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Investing in Increased Efficiency and Throughput – Advanced Manufacturing and Automation at TuscoMFG

Trumpf TruLaser 1030 machine at Tusco Manufacturing.

In the past few years, the manufacturing sector has faced a myriad of economic challenges. The COVID-19 pandemic brought unprecedented shutdowns and significant disruptions to global supply chains, often resulting in delayed production and increased costs across industries. Couple that with acute worker shortages, record inflation, and rising interest rates plagueing the industry, forcing companies to tighten the financial constraints under which they operate. These challenges have not only impacted production timelines but also increased the cost of goods, creating a ripple effect across various sectors reliant on manufacturing.

Investing in advanced manufacturing technologies and automation has emerged as a crucial strategy for manufacturers to stay competitive and resilient. By adopting modern technologies, manufacturers can streamline production processes and reduce dependency on manual labor. This approach not only enhances operational efficiency but also contributes to long-term cost savings, which is crucial in an environment of rising expenses.

TUSCO MFG Investments Benefit Our Customers

Tusco MFG is fortunate to be positioned to invest in new equipment. We recently invested in two state-of-the-art pieces of equipment: an automated hardware insertion machine and a Fiber laser capable of unmanned, “lights out” operations. These represent more than just an upgrade in our manufacturing capabilities; they are a strategic move towards future-proofing our customer’s interests against ongoing industry challenges. These investments translate into a host of benefits for our customers, including increased manufacturing efficiency, reduced waste, and improved quality.

Hardware Insertion Machine Improves Efficiency and Quality

The automated hardware (PEM) insertion machine, a Haeger 824 One Touch 5e Lite, is designed to improve operator efficiency and process control. The auto-feed system accommodates studs, nuts, standoffs, and any special fasteners from M1.5 to M10. The quick-change dual upper station allows for quick change between setups.

The automated system will allow us to:
• Eliminate secondary weld operation on parts where appropriate, saving time.
• Seat the PEMs properly into stainless steel material, expanding our capabilities.
• Combine operations with up to six different PEMs in one setup, creating a more efficient operation.

This means that products can be completed more quickly, reducing wait times and enhancing customer satisfaction. Additionally, the precision and consistency offered by automation ensure a higher quality of the final product, reducing the likelihood of defects or the need for rework.

New Laser Offers Many Advantages

The introduction of the Fiber laser, a Trumpf 1030 TruLaser Fiber Laser, which is expected to be installed soon, takes our commitment to innovation a step further. Capable of operating unmanned, this equipment allows for continuous production, even during non-business hours, creating a bridge between shifts, effectively increasing output without the need for additional manpower. This capability is particularly valuable in addressing the current labor shortages, ensuring that our production can keep pace with customer demands.

The 2D laser system features EdgeLine Bevel that allows chamfers, countersinks, and radii to be cut directly on the machine, eliminating many manual process steps. It will double the capacity of our laser cutting capabilities and provide opportunities for tightly nested cutting jobs because of its nano-joint technology. It also reduces material waste as the parts can be nested closer together than with micro-joints.

Typically, small parts are connected to the scrap skeleton by a small piece of uncut material across the entire thickness, which is called a micro-joint. These joints add additional labor as the parts must be manually removed from the skeleton, which can be difficult with midrange sheet thicknesses, and the extra bit of material left behind must be filed or ground off. Nano-joint technology leaves the part connected to the skeleton by partially cutting through a small section leaving the bottom end of the kerf uncut, making removal of the part much easier and virtually eliminating the need for filing or grinding for most parts. Because the nano-joint is created in a continuous cut, the part can have several nano-joints without having to stop and pierce the piece again, making it more efficient.

Partner With a USA Manufacturing Company That Will Invest in Your Future

Challenges occur, and technology changes. We feel to provide our customers with the best experience, we must make investments to adapt and advance our processes. Early this year, we made an investment in a plant redesign that optimized our plant floor for increased efficiency and throughput. Along with this most recent equipment investment, we are demonstrating our desire to help our customers remain competitive. Experience the benefits of working with us; contact us for a quote on your next sheet metal project.

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