29 April 2008
Accelerating the drive towards greater efficiencies in truck exhaust component manufacture

“Few would dispute that in today’s fast-paced global economy, automotive exhaust manufacturers face greater cost-saving challenges than ever before,” comments Christian Rogiers, of world-leading tube bending and end-forming technology specialists, AddisonMckee.

As shorter product life cycles, greater product quality expectations, and an almost relentless pursuit to decrease production costs cause companies to look closer at their current manufacturing processes, exhaust component manufacturers increasingly require greater flexibility and even faster tool/part changeovers, with the benefit of automated set-ups accelerating maximum bender utilization.

Consequently, machine robustness, rigid specifications regarding tube bending and form accuracy, and even the availability of consumable tooling and spare parts on extremely short notice, are all becoming critical factors to ensure that production plants remain in operation during scheduled production shifts.

Significant cost reductions

As the drive for greater manufacturing accuracy and enhanced materials efficiency increasingly becomes a focus of the global automotive industry, AddisonMckee has been showing increasing numbers of vehicle manufacturers and exhaust OEMs how significant cost reductions can be made by investing in the latest tube bending and end-forming technologies.

Reliability and repeatability

Via the use of pioneering design, state-of-the-art manufacturing capabilities, which enable rapid solutions to market, and a focus on translating each customer’s vision and functional requirements into a leading-edge solution, AddisonMckee has established a considerable, industry-wide reputation for bringing enhanced production capability to even the most complex truck exhaust tube bending and manipulation requirements.

Utilizing latest technology

“We have made it our focus to provide an impressive suite of tube manipulation solutions for the truck exhaust industry, all built around proven designs and utilizing the latest technology,” adds Director of Global Marketing, Christian Rogiers. “Where appropriate, we also offer customers the opportunity to benefit from technology upgrades, in order to fully maximize the life-potential of their existing AddisonMckee machinery. Our solutions for the truck exhaust sector range from large diameter tube bending and end-finishing machines and associated tooling to fully automated and integrated production cells, muffler and catalytic assembly machinery, and numerous other solutions.

30% reduction in component manufacturing times

A premier illustration of AddisonMckee’s ability to assist manufacturers in achieving significant production efficiencies in these cost-sensitive times was shown in their recent demonstration to a leading exhaust manufacturer of how component manufacture could be accelerated by 30%.

Adds Christian Rogiers, “At a time when every minute shaved off production duration impacts on business viability, capability and profitability, we were particularly pleased to demonstrate how investment in models from our DataBend™ range would impact favorably on the balance sheet.”

In this particular example, and to assist the truck exhaust manufacturer in question to justify their planned switch to AddisonMckee machinery, the tube bending specialist set up like-for-like manufacturing trials which also provided an opportunity to demonstrate the renowned accuracy, reliability and repeatability that investment in AddisonMckee technology brings.

Added value

As a further example of AddisonMckee’s commitment to outstanding customer service, in addition to demonstrating how significantly quicker component-to-component manufacturing time could be achieved, along with the creation of considerably less waste material, AddisonMckee also worked directly with the customer in question to assist in the re-development of some of their exhaust components. This enabled the reduction of various cutting and welding procedures in favor of the greater use of single piece tubing, in order to offer significantly less resistance to exhaust gas airflow.

The organization in question subsequently went on to purchase a DataBend™ DB150 ESRB (E- all-electric, S – stack, R – multi-radius, B – Boost) tube bender for the manufacture of numerous short-run, large diameter exhaust components as well as a smaller DataBend™ DB20 ESRD – a Dual (D) capability model that will be used for the creation of smaller components, including brake lines and air-conditioning tubing. This model enables both left-and right-hand tubular components to be bent using the same bending head.

Consider benefit of premier technologies

Concludes Christian Rogiers, “At a time when global economic influences are putting a greater focus on the need for efficiency and reliability more than ever before, I would urge manufacturers, to consider how the choice of premium technologies can not only deliver significant economies, but also assist in showing the levels of profitability that the automotive sector in particular, desires to achieve.”

About AddisonMckee

2008 winners of Managing Automation magazine's Progressive Manufacturing 50 Awards – a prestigious award based on an organization’s ability to use information and automation technologies to transform its business and create a sustainable competitive advantage – AddisonMckee is globally renowned for the design, manufacture and supply of some of the world's finest tube bending and end forming technologies - for increasingly complex automotive, aviation, truck and shipbuilding requirements.

In addition, AddisonMckee also offers highly innovative muffler and catalytic converter assembly solutions, hydraulic press machinery, tube inspection systems, plant automation and complete workcell integration.

In addition to these capabilities, a whole range of tooling and accessory options are also provided, as are comprehensive maintenance and service contracts, training and education programs and financial services. Where applicable, AddisonMckee is also able to offer customers the opportunity of machine rebuilds, refurbishment, upgrades and trade-ins.

From its state-of-the-art manufacturing centers in the USA, United Kingdom, Canada and China, AddisonMckee is committed to providing rapid solutions to market and also regularly assists clients in product prototyping, parts development, small production runs and pre-production sample development.

AddisonMckee is principally owned by WHI Capital Partners (WHICP), a Chicago-based private equity group that invests in middle market, industry-leading companies with solid financial fundamentals and proven management teams. WHICP is an affiliate of William Harris Investors, Inc., a family-based asset management firm founded by Irving B. Harris in 1987.

For further information please contact:

Rachel Thomas – BHL Marketing
E-mail: rachel@bhlmarketing.com
Tel: +44 (0) 1244 851850
Fax: +44 (0) 1244 851888

Christian Rogiers – AddisonMckee
E-mail: crogiers@addisonmckee.com
Tel: +1 513 228 7076
Fax: +1 513 228 7226