Investment in machining technology has facilitated growth and diversification.
It might be 18 years ago since Toolco Engineering invested in the company’s first CNC machine and it opened up new possibilities for the company, but the company continues to invest in CNC machines and is taking advantage of the benefits that CNC machining offers.
Before owner Rudy Kutzer took this decision, machining needs were split between in-house manual lathes and mills and time on the machines to complete orders was exhausting for Rudy, a hands-on owner of a general engineering business that offers turning and milling as its main machining processes.
“When numerical control was being introduced in the 1980s and 1990s there was still a lot of scepticism about the technology. However, it proved to be the biggest disruptive machining technology of that era, maybe even the biggest disruptive technology ever, and it continues to be so. The potential impact of this type of technology perhaps was not appreciated or apparent at that early time of development.”
Toolco Engineering can machine components in many different types of material
“The natural transition from NC to computer numerical control (CNC) was certainly impactful, but that was simply an evolutionary step thanks to advancements in digital computer technology.”
“Today, some similarly say that additive manufacturing (AM) could possibly be a huge game changer in terms of discrete-parts production. Thus far, however, AM seems to be more of a complementary technology to CNC machining, not a replacement.”
“Then Industry 4.0 came along. Industry 4.0 may sound like something in which only large, multinational manufacturers are players, but that’s not the case. Digitising information flow straight from the shop floor to a quality measuring system and being able to react in real time is something that all manufacturers can do, no matter their size. This is an industrial revolution in which companies of all sizes can participate.”
“Now we have the Internet of Things (IoT), AI, machine learning and Smart Factory concepts which are not just applicable to mechanical engineering. We all have to adapt and continue to learn if we want to stay competitive and stay in business.”
Components on show in the display cabinet
“The most recent and latest technology machine bought and I believe the first of its kind in the country, is a DN Solutions (Doosan) LYNX2600 SY, which is a sub spindle machine with Y-axis milling and a main chuck bar working diameter of 81mm.”
“The rise of electronics and computers and the use of robots for many mundane and repetitive operations has been just short of phenomenal.”
“It’s no secret that converting from manual machine tools to CNC machine tools increases productivity and profits for machine shops. By automating manual operations, a CNC machine turns out parts 75 to 300 per cent faster than a manual machine. It also assures repeatable accuracy, makes complex parts more easily and reduces scrap, rework and manufacturing costs.”
“Owners of old manual lathes or milling machines confronted with today’s capacity crunch have a few choices for increasing throughput without buying a new CNC machining centre. They can retrofit an existing machine with a CNC control package or a DRO, or they can buy a new manual mill with a CNC retrofit package in place from the outset.”
“It used to be said that if a company had the capability to machine in either manual or CNC mode it helped the company grow its skill sets and capabilities in concert with the company’s growth while maintaining its requisite flexibility. That is how we thought at the time but today if you are not fully CNC equipped you will miss out on opportunities. The need for rapid turnaround and accuracy are what high-tech machine tools offer a machine shop.”
The company has two Doosan Lynx 300M turning/milling lathes
Solid pipe sections that have had some bending and threading done
“Because of the programming flexibility CNC has brought to the shop, we can also respond in hours to prototype jobs that once took days to get done. Plus, once we get the first component programmed, we very quickly make as many as the company needs, even families of different sizes.”
“The transition from making a component on our manual mill to writing a programme and then showing a non-machinist how to execute the programme is a much smaller step with CNC technology, that at first we did not realise. CNC lets us take people with lower initial skill sets and teach them machining much faster with CNC machines.”
“The reason I got into machining was that I wanted to be different and offer a service that was not readily available. At the time I figured, after seeking advice, that woodworking, construction, electrical and other everyday occupations would be competitive and a bit tougher to be successful in as an individual or as a company. Forming or shaping metal was an occupation that was not sought after by many but very necessary. Wherever you look there are products and fixtures that in essence have started off in a foundry or machine shop.”
When Rudy started his business in 1992, money was very tight. He had qualified as a fitter and turner and had no ambition to work for a boss for the rest of his life. With the help of some funding by a couple of partners, Rudy purchased a 2 metre conventional lathe and set up shop in a rented section of a factory in Paarden Eiland, Cape Town.
Sprockets machined for a client
Toolco Engineering can offer bar feeding applications
“Cost effective productivity is something we all aim for in manufacturing whether it is using old or new technology. In our case and the use of the old technology, we have manual equipment which we use for maintenance and one-off walk-in jobs. They generally are not precision components and only one machining process is required.”
“Most of the work I was doing was for one company – a manufacturer and repairer of hydraulic equipment. The company also manufactured and maintained waste compacters, roll-on-roll-off units, skip loaders and refuse bin lifters and their clients were mainly in the city municipality environment.”
“There was plenty of work and the company did expand. We were machining, and still do, many different components including bushes, pins, studs and many others. None of them were high numbers or production runs but there were many different components. This made the machining aspect very interesting because of the variety of components.”
“We were operating in a low volume, high mix environment. However, the draw back was that we had put all our eggs in one basket and my partners were also involved in that business. Not a good position to be in but I must be grateful because the business operated successfully for its first 10 years and this gave me the opportunity to buy out my partners.”
The original 2 metre conventional lathe that Toolco Engineering started off with in 1992
One of the first CNC machines that Toolco Engineering purchased was a Daewoo Lynx 220 CNC lathe which was installed in 2005
“This took place in 2002 but it still left me with one customer. I had also started to deal directly with the municipality but I was in a very vulnerable situation. The buy-out gave me the freedom to do this and although I kept supplying the original client up until last year, their work as a percentage of my turnover had dropped dramatically so it was a minor hiccup.”
First CNC bought in 2005
“From the first day that I had complete control of the company, Chad of Puma Machine Tools was the one to advise me to purchase a CNC machine. ‘It will open doors’, ‘You will get new clients’, ‘Production will be faster and more accurate’, ‘You will never look back’, all the buzz phrases that a machine salesman would be throwing at you.”
“But in a time when you had to be cautious it was not an easy decision. There would be a whole culture change and of course a huge learning curve. But I did eventually make a decision to purchase a Daewoo Lynx 220 CNC lathe which was installed in 2005, and yes the machine salesman’s phrases are all correct.”
“Not long after my first CNC purchase another Doosan Lynx 220 lathe arrived. Both of these machines are still in operation and I have added more CNCs, two Doosan Lynx 300LM turning/milling lathes, a Doosan DNM650 vertical milling machine with a 4th Axis (X-axis 1270mm and Y-axis 670mm) and a Doosan Lynx 220 with barfeeder and collet chuck. The most recent and latest technology machine bought and I believe the first of its kind in the country, is a DN Solutions (Doosan) LYNX2600 SY, which is a sub spindle machine with Y-axis milling and a main chuck bar working diameter of 81mm. The manufacturing company is now known as DN Solutions today.”
Components ready for delivery
More components machined by Toolco Engineering
“Amongst them I have two turn mills and a milling machine. This gives me the flexibility of processes that I need and also if a machine is down for maintenance or repair, I can still operate on the other machine.”
“The DNM 650 has a 4th axis which gives me extra capabilities. My future venture in new technology would be for multi – axis, multitasking machine so that we can do complex one station machining.
Introducing the Lynx 2600SY
“However, I have been able to invest in DN Solutions Lynx 2600SY, a multi-function CNC lathe with milling capabilities and sub-spindle. The Lynx 2600 series is a high-performing horizontal turning center that enables complex machining using only one set-up. It has a maximum machining diameter of 380mm and an upgraded structural rigidity/accuracy to increase its machining capability and productivity through outstanding reduction of both cutting time and non-cutting time for complex shapes machining.”
“The machine was installed earlier this year and it should facilitate our growth and diversification that we are looking for.”
Owner Rudy Kutzer
“If machinists know how to run one of our machines, they can pretty much run all of them. We have standardised on the one brand – DN Solutions. This eliminates issues caused by having machines or controls that can be run only by employees with certain specialised knowledge. I don’t have to worry about someone not having enough work to stay busy. There is always a machine that does not have a dedicated machinist or operator.”
“We machine most materials, including titanium, and we will machine from block. A recent example is a component that we machined for a company that is involved in the piling industry and it was reduced to 15kgs after it started off at 75kgs.”
“We have a Solidworks licence and currently we operate from a 400m² factory in Stikland, Western Cape and employ 5 machinists.”
For further details contact Toolco Engineering on TEL: 021 948 9648 or visit www.toolcocnc.co.za
