Between rapidly advancing technology and growing demand for higher quality and more precise parts, fabrication shops are under increasing pressure to grow and adapt. Those that don’t will likely face production bottlenecks and quality issues that start costing time and profit. However, with limited workforce availability and outdated equipment, many shops must walk a thin line between achieving operational efficiency and controlling capital expenditures. Industrial retrofitting and conversions of manual equipment and automated systems is one way shops can reduce costs, prolong equipment life, and meet growing demands.
What Industrial Retrofitting and Conversions Offer
Upgrading legacy machines with modern controls, sensors, and semi-automated processes is a growing practice in small and mid-sized fabrication shops. When carried out by experienced experts, industrial retrofitting and conversions can dramatically reduce cycle times.
Consider the following example:
A small fabrication shop with a monthly production run of 2,000 parts and an average cycle time of 15-20 minutes upgrades to an automatic straightener that performs the same job with far fewer mistakes in just 8 minutes. In this case, retrofitting their equipment reduced labor requirements by over 250 hours a month.
By upgrading manual straightening presses with advanced control systems, motors, and pneumatics, shops can reduce scrap rates with improved throughput and consistency. These benefits multiply when shops retrofit older automated machines with cutting-edge processes.
Typical Industrial Retrofitting and Conversions for Straightening Equipment
The goal of any industrial equipment upgrade is to improve operational efficiency and bring systems up to current performance and safety standards. While the type of upgrades depends largely on the machine’s size, capacity, and tonnage, targeted upgrades can ensure shops stay competitive with minimal capital expenditures.
Typical upgrades may include:
- Installing energy-efficient electrical cabinets
- Replacing motors and pneumatics with cutting-edge systems
- Adding servo or CNC controls
- Integrating digital measurement and data logging sensors
- Upgrading safety systems and PLCs
- Incorporating remote monitoring capabilities
Retrofitting pre-existing straightening machines is a cost-effective way for smaller operations to take advantage of newer technologies without the larger upfront investment. A well-executed conversion can not only improve cycle times and reduce material and labor costs, but it can potentially do so at a fraction of the cost of new equipment.
When a Retrofit May Not Be Enough
Retrofitting industrial straightening equipment can help small fabrication shops stay competitive. When the machines are in good condition and won’t require structural repairs or alterations, industrial retrofitting and conversion services can produce quicker ROI. However, there are some cases where retrofitting straightening equipment becomes impractical.
A 20-year-old well-used but sporadically maintained manual straightener, for example, might require new hydraulic assemblies and a frame rebuild to support the upgrades, which can cost nearly as much as a new system but without all the benefits. A smarter long-term investment in this case is a new automatic straightener. Other important considerations include:
- Tool Changeover Requirements: If the shop has a wide product variance with multiple tooling changes, upgrading manual equipment would prove cost-prohibitive.
- Full Industry 4.0 Compatibility: Industrial retrofitting and conversions help bridge the technology gap but can’t replace the level of connectivity that MAE-Eitel’s automated straightening machines can achieve.
- Capacity to Scale: Upgrading equipment can only do so much, and if volume requirements are expected to increase drastically, future-proofing capacity with systems designed to handle it may require investing in new automated straightening equipment.
Let MAE-Eitel Straighten It Out
Deciding between investing in new, advanced straightening equipment or taking advantage of cost-saving industrial retrofitting and conversion services shouldn’t be made without a thorough understanding of the equipment’s limitations. The experts at MAE-Eitel leverage extensive experience to help customers reach the best choice for their current and future needs. Contact MAE-Eitel today and let us help you straighten it out.
