Sargent Metal is leading the way in lean manufacturing. We are reducing the cycle time of processes, increasing flexibility and improving quality to eliminate waste in all its forms. The manufacturing stratagem at Sargent Metal enlists and demands a total solution benefit from individual operations. Incorporated to accomplish a single objective, the manufacturing area becomes a focus-driven machine that attains cost reductions OEMs are expecting from an innovative manufacturing partner. While some companies dream of continuous flow manufacturing, Sargent Metal has implemented a process that demands total floor optimization throughput which facilitates a true “Pull” manufacturing system.
Automated Storage and Retrieval
All functions of our manufacturing facility are connected to the 130-shelf Automated Storage and Retrieval System (ASR). Scheduling software designates order sequencing and signals the ASR of pending orders to process. The ASR then appropriates specific metal blanks for processing and the metal blanks are delivered to the assigned operation (laser, punching, bending, robotic bending). Once completed, parts are delivered to an additional operation or secured for shipping.
In a cost-reduction solution environment, laser operations become more than just an “operation.” Sargent Metal has incorporated its fleet of precision lasers with its ASR to provide complete connectivity from design to part. The lean operation reduces human touches, thus eliminating costly errors normally associated with standard manufacturing processes.
Sargent Metal has two Trumpf L3050 Lasers. The Trumatic L3050 5,000-watt laser is a dynamic, high-powered, flatbed laser cutting center, one of the fastest and most accurate machines available. Couple this with the ASR and Sargent’s workflow can be fully automated to increase productivity. Sargent Metal acquired the latest in technology and Trumpf reliability with the purchase of the Trumpf L3040, a 4,000-watt laser that uses an additional super-dynamic, high-speed axis to minimize laser cutting time.
When assessing an operation in a manufacturing environment, the relevance of the operation is dependent upon its effectiveness in achieving the overall goal. CNC punching is critical in the effort to achieve cost-solution goals for the customer. To address this necessity, Sargent Metal’s punching operation is intergraded into both a totally automated system and flexible manufacturing cells. Both systems are performance driven.
The Trumpf TC5000 is connected with the ASR; metal blanks are delivered, punched and robotically staged for the next operation. If the next step involves forming, the parts are sequenced via programming software and delivered to an assigned pedestal/press brake. The operator processes the needed parts for the next operation. All operations are scheduled electronically and prioritized.
Sargent Metal also employs cellular manufacturing techniques. Several punches are set up within an individual cell; the cells are fully-automated and autonomous to the ASR. Material is loaded through an automated system unique to that individual CNC punch, processed (punched) and unloaded back into the same automated load system. Parts are then placed on a pallet and transferred via forklift to the next operation. Sargent Metal is confident this excellent system will lead the company to achieve its performance goals.
Bending has always been considered the art of the fabrication process. Unfortunately, the set-up cost has always made this area a challenge when addressing cost solutions. Sargent has focused on bending with the same objectivity it has utilized with other processes and in the context of the overall operation. The result has been raising the entire bending process to a new level. Sargent Metal has resolved the challenge!
Sargent Metal manufactures Smart Vent®, an automatic home foundation flood vent. Sargent Metal controls the finished goods inventory owned by Smart Vent. Demands are received by Smart Vent, packaged by Sargent Metal employees and sent out the same day for delivery to the customer. Visit www.smartvent.com.
Utilizing the latest kanban manufacturing techniques, Sargent Metal offers Lean Assembly Manufacturing. The teaming of manufacturing and team-assembly services complements existing Sargent Metal workflows and ensures a seamless cost-effective process.
Directly behind the welding subassembly stations are the purchased parts required for the entire operation. These parts are set up on a kanban system. Each location is part-specific and quantity-specific and utilizes a simple visual replenishment system. At the end of the welding subassembly stations, all the fabricated in-house parts are in kanban carts.
The progressive assembly line is designed to work as a moving line for the simplest models. Also, we can install portable tables as static workstations while building the more difficult models. Supply bins at the assembly stations are fed from the kanban supermarket of purchased parts. Workstations are designed to fit the ergonomic needs of most employees.