Genex sees benefits of press automation

The installation of BSA Machine Tool-supplied Cattaneo press automation equipment is enabling Genex Engineering to achieve extremely high production levels

The installation of BSA Machine Tool-supplied Cattaneo press automation equipment at Genex Engineering is enabling the Walsall-based specialist supplier of metal pressings and assemblies to achieve a level of output from two power presses that surpasses the production capability of at least six stand-alone conventional machines.

"The two lines represent the best there is in modern, cost-effective pressing capability," says the company, "because once set-up they run completely unattended." And that is vital in today's competitive marketplace where customers are continually pressurising suppliers to reduce costs.

"Our customers are driving for us to make cost reductions, that doesn't mean they want us to produce 'cheaper' components - it means they want high-quality components at less cost to enable them to maintain their market shares.

The use of automation is the only way we can meet these demands.

"If we can produce a finished part at every blow of the machine, then we can reduce our costs and our stock inventories while improving cash flow.

That's what allows us to turn our stock 12 times a year!" With 55 employees and a 27,000 sq.ft site on the Leamore Industrial Estate, Genex Engineering produces between seven to eight million automotive pressings each year on a range of power presses rated at 20 to 100 tonnes.

The company serves a network of first-tier suppliers and aftermarket dealers, mostly UK-based but with some direct exports to Continental Europe.

Most work centres on the production of manifold clamps and exhaust brackets - made to customer drawings or samples - from 2 mm and 2.5 mm steel and in monthly batches ranging from 500- to 500,000-off.

The benefits of press automation were initially felt in 1998 when BSA supplied, as a package, a Pressix CNR 100 mechanical power press along with a Cattaneo combined servo-straightener feed unit.

This was the first time that Genex had applied end-to-end automation in the press shop, and the combination of a quality press and ancillary equipment coupled with BSA's technical expertise resulted in unrivalled component consistency and throughput.

The installation was made at a critical time.

An existing press line had failed, and Genex quickly needed a solution that while matching its technical needs also satisfied its space and budgetary requirements.

BSA was the only company that could meet all three demands.

Rated at 100 tons, the Pressix C-frame press has a table of 950 mm by 660 mm and features a variable stroke of 10-130 mm and variable and fixed speeds of 30-90/min and 65/min, respectively.

As standard, the machine incorporates an innovative rapid stroke adjustment facility to assist quick toolchange, while a multi-way slide guidance system provides high accuracy, and extended tool life.

A recirculating captive lubrication system ensures tools are kept clean and that workpieces are contaminant-free.

Hydraulic de-jamming is standard, along with an adjustable pneumatic slide balance system.

The Cattaneo servo-straightener system with integrated coil cradle can accommodate 2,000 kg coils and maximum strip widths and thicknesses of 350 mm and 3.5 mm, respectively.

Maximum feed rate is 80 m/min.

This installation uses a four-stage progression tool to successfully produce four sizes of brackets for Genex.

However, it was the arrival in 1999 of a new contract for the manufacture of silencer box plates that put renewed pressure on Genex's manufacturing capacity - not only in terms of throughput, but also in terms of component complexity for the production of parts "that aren't as simple as run-of-the-mill bracketry".

Genex's parent group had acquired a company that was already producing these components, and while consolidating the group's manufacturing capabilities Genex took on this job (while handing over all its tube bending and swaging to its new sister company).

Genex also took on the manufacture of several components that were formerly bought-in.

"We knew that by moving around a few jobs our existing press capacity could handle the extra work, but we also recognised that additional press automation would enable the parts to be produced in the most cost-effective manner - in the same way as the Pressix line was working." So Genex looked at its options.

"The Cattaneo equipment had worked well and while operator familiarity was a factor in equipment selection, also important were value for money, of course, and floorspace requirements.

The Cattaneo is a compact unit occupying only 3,500 mm of floorspace compared with a conventional feeder line that would need around 7,000 mm." Genex's policy of investing in automation to speed production and therefore reduce costs doesn't start and finish with the coil handling equipment.

"Quick change tooling is also important.

By having a tool rack close to each machine, if the conditions are right we can change a tool in 15 minutes.

In addition, while toolchanging is taking place, the coil is being changed (if necessary).

And because the lines run unmanned, we also have load and force monitoring systems (also supplied in the package by BSA.) "Once the tool is changed, the coil loaded and the machine set, finished parts come off without operator intervention.

Now that's what we call state-of-the-art production.".

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