NEW LITERATURE AVAILABLE Call or write your local representative for copies of our literature. PPRM Brochure

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1 NEW LITERATURE AVAILABLE Call or write your local representative for copies of our literature. TRADE SHOWS Look for us at the following trade shows: CIMES & CMTF Beijing, China June Mach Tool Int'l Fair Poznan Poznan, Poland June MT&T Jakarta, Indonesia August MOS Celje, Slovenia September 6-13 TATEF Istanbul, Turkey September MSV Brno, Czech Republic September Intertool Vienna, Austria October Cost-Effective Fabrication Brochure Parma Series Brochure Orion Brochure PPRM Brochure PPEB Brochure ADDITIONAL BROCHURES: PPEC Brochure Siena Series Brochure Global Series Brochure MVS Catalog Sheet CADMAN Brochure Euroblech Hannover, Germany October FABTECH International & AWS Welding Atlanta, Georgia, USA October 31 - November 2 Metavak Gorinchem, Holland November VIDEOS/CDS AVAILABLE Axel Alpha 1012 Orion Axel 3015 S Linear Axel 3015 LT Impuls 4020-R Impuls kw Impuls 4030 Omega System Siena Series Tandem Press Brake PPEC Parma HEADQUARTERS LVD Company n.v. Nijverheidslaan 2 B-8560 GULLEGEM BELGIUM Tel.: Fax: info@lvd.be Strippit Inc Clarence Center Rd. USA-AKRON NY UNITED STATES Tel.: Fax: info@strippit.com SUBSIDIARIES * LVD BeNeLux n.v. Hondschotestraat 112 B-8560 GULLEGEM BELGIUM Tel.: Fax: benelux@lvd.be LVD GmbH Europastrasse 3/1 D LAHR GERMANY Tel.: Fax: info@lvd-gmbh.de LVD s.a. ZI du Plouich - rue du Commerce B.P. 131 F RAISMES FRANCE Tel.: Fax: info@lvdsa.fr LVD Italia s.r.l. Via Baganzola 29 I PARMA ITALY Tel.: Fax: info@lvd.it LVD Limited Unit 3 Wildmere Road UK-BANBURY, OXFORDSHIRE OX16 3JU UNITED KINGDOM Tel.: Fax: mailbox@lvduk.com LVD Swe-Nor A/S Postboks 78 Ellingsrudåsen N-1006 OSLO NORWAY Tel.: Fax: SWEDEN Tel.: Fax: lvd@lvdsn.no Hämeskone Oy Kivipyykintie 2 SF VANTAA 26 FINLAND Tel.: Fax: hameskone@hameskone.fi LVD GR E.P.E. Metamorfoseos Street 20B GR VOLOS GREECE Tel.: Fax: lvd@otenet.gr LVD-Polska Sp. z.o.o. Ul. Wyspianskiego 45 PL KEDZIERZYN- KOZLE POLAND Tel.: Fax: info@lvd.pl LVD SIT d.o.o. Bevkova 7 SLO-5271 VIPAVA SLOVENIA Tel./Fax: igor.badalic@siol.net LVD S 2 = Ul. Postova SQ TORNALA SLOVAKIA Tel.: Fax: szaszi@lvds2.sk LVD Napomar s.a. B-dul Muncii Nr. 14 RO-3400 CLUJ NAPOCA ROMANIA Tel.: Fax: merlas@lvdnapomar.ro LVD do Brasil Ltda. Rua Felisberto Petroni 71 Vila Viotto CEP 13, JUNDIAI-SP BRAZIL Tel.: Fax: global.lvd@terra.com.br P.T. LVD Center Mangga Dua Plaza Block N/37 RI-JAKARTA PUSAT INDONESIA Tel.: Fax: lvdindo@bit.net.id LVD (Malaysia) Sdn. Bhd 14, Jalan Kartunis U1/47 Section U1, Temasya Industrial Park MAL SHAH ALAM Selangor Darul Ehsan MALAYSIA Tel.: Fax: lvdm@tm.net.my LVD Company Ltd. 45 Soi Phattanawet Sukhumvit soi 71 Prakanong T-BANGKOK THAILAND Tel.: Fax: lvdt@ksc.th.com LVD-Strippit (Nanjing) Technology Company Ltd. Dongyu Bldg. 16F/D Baixia District, 18 Zhenghong Street NANJING CHINA Tel.: Fax: lvdcn@e172.com 8

2 LVD S GLOBAL PERSPECTIVE N U M B E R 6 - S U M M E R The LVD Difference By Carl Dewulf, President and Managing Director, LVD Company n.v. Small Enough to Care, Big Enough to Cope: It's a theme you may see other firms promote. At the LVD Group, it's a philosophy we take to heart. Touch Screen Control for PPEC The PPEC CNC hydraulic press brake now features a touch screen control to further simplify bending operations. The control employs the same fast infrared touch screen technology used reliably on LVD's MVS shears. A Linux operating system ensures high stability. Easy to use software developed by LVD allows for fast and simple non-graphic programming with minimal training. The software is ideal for quick programming of simple parts and is suitable for all levels of users. The PPEC s touch screen control is designed to function in industrial environments, is easy to use and highly reliable. Parma Punch Press Line Expanded Page 2 CADMAN-CNC Upgrade Page 2 Easy-Form Laser Case Study Page 3 Recent Installations Page 3 Vlassenroot Adds 2000-ton Press Brake Page 4 Axel Laser Drives Innovation Page 5 Turkey: Customer Profiles Pages 6-7 Literature Available Page 8 Trade Shows Page 8 We pride ourselves on managing our resources well, putting our customers first, and on operating with an open attitude that invites collaboration with other firms to develop truly innovative products and solutions to the benefit of our customers. Being small enough to care means we value each customer and work to maintain our relationship over the long term. We strive to be customer-friendly at every level of our organization. From the moment you visit our corporate headquarters in Belgium, you will experience this difference. Keeping close contact with our customers helps us deliver tailor-made solutions for their applications. Vlassenroot, a world leader in the production of telescopic boom sections for the mobile crane industry, is a striking example. The company has a custom shear one of the largest in Europe a custom press brake, and refurbished press brakes. It has transformed the scope of its business with the ability to cut and form longer, continuous plate. LVD has played a pivotal role in the company's growth. Being big enough to cope means we have access to the resources that keep us innovative. By reaching out to work with leaders in other fields, we are able to consistently produce advanced, high quality fabrication equipment and a number of industry firsts. Just as we foster close relationships with our customers, we've built partnerships with suppliers, universities and other firms beyond the metalworking industry. The CADMAN -CNC control is one example of how LVD sources technology and expertise from other industries to develop a superior product. Collaboration with companies like GE Fanuc helps LVD develop high quality products and bring new products to market in the shortest possible time. Pictured above is the GE Fanuc facility in Japan. It's a strategy that's proved its worth: our Easy-Form Laser angle measurement system was developed in close collaboration with the University of Leuven. In working with Picanol, a leading manufacturer of high-tech textile machinery, we developed the motor drive system for the PPRM press brake. Ronald Vanbelleghem operates LVD's courtesy van, a service offered to customers and visitors. Ongoing collaboration with GE Fanuc supplies our laser systems with advanced, fully integrated control and drive systems that give the user full control over the cutting process with the most reliable laser technology in the world. Recently, we worked with Fanuc to engineer a 2.5 kw laser source suitable for our economical Orion machine, matching product development with market needs. Similarly, work with H&L produced sophisticated press drive technology used in our Global, Siena, and recently debuted Parma turret punch presses. Satisfying your requirements with effective fabrication solutions and attentive support is at the heart of our Group efforts. We invite you to experience the LVD difference. Contact us today. MESSAGE FROM THE CHAIRMAN: BUILDING REWARDING RELATIONSHIPS By Jean-Pierre Lefebvre At the foundation of any business is the building of strong relationships, internally and externally. Superior products, advanced process technologies, and successful installations are possible because of good relationships. At the LVD Group, we believe in the power of relationships and we continually work to foster strong ties with our customers, vendors and employees. Building solid relationships has made us better focused on the needs of the market. Case in point: the development of our new Parma punch press was initiated through close involvement with existing customers both contract manufacturers and OEMs who told us their requirements for punching machinery included the need for a compact yet capable machine that is both efficient and economical. The challenge to design and build the Parma in a short time span was possible through close work with our component suppliers. The end result: a machine that meets current production requirements, engineered and built in the shortest time to market in LVD history. Creating and maintaining strong relationships does more than help us deliver a product to market faster, it also helps us thrive and grow as an organization. The relationships we build and manage improve our internal operations. Strong partnerships with our international offices allow us to apply the experience or process improvements from one facility to locations worldwide. Improving our internal operations positions us to compete more effectively in all markets. Building strong relationships has many rewards, and the LVD Group will continue to put a high value on the relationships we build with you and for you.

3 D I S C O V E R Y Parma CNC Punch Press Line Expanded The family of Parma CNC turret punch presses now includes the Parma 1225 with workpiece size capacity of 1250 x 2500 mm. The Parma 1212 handles workpiece sizes up to 1250 x 1250 mm. Parma punch presses provide productive, reliable performance that is affordable for all shops, including entry-level fabricators. These 200 kn machines deliver up to 300 hits per minute on 25 mm centers, and up to 650 hits per minute in nibble mode. A ± 0,1 mm finished part accuracy and ± 0,05 mm finished part repeatability is achieved. Parma punch presses process material thicknesses up to 3,5 mm mild steel and up to 6,35 mm aluminum. A patented Smart Clamp feature automatically determines exact clamp positions to provide the smallest possible no-punch zones to improve material utilization. ADVANCED HYDRAULIC RAM TECHNOLOGY Parma's servo-driven hydraulic ram offers complete control of ram position to achieve the highest punching rates of any machine in its class. Parameters are easily accessed and changed to provide optimal forming characteristics and to reduce slug pulling. The advanced hydraulic drive system reduces noise and shock to increase machine longevity and reduce tool wear. A 21-station turret features three-direct drive auto-index stations. CADMAN - CNC Upgrades Available A direct drive axes configuration provides the industry's tightest tolerances. This design better controls both part tolerance and repeatability to eliminate backlash and wear for repeatable accuracy and reliability. TURRET FEATURES THREE AUTO-INDEX STATIONS Parma features a 21-station thick-style turret with all stations keyed for maximum tool load flexibility. This versatile turret design allows every station to accept shaped or round punches and dies, reducing set-up time. The machine is standard with three 50,8 mm auto-index stations. Each station Enhance the performance and extend the life of your PPEB press brake with a CADMAN -CNC control upgrade. LVD's CADMAN-CNC Upgrade Program updates both hardware and software to increase processing speeds and hard disk capacity, improve uptime, simplify the user interface and add new functionality. The upgrade includes a new industrial PC board with 256 MB RAM and Pentium III 1 GHz processor; 40 GB hard disk; optical trackball, USB port and RS232 connection, and the latest software version pre-installed. The updated software provides directly usable bending parameters and refined BA and Ri calculations for improved The Parma 200 kn CNC turret punch press combines flexibility and precision performance in an easy-to-use machine. accepts tools up to 50,8 mm in diameter, including wheel-style or scribing tools. The turret features replaceable hardened steel guide bushings for accurate punch and die alignment, eliminating the need to rebore the turret. Hardened outboard shop pins provide precise alignment of punch and die for exceptional hole quality. A large tool door allows easy access to the turret for tool loading. Quick-change die holders further reduce set-up time. POWERFUL PC-BASED CONTROL Parma punch presses are equipped with the GE Fanuc 0iP control featuring self-prompting screens that simplify use while maximizing efficiency. The control allows the machine operator to edit, input or output programs during machine operation to reduce set-up and improve productivity. A PCM card slot, RS232 or network interface allows simple updating of software revisions and easy backup of parameters and part programs. Parma machines are available with the CADMAN-P 3D offline programming system. This powerful PC-based system offers automatic tool selection and turret configuration, including the identification of optimum tool stations and turret loading. interpolation of bend allowance. The software applies LVD's extensive bending expertise to supply a wealth of useful bending information for the operator. The upgrade program also provides 12 hours of software installation and training. Upgrade options include an alphanumeric keyboard, replacement of passive screen with active screen, an update of CADMAN - B 3D software, and additional control and software training. This upgrade program is recommended as preventative maintenance for PPEB press brakes four years and older. For more information, contact LVD at info@lvd.be. What Customers Are Saying About the Parma: OSM CORPORATION OSM Corporation manufactures vehicle components for the military. The company punches 4.5 mm hot rolled carbon steel. Parts move from punching to secondary forming and finishing operations. We weren't in the market for a punch press, but the Parma 1212 was a competitive price and had a good combination of features which influenced us to make the purchase, said Rod Olson, president. The machine makes economical sense, added Olson. The 21-station turret is a perfect size for us, and features like Smart Clamp and the bridge frame construction appealed to us. The bridge frame construction gives the machine stability while the turret size allows a faster station-to-station indexing, said Olson. In addition, the brush table and hydraulics have reduced our noise level by approximately 70 percent. PRODUCT INTEGRATION & MANUFACTURING Product Integration & Manufacturing is a precision sheet metal fabricator that produces a variety of parts for Fortune 100 and Fortune 500 firms. The company punches aluminum and stainless steel up to 5 mm as well as 3 mm cold rolled steel. We are a young company-threeand-half years old and the Parma allowed us to get considerable capacity for a reasonable cost, said President John Breedy. The majority of our parts have countersinks with tight tolerances, said Breedy. We do forming, embossing, coin forms and countersinks on the Parma. Plus, features like the standard brush table was an advantage to us because we process a lot of aluminum. Parma is the workhorse of the operation. Breedy has moved jobs from three other punch presses to the machine. The speed of the machine allows us to be very productive, said Breedy. The Parma has put us in a very good position for a small company. 2

4 N U M B E R 6 S U M M E R Bending Angle No Longer an Issue ARNOLD HAS EXCELLENT EXPERIENCES WITH THE LVD BENDING TECHNOLOGY (gk) When there are special parts to be bent or product startups coming up at Arnold, there is no more need to worry about which one of the different press brakes will carry out this task. Such difficult tasks are in principle assigned to the new LVD, which gets the perfect match from the very first angle, due to its unique combination of laser angle measurement, Stone Radius of the die and its extensive data base. At least with regard to machinery many sheet metal fabricators tend towards monogamy, i.e. they mainly work with one supplier, which definitely has its advantages. Yet, Arnold AG proves that this is not the only successful strategy. Machines in blue, red, orange and other colors stand next to each other harmoniously at the plant in Friedrichsdorf. Basically, the system that best meets the current requirements is purchased. I cannot see any advantage in tying myself down to one manufacturer, says production manager Hubert Kramer. The market is constantly moving and the manufacturers always have to prove themselves time and again for us. The effect is obvious: irrespective of the manufacturer, the optimal system for each purpose is acquired. There are no doubtful compromises. Considering Arnold's thorough sheet metal know-how and the extensive tests that precede each new purchase, the question of course is: which one of the various press brake manufacturers can best fulfill the currently propagated statement first part, good part. The winner is LVD. Kramer: We have taken into consideration various manufacturers and tested different machines. For our field of application which comprises a large range of materials and parts, all strictly calling for high angle accuracy, LVD definitely offers the best solution. LVD has obvious advantages, especially due to its unique combination of laser angle measurement system, Stone Radius of the die and the extensive data base, which contains a great deal of know-how. Besides the Stone Radius of the die (allows the sheet being bent not to be drawn into the die but to roll away almost without friction and therefore material sparing thanks to the special contour also with stainless steel almost scratch-free), Hubert Kramer has been especially attracted by LVD's laser angle measurement system. Flexibility, fast reaction times and the mastering of an enormous variety of parts represent Arnold's fundamental strong points. We are the ideal partner for complex single parts, small series and Arnold AG in short Arnold AG, Friedrichsdorf, specializes in highquality metal design components, guidance systems, industrial supply of components, assemblies and housings, as well as in the production of works of art. In 2004 the company generated a turnover of approximately 28 million Euros. It currently employs about 230. product start-up and phase out. The laser measurement technique of LVD has clear advantages here, as the system measures the angle during the bending process and corrects the bending parameters accordingly. As a result, the angle matches perfectly from the very first part. To this end we do not need an individual sensor for each punch or die form, as the laser measurement system covers all punch and die forms, and through the CNC-controlled movement of the sensor to the relevant measuring point, one can go to as many measuring points as required with only one laser sensor. The angle measurement even allows to compensate for the negative influences of strongly fluctuating sheet metal qualities. We have the sheet material delivered to us daily, just-in time and in the respective required quantity.yet, it is quite possible that the sheet supplier does not pick the sheets for a certain order from one batch and that consequently, we get to process different The ROBOformER robotic bending cell featuring LVD's PPEB press brake with Easy-Form Laser bending system is improving the productivity of fabrication shops throughout Europe and North America with numerous installations in place. The ROBOformER marries the best of bending, automation, control and systems integration technologies. Arnold AG produces high-quality metal components, including assemblies and housings. The company achieves quality parts from the first bend using LVD's adaptive forming technology. qualities. No problem for the LVD machine, which thanks to angle measurement bends the parts with great accuracy irrespective of the material. Through the deliberate usage of machines from different manufacturers the company can apply the optimal technique for each application.yet, this also makes the programming of the systems more difficult. Hubert Kramer says: We no longer have any problems with bending. But this does not mean that the bent parts are always an exact match. What bothers us is the seriously fluctuating and lately also clearly decreasing quality of the sheet material, since the bending radius changes according to the quality of the sheet and so does the unfolding. Even when the bending angle matches, this does not necessarily mean that the component matches as well. However, this unpleasant situation could change in the foreseeable future. At the moment we are working on installing an overall solution which should also make the unfolding match perfectly regardless of whether we bend on an LVD, a Hammerle or an Amada, Hubert Kramer explains. For that purpose, the other machines are currently entered into the Cadman B Software at LVD and the production manager is optimistic that this way he will be able to realize an overall solution. If the tests are successful, Cadman B will be the standard software at Arnold for the unfolding and the bending programs. By then the smaller sister PPEB 135 should also be operational, as a second, smaller LVD press brake with a bending length of 2 meters and 80 tons of pressing force has already been ordered in addition to this 3 meter long machine with 135 tons of pressing force. No wonder considering the extraordinary positive experience. Kramer explains: The LVD press brake and especially the laser measurement system have convinced us from the very beginning and the correctness of the decision has been completely confirmed in practice as well. Installation was already sensational: the press was installed and after eight days production had already started. The PPEB has ever since convinced us with high angle accuracy, even with poor quality sheet material. Also the service has been fantastic: if we need anything, LVD reacts immediately. Reprinted with permission from the November 2005 issue of BLECH. LVD equipment is installed in manufacturing facilities across the globe, including some of the best-known manufacturing companies in the world. Recent installations include the following. Agrostroj Pelhrimov,Czech Republic, has added four PPEB-8 press brakes to its production facility. The company has a total of eight PPEB machines, all purchased within the past year. Agrostroj Pelhrimov is a leading producer of agricultural machinery within the Czech Republic. Glastronix, Bangalore, India has installed their third Global CNC turret punch press.the machine will add capacity to manufacture sheet metal enclosures, transformers and power supplies for the medical and electronic industries. Heat and Control, Inc., Brisbane, Australia, has equipped their manufacturing facility in China with two PPEB precision press brakes, PPEB 400/61 and PPEB 200/40. The company is the world's leading manufacturer of food processing and packaging equipment. The PPEB 400/61 features increased stroke and daylight. KONE Mexico S.A. de C.V., a subsidiary of KONE Corporation, has purchased two PPEC 220/30 press brakes for its newly established production facility in Torreon, Mexico. Kone is the world's fourth largest elevator and escalator company. The Torreon plant will manufacture a range of elevator components. Niles-Simmons, Industrieanlagen GmbH, Chemnitz, Germany, has added a PPEB 220/40 press brake with Easy-Form Laser and an Impuls 4020-R laser system with rotary axis to its manufacturing plant. Niles-Simmons is a leading manufacturer of CNC turning and milling centers. Pelco Products, Inc., USA, has installed a PPEB 640/80 tandem press brake at its production facility in Oklahoma. The company manufactures traffic control, utility, lighting and communication signal hardware as well as decorative lighting and utility hardware. The tandem press brake provides synchronized operation of the two machines through a single CNC control, LVD's CADMAN -CNC. Schwarz, Dornstetten, Germany, recently purchased an Axel 3015 L Linear with an integrated automatic load/unload station, and tower system as well as a PPEB 220/30 press brake with Easy-Form Laser system. Schwarz is a precision fabrication shop. 3

5 D I S C O V E R Y 2000 Ton/14 Meter Press Brake is Boon to Manufacturer of Telescopic Booms Nestled in the neighborhood of Bijgaarden, just seven kilometers away from the city center of Brussels, is Vlassenroot ( one of Belgium s best known steel fabricators. Vlassenroot specializes in manufacturing large, complex steel structures and is internationally recognized for producing telescopic boom sections for the mobile crane industry, including work for Grove, Liebherr, Faun, PPM-Terrex, Link-belt, Luna, Demag, Kato and others. The variety of the company s work and its operating philosophy make flexibility critical to its productivity. In addition to telescopic booms, Vlassenroot is one of the premier steel service centers in Belgium and produces parts for bridge construction, railway wagons and road trailers, sea-going and inland vessels, offshore drilling and production platforms. Work is divided between its m 2 manufacturing facility outside of Brussels and a sister facility in Germany where formed booms are welded, painted and assembled for delivery to the mobile crane supplier. Vlassenroot s PPEB-H 2000 ton multi-axis CNC press brake features a 14-meter bed equipped with programmable back gauges and material supports with motorized pushers. The company, which is celebrating its 80th year in business, continues to distinguish itself by investing in equipment that further expands its capabilities. Earlier this year, Jean-Charles Wibo who purchased Vlassenroot in 1995, added to his We are working with very large sections of material that can range from 9 to 14 meters long in thicknesses of 4 to 12 mm, said Mr. Deumans. Manipulating the material is just one of the difficulties we have in bending these parts. The more important issue is controlling the radius and angle of the bend, as the material we use is a high strength low alloy product that can produce a spring back as much as 60 degrees.to maintain a tolerance of ± 1 millimeter of the length of the part requires a good machine and a skilled operator who understands the characteristics of the material being formed. custom shear replaced three older shears and reduced set-up time by 35 percent. Recently, Vlassenroot contracted LVD to upgrade many of its older hydraulic press brakes by adding CADMAN -CNC controls and heavy-duty back gauges. Prior to purchasing the PPEB 2000 ton machine, most of my existing press brakes ranging from 500 to 4000 tons were manually controlled, explained Mr. Wibo. With the assistance of LVD, I was able to transform these machines into more current technology providing my operators with a single control system, easy programming capability, programmable back gauges and new tooling. To maintain its position as a leading supplier of telescopic booms to the mobile crane industry, Vlassenroot relies on the service and support of its suppliers. Servo-controlled with state-of-the-art hydraulics and electronics, the PPEB press brake maintains a tolerance of ± 1 millimeter the entire length of the part. Technical expertise coupled with state-ofthe-art cutting and bending technology allows Vlassenroot to produce high quality products and meet just-in-time delivery requirements. formidable forming and bending capacity an LVD PPEB-H 2000 ton multi-axis CNC press brake with a 14 meter bed equipped with programmable back gauges and material supports with motorized pushers. The custom press brake is a significant addition to Vlassenroot s production capability and helps the company be more responsive to its customers. We are able to react quickly to our customers needs, said Mr. Wibo. Our ability to respond is key to our survival and makes us unique. It is a major strength. Wibo s business relationship with LVD began several years ago when he purchased a 14- meter hydraulic plate shear. The custom MVS shear, one of the largest in Europe, is capable of producing two to three cuts per minute in mild steel up to 20 mm thick. The Vlassenroot s core business is manufacturing boom sections for telescopic cranes. The company s bending equipment allows it to form large material sections from 9 to 14 meters long. We operate our machines 24 hours a day, seven days a week, said Mr. Wibo. If we lose one hour of production due to machine downtime it is lost forever and cannot be gained back. It is therefore essential that we align ourselves with companies that can meet our operating standards with technology and service. The addition of a 2000-ton multi-axis LVD press brake further expands Vlassenroot s capability to produce the complex steel structures for telescopic boom sections supplied to companies such as Liebherr, Grove, Faun, PPM-Terrex, Link-belt, Luna, Demag, Kato and others. Mr. Wibo explained that he not only wanted to add more forming capacity but also wanted the ability to produce long profile parts that could be formed between the frames of the press brake, providing a larger part in both length and depth. Forming telescopic booms is no easy task, explains Vlassenroot s Manufacturing Manager, Bart Deumans. Vlassenroot also boasts one of Europe s largest shears. The shear is able to cut 14-meter lengths of 20 mm mild steel and weighs 209 tons. 4

6 N U M B E R 6 S U M M E R Axel Laser Drives Innovation at UK Manufacturer Since it was founded 35 years ago, Thompsons (UK) Ltd has grown steadily to become the UK's leading manufacturer of truck tipper bodies, with a 50 percent share of the construction market. It also makes a wide range of other specialist bodies for vehicles that include refuse disposal trucks and brick carriers. From building two or three tippers a week it now makes up to 35 a week, and prides itself on being able to provide a premium bespoke product. Now an LVD Axel laser is helping it to offer its customers more choice, better products and faster development times while improving manufacturing processes and saving material. Every tipper body is potentially different, and this depends on the customer's preferences and requirements, as well as the chassis it will be mounted on a body for a Scania will be different from one for a DAF, for example. Everything is bespoke, says Sales Director, Scott Burton. Each customer has their own ideas and additions they would like. We come up with a design to suit them. The laser is an integral part of us trying to enhance our product, make it even more superior to our competitors and help us to continue to grow our market share. General Works Manager Bernard Mullaney explains the thinking behind this. We aim to keep our steel as raw material for as long as possible, and only convert it into a product when we have a sale for it and the truck's here. Before we had our own laser we normally had to order batches of 50 or 100 parts from the profiler, so if we wanted to change the design we would have to scrap all the stock we'd had cut. Director, Alan Burton, drew up an outline specification for what they wanted, based on the material sizes and thicknesses they planned to cut. The size, power and configuration tend to be driven by what you want to cut. We worked out that we wanted to be able to cut 3000 x 1500 mm sheet. In practice, we only use sheets up to 2500 by 1250 mm, but it made sense to go for the next size up just in case. When it came to material thickness we started off by looking at 25 mm, but when we looked at the percentage of 25 mm sheet we used and the extra cost of going to a 6 kw laser we decided to stick to 20 mm sheet and a 4 kw laser. Mullaney and Burton then went out and spoke to all the major manufacturers, spoke to some of their customers and looked at the machines in action. On the basis of this research the clear choice was the LVD Thompsons typically cuts sheets up to 2500 x 1250 mm using a 4 kw power source. machine. Not only did it have the required performance, rugged construction and ease of use, it also looked the part. The LVD Axel was a true 4 kw machine, An operator loads material onto the laser system s shuttle table. The shuttle table design allows one table to be loaded while the machine is cutting on the other table, maximizing uptime. and we'd seen that 4 kw machine actually cutting 20 mm plate in Belgium. We had originally been thinking of a fixed table machine, but when we saw it running we realized that a shuttle table would allow us to get the more out of it. The whole machine is very compact anyway and the shuttle table doesn't actually add a great deal to the space it needs, says Mullaney. But the performance of the machine wasn't the only criterion. If we buy a new machine we want to make a selling point of it and show it to customers. A lot of machines look as if they've just been bolted together, but the LVD Axel struck us as the type of machine we would like to show off to people. But once you have invested in the technology it is no longer a case of what you have to cut on the laser, but rather what you could cut on the laser. When we ordered the laser we probably weren't using enough laser cut parts to justify buying our own machine, says Mullaney. But we've had the machine since February now, and it's running more than 50 hours a week. In the past, if we didn't see the need to laser cut a part we wouldn't - so we would settle for a rectangular part we could cut on the guillotine. Now we are starting from the point of thinking how we would like to do the job and asking if a rectangle is the best solution. Maybe it's better if we can incorporate curved profiles or a radius on the corners. If it improves the product there is no point not doing it. The machine is there and we want to utilize it to the full, and we want to make the product unique to us and better. To give an example, Thompsons used to use some 25 mm flame cut profiles. The laser can cut this thickness, but it is at the top of its range and produces a much better cut on 20 mm material. By redesigning the parts, Thompsons was able to make them all from 20 mm which saved weight without compromising the specification. Of course, they could have done this before they had the laser, but when the work was being subcontracted out there was no driver to do so. Scrap savings have been important too especially on micro-alloyed abrasion resistant steels. The material we buy is 6700 x 2400 mm, and I don't know anybody who builds a tipper body that's 6700 mm long. So we always ended up with large offcuts. Because it is abrasion-resistant you can't machine it or drill it, so we ended up scrapping it. It only takes three or four of these chunks and you are throwing away a complete plate of expensive, high-quality material, says Mullaney. Now we are using the laser to cut tailgate profiles out of it. So we are not only using material that we would previously have thrown away, we are also improving the durability of the product. With the laser we can do a prototype part, and if we don't like it we only scrap one part and then make another one. That's where it is changing things; we've brought the control over that process back inside the factory. Before they looked at the market, Bernard Mullaney and Thompsons' Managing Thompsons is the UK s leading manufacturer of truck tipper bodies with a 50 percent market share. The impact the LVD laser has made is all about competitive advantage, says Scott Burton. It has made us much more innovative, and helps to keep our products unique. We can make an individual item, for an individual vehicle, and to an individual's taste. We can tailor it to exactly what the customer wants and it can't easily be copied by our competitors. 5

7 D I S C O V E R Y SPOTLIGHT: TURKEY High Performance Equipment Has Global Reach AHMET YAR REFRIGERATION A visitor to the Ahmet Yar Refrigeration ( plant in Izmir, Turkey is greeted with an impressive display of Turkish contemporary art covering the walls of the foyer and office areas before entering the modern manufacturing facility. countries is creating a high demand for our products and services, said Oktay Yar. To accommodate this growth the company built a second plant in 2003 with over m 2 of manufacturing space.yar chose to equip the new facility with LVD equipment because of LVD s technology, as well as to maintain a commonality of machines, simplify training requirements for operators, and because of the strong local service support and availability of spare parts. Akimsan s Global 30 CNC turret punch press punches materials up to 6,4 mm at full production speed. The Global CNC turret punch press provides accuracy of ± 0,10 mm with a repeatability of ± 0,05 mm over the entire table. The accuracy of finished parts ensures the success of secondary bending operations. This display of art and manufacturing expertise is in contrast to the company s start in 1948 when Mr. Ahmet Yar began the business repairing electric motors and refrigerators for the NATO forces stationed in Izmir. As the demand for refrigeration grew in Turkey, Mr.Yar began manufacturing refrigeration units and by 1982 had moved into a 6000 m 2 facility where he was joined by his sons Oktay and Ali. Driven by the need to improve their manufacturing capability, the company visited a trade show in Germany in 1993 where they were introduced to LVD. Oktay Yar recalls that until that time all sheet metal parts manufactured at the company were produced manually. The installation of LVD turret punching machines, CNC press brakes and shears enabled the company to improve productivity and provided the flexibility to design and introduce new refrigeration models. The quality and appearance of the sheet metal parts that go into our refrigeration display units is extremely important to us, said Oktay Yar. Our products are seen by the consumer every time they go to the grocery store. It is important that our displays project a good image and design, said Yar. Accuracy of punched holes and profiles as well as the forming accuracy of our fabricated sheet metal parts is essential for us to achieve this image and because our display can be very large, part accuracy is important for our assembly process and installation at the customer s location, said Yar. AKIMSAN As a subcontractor of sheet metal parts, Akimsan ( located in Izmir goes far beyond the borders of Turkey to service its customer base. Founded in 1988 by Mr. Tayfur Altinküp, the company started as a press shop producing stamped parts with mechanical and hydraulic presses. They also produce their own tooling for this purpose and have gained a reputation for supplying parts to a diverse group of clients that includes automotive, home appliances, heating and air conditioning, food packaging machines and electromechanical components. Its customers are located in Europe, the United States, and China. In order to be more flexible and to provide a broader range of services to its customers, Akimsan purchased several LVD CNC machines, including two Global CNC turret punch presses and PPEB precision press brakes. As Altinküp explains, these machines further his goal of providing his customers with accurate parts, delivered on time and at a competitive price. Dedicated to the design and manufacture of refrigerated display units and cold storage rooms for the food industry, Ahmet Yar, with 300 employees, is now the largest supplier of this type of equipment in Turkey and is recognized internationally for its quality and diversified product range. The growth of the large grocery chains and food suppliers in Turkey as well as bordering Ahmet Yar produces modular cold storage units as well as supermarket refrigeration units. Ahmet Yar s products have a high content of sheet metal parts. These parts are all fabricated using LVD CNC equipment, including two Global CNC turret punch presses manufactured by LVD s subsidiary company Strippit, Inc., in the United States. Ahmet Yar operates three shifts per day. Akimsan manufactures a range of precision sheet metal components including washers, locks and hinges used in the automotive, heating/cooling, food and electromechanical industries. The company s m 2 facility houses state-of-the-art fabricating equipment, including two CNC punch presses and three LVD press brakes. The equipment gives Ahmet Yar the flexibility and capability to manufacture innovative refrigeration products. Punch press features such as three programmable, relocata ram stroke; and an advanced hydraulic press drive are key 6

8 N U M B E R 6 S U M M E R Flexibility and quick response to the demands of my customers is very important, said Altinküp. If they ask for a change in product design or if a hole or contour in a part changes in size or shape to meet a specific situation, I must be able to respond quickly. I can only do this if I have the right type of equipment in my factory and the support from the supplier of the equipment. Akimsan has two manufacturing plants with 7000 m 2 of manufacturing space and 250 employees. The company typically operates two shifts a day and often runs its punching machines 24 hours a day. Because of the demanding production schedule, equipment reliability was an important consideration for Altinküp. FRITERM A tour of the Friterm ( refrigeration and air conditioning products plant in Tuzla, Istanbul is an interesting experience by itself but if the tour is given by Mr. Metin Duruk, founder and president of the company, the world of refrigeration takes on a whole new meaning. Mr. Duruk who started the company in 1979 is an industrialist with a vision who has succeeded in taking his company to the highest level of domestic and international manufacturing standards. Friterm is well known for its work in the field of commercial and industrial AC and refrigeration projects as a contractor and a manufacturer of equipment to the food processing and ice cream industry. In 1996 Friterm decided to specialize in the design and manufacture of finned type heat exchangers that now include air cooled condensers, air coolers, dry coolers, water/ steam air heaters and coolers, oil coolers and heat recovery coils. The company is also expanding to include production of Friterm manufactures a range of air-cooled condensers, air coolers, dry coolers, waters/steam air heaters and coolers at its production facility in Istanbul. To keep pace with production requirements Akimsan recently purchased a third LVD Global CNC turret punch press. Altinküp s decision to purchase additional LVD equipment was based on machine performance, reliability and features that provide flexibility such as the three programmable work clamps supplied as standard equipment with the Global machines. ble work clamps; Smart Stroke, which optimizes the to Akimsan s productivity. Friterm uses three Global punch presses. The machines large turret capacity, powerful control capabilities and automatic features like Smart Clamp TM reduce set-up time and minimize operator intervention. radiator coolers and turbine inlet air cooling coils for the power generation and ship building industry. The Tuzla factory has m 2 of manufacturing space with 220 employees supported by a staff of 25 qualified engineers. Mr. Duruk is proud of his workforce and is quick to point out that all of his employees are graduates of technical high schools and receive up to 25 hours each year of technical training to ensure that their proficiency and work skills are maintained to a high level. A well educated work force is key to our success in producing a quality highly reliable product, said Duruk as he makes plans to open a new m 2 coil manufacturing plant in Sheet metal parts for the refrigeration units were manually produced until a few years ago when Friterm made the decision to invest in CNC controlled press brakes and punching machines. After a great deal of research into the capabilities of various machine tool builders, Friterm decided to purchase LVD equipment. This decision was influenced by LVD s reputation for supplying high quality technically advanced press brakes and their ability to provide local service and support. Among the machines supplied by LVD are two Global CNC turret punch presses manufactured by Strippit Inc., LVD s US Subsidiary. A third Global CNC punch press has been ordered by Friterm and will be placed in operation shortly. Rated in the top five companies in Europe for manufacturing heat exchanger equipment, Friterm is positioning itself for the current and future role of Turkey as a manufacturing base serving markets in Europe, the Middle East and Asia. Duruk is well known in the refrigeration industry in Turkey and is the founder of ISKAV, the heating, refrigeration and AC research and education foundation. Friterm is a member of various industry associations including ISKID, EUROVENT, TTMD and ESSIAD. Often consulted for his knowledge on the subject of refrigeration, Duruk teaches refrigeration courses at the Istanbul Technical University and has provided laboratory equipment for its students. Added manufacturing capacity has allowed the company to expand its production. Today Friterm also produces radiator coolers and turbine inlet air-cooling coils for the power generation and ship building industries. 7