Wilson gains manufacturing flexiblity with a Bytrans system.

John G. Wilson Machine Ltd. (www.jgwilson.on.ca) is a high-performance, contract manufacturing operation with more than 150 employees, a 100,000-square-foot facility and a diverse range of metal processing technologies. "Our focus," explains President and Co-Owner Randy Wilson, "is to offer our customers completely seamless service, from file to part. We like to react fast to customer challenges, and this is why we invest heavily in our technology."

One of the company's customers started to require frequent, large, production runs. Wilson Machine knew the best way to meet this demand was to move into the fast lane of laser cutting technology.

The first system installed was Bystronic's (www.bystronic.com) Bystar 3015, 4.0 kW laser cutting system with rotary axis and a Bystore 16-shelf tower. "After the installation of the first system, our customers' demands for this new capability were overwhelming," says Wilson. A second system, the same ByStar 3015, 4.0kW but with Bytrans automation, was installed a year later. In less than two years, both lasers were running 22 hours per day, five days per week. While both systems were fast, reliable and productive, the automation coupled with Bysoft software proved to be one of the most helpful factors in streamlining the shop's workflow.

Wilson Machine gained flexiblity and increased production time by installing the Bystore storage tower because it enabled seamless, on-the-fly material change-overs in less than three minutes, as well as large production runs and lights-out manufacturing. The Bytrans material handling system added more flexibility by facilitating finished part accessibility with short runs, while its single material deck was effective for high production jobs. The system is a key factor in Wilson's ability to produce 45,000 to 50,000 steel strapping dispensers per year in 30 to 40 different models.

"During the day, we like to focus on fast product delivery to the customer," Henry explains, "The system's easy access design allows our operators to pull the finished parts off of the table, and tag and send them to customers as soon as they are completed." During evening or off-hours, the company uses the system's stacking capability to store finished parts. In the morning, operators take the finished parts from the stock on one table as the machine continues processing product on the other.

Automation has maximized the shopping cart manufacturer's up-time. The ability to manufacture lightsouthas reduced internal bottlenecks and increased workflow. "We believe we have reached a significantly higher level of productivity than if we had just purchased a stand-alone laser," says Henry, "We have run our laser with the Bystore unmanned for up to 87 hours on a single weekend." However, he says a person occasionally has to go into the shop to unload finished product from the table. "With certain jobs, especially during particularly hectic times of the year, this configuration has given us a huge advantage. It ensures that we have the finished product in the hands of our customers as soon as possible," explains Randy Wilson.

Both Henry and Wilson agree that automation has enabled them to use their capital equipment investment to its capacity. Henry, who has a background in CNC programming, says he believes that the software is the "driving force" of any laser cutting system. "You can have a top-of-the-line laser, but if you do not have excellent software, you do not have a good marriage," he explains.

The company's philosophy is to provide prompt customer service in the face of any challenge, and software has played a valuable role in achieving that goal.

"Sometimes customers walk in the door with a raw part in hand and say 'I need something that looks like this,'" says Henry. With Bysoft software, Wilson Machine's engineers have the ability to create a part in a flat pattern. For example, one customer came in with a thrasher blade from a combine that was mangled beyond recognition. Henry says he was able to give the customer a fully finished, replacement blade that afternoon because of the Bysoft software that converted the blade into a pattern as a .dxf file for direct loading into the laser.