitement that has arrived with this installation.

“This machine is going to produce a product that is significantly better than anything on the market ... especially when compared to plasma or oxyfuel cutting,” said General Sales Manager David Vachon.

The parts the laser is now producing require less work after being cut. This means that the company can produce a finished part rather than a semifinished part.

“Creating added value through the elimination of redundant machining, welding, handling, and transportation results in a lower total supply chain cost for our customers. Improving our
customers’ competitive position is the secret to our long-term success, which means better margins and better profitability for all of our supply partners,” said Zenaitis.

Debro serves many industries, including construction, material handling, transportation, communications, and metal fabrication. It also provides nextday delivery of a wide variety of warehouse stock items.

“The aggregate industry is very strong for us right now as is the farm implement industry,” said Vachon.

Since Debro is not tied directly to the automotive industry—at least as far as supplying the tiered system is concerned —the company has not felt the direct repercussions of that specific downturned segment of the industry. Debro does, however, operate within the southern Ontario manufacturing base, and it has seen many of its customers impacted by
the continuing downward trend in manufacturing activity and the resulting loss of jobs over the past decade due to a loss of competitive advantage. Debro’s recent investment is geared to improving its customers’ ability to stem this tide.

Revitalizing Debro
In 2006 when Zenaitis joined the company, the concept of buying a laser was well under way. However, the laser that was under consideration was available with only a 6-kW laser source and had a much narrower and shorter cutting table than the company required. He wanted to ensure that the latest technology was installed.

That meant a re-evaluation of the purchase, a building modification to accommodate a large table, and the eventual selection of the NTC laser from Paramount Machinery, of Mississauga, Ont.

“When I came onboard in 2006, the mandate was to revitalize the business,” said Zenaitis. “The last piece of equipment that was purchased was a four-head plasma machine some 12 years ago. Now, with the addition of the laser cutting system, we have the technological resources in place to grow the business.”

This machine is well-suited for long production runs due to its long bed length and laser cutting power. For Debro this means better part quality and the ability to create many different parts without stopping the laser because of the machine’s capacity and cutting table.

However, it is also important to the company to keep capacity open for prototyping and future product development.

“Our customers are really challenging us to create the complex parts that they need and do so in a cost-effective manner,” said Zenaitis. “Since the installation we are seeing new orders and finding new customers that are interested in the long, laser-cut parts that we can produce.”

After the investment was made and the installation complete came the hard part: cutting steel. Prior to any parts being produced, training and setup had to be finalized.

“Paramount Machinery took care of all of the deliverables ... we negotiated a complete turnkey-style installation,” explaine Zenaitis. “Setting up the cutting library and conditions was done prior to any actual work being performed. NTC, Paramount, and our staff worked very hard and very well together in order to get this done so that we could begin to accept our first commercial orders.”

The company will now focus its energies on adding even more value to the parts they create. Following the upcoming installation of a conveyor system to aid in the unloading of parts, Debro will look to add a bending operation to the shop floor.

“The customers that we are working with and looking for have more than just laser needs, and we want to be able to offer them formed, processed parts as well,” added Zenaitis. “We also realize that ISO certification is important to many of our customers, and Debro is well on its way to becoming certified to the lastest ISO Q9001-2008 standard.”



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