However, like many manufacturers, Symmons, a 66-year-old, family-owned company, was aware that manually loading 12-foot bar stock added considerable time to certain production runs. First, the operator had to constantly watch the machine to know when it was time to load a new 12-foot bar. “It rarely happens that the operator is standing by the machine when the next bar needs to be loaded. Sometimes the machine stands idle for as long as 30 minutes before the operator reloads,” says Sandvik.
In addition, Sandvik noted a 3” diameter brass and bronze bar that is 12 feet long weighs about 280 lbs., which makes lifting and positioning the bar a difficult and time-consuming task for the operator. Then there is the issue of machine spindle speeds. 12-foot bars require a lower RPM than properly supported shorter bars to ensure safety and precision.
Given all of these factors, Sandvik was tempted to test a Quick Load Servo S3 automatic bar feed from LNS America, Inc. (Cincinnati, OH) but was still skeptical. “I wanted proof that the results would justify changing our methods.” So the distributor, Robert E. Morris and LNS America, inc. suggested a 60-day trial. They agreed to install the Quick Load and Symmons agreed that if it lived up to their expectations, they would keep it.
“We tracked each job that went through the test set-up and compared the results to identical jobs run with a 12-foot bar feed,” said Sandvik. “On average, we saw a 25% reduction in cycle time with the Quick Load – not counting the up to 30-minute idle machine time on the 12-foot loaders when the operator isn’t readily available to load a new bar. The results are even more impressive if you factor in the additional time savings. Not to mention we were able to increase machine tool spindle speeds by 20% right off the bat.”
Sandvik also notes that the LNS automatic short bar feeder reduces the possibility of operator injury and frees the operator to work on other jobs while the Quick Load keeps feeding bar stock.
Obviously pleased with the results, Symmons has ordered 3 more Quick Loads and is setting up a more sophisticated sawing operation to handle the bar preparation for the over 9 million shower valves, faucets, and other parts the company produces each year.
“We receive about 100,000 pounds of bronze and brass bar stock each day,” Sandvik notes, “so we need a bar prep operation that can handle the workload. Given the savings we realize with the LNS Quick Load versus our traditional 12-foot operations; however, this change is a very sound investment.”
The choice of an LNS America bar feed was obvious, according to Sandvik, based on his past experience with LNS America products and services. LNS America, inc. helps manufacturers improve productivity with bar feeds, chip conveyors, coolant management systems, work support devices, and other production accessories.