Facility
History
Details
100,000 sq. ft. production floor in 3 open bays surrounded by 18 acres of fenced storage.

Facility:

check Building: 100,000 sq. ft. production floor in 3 open bays surrounded by 18 acres of fenced storage

check Lift: 45-ton and 30-ton overhead cranes with 32 ft. clear space under hook

check Access: Road: At I-380 and US 30, 20 minutes north of I-80 and 45 minutes south of US 20 in east central Iowa

ASSOCIATES:

check 150 total Associates including 10 Process Engineering, 4 Quality and 12 Administrative

check 3 Shift operation

Design / Engineering:

check Solidworks, Inventor™, AutoCAD® and Mechanical Desktop® operating on 9 workstations

check Concept development, prototypes and design for manufacture from Solids Modeling

check Reverse Engineering using Faro Arm CMM --- from model to CAD

check Input accepted from dxf, dwg IGES, SLDDRW, SLDASM & SLDPRT files or prints; ProE™ compatible

check EDI (Electronic Data Interchange) and Bar Coding

check ERP Vantage™ by Epicor Software for facility-wide, real time scheduling and resource planning; data collection on the floor

Blanking:

3D FabriGear 300 Structural Shape Laser:

check Automatically loads up to 26’ Random lengths of:

    • Round Tube to 11.8” dia. x 5/8” wall
    • Square or Rectangular Tube to 10” x 4” x 5/8” wall
    • Beam to 8” x 5/8” wall
    • Channel to 8” x 5/8” wall
    • Angle to 8” x 5/8” wall

check 4000-watt, 26-axis laser

check 5-spindle tapping head to cut, drill, bevel, countersink & tap as concurrent operations without fixturing

check Automatically unloads finished part

Lasers:

Saws: Capacities to 18” wide x 24” vertical with automatic feed and powered conveyors for straight and angular cuts
Ironworker:  120-ton capacity, 12” throat, for flat, round and angle punching and shearing

Machining:

Mill: Vertical CNC; 27” travel, 12” cross-feed, 17” height, 45 deg. tilt head.
Bridge Mill, CNC: 4’ x 8’ table

Fabrication:

Brake press, Precision: 4 CNC Amadas from 50-ton to 138-ton w/ 14’ bed and 8-axis controls
Brake press, Heavy: 1,250-ton Cincinnati w/ 20’ bed, 26” throat, 16’ between housings and CNC backgauge
Rolls: 1-1/2” x 1-1/2” x 3/16” angle, 1/4” x 6 ft. plate
Hardware Insertion: Haeger 6-ton Press for rivets, panel fasteners, eyelets, spacers, studs, nuts and standoffs
Tube Bending: Eaton Leonard 300, Premier Controller networked to Vector Measuring Machine for self-correction forms up to 3” pipe

Welding:

Welding: Dual Robotic Pulse System with 4 headstocks, 12’ span, 35 MIG welders, 3 TIG welders for mild and stainless steels and aluminum
AWS Certified Welding Inspectors (CWI) Cross-Functional Team: Engineer, Welder and Inspector oversee process improvement, training and inspection; all welders are AWS D1.1-certified, minimum
Spot Welding: 150 KVA certified spotwelder

Quality Assurance:

Coordinate Measuring Machines:

check Faro portable articulated arm with 72” reach; sensing probe accurate to +/- 0.002” with input directly into AutoCAD for reverse engineering, modeling

check Vector 4xl laser VMM: designed for measurement of formed tube; two-way communication to Eaton Leonard bender for instant spring-back adjustments and consistent parts

AWS Certified Weld Inspectors Team (See Welding)

Magnetic Particle Inspection is available on request

Quality System registered to ISO 9001: 2008 accreditation

Finishing:

Sand/Shot/Glass Bead Blasting: Facility on site
Polishing: Stainless steel polishing, pharmaceutical / sanitary to a # 4 finish
Paint: Both powder and wet spray systems for large and small parts

check Conveyorized powder system for parts to 60” x 60” x 80” with heated phosphate cleaning and convection bake oven

check Batch wet spray paint booth for parts to 12’ x 25’ x 12’ high with assisted drying

check Truck drive-in wet booth 40 ft. x 50 ft. x 22 ft. high, overhead crane access