Port Coquitlam, British Columbia: Investing millions of dollars in the latest automated equipment and hundreds of hours in advanced training, Metalcraft Technologies proves that the best technology, wisely used, results in quality, productivity and success. In the competitive fabricating industry, smart use of the best equipment most often wins the race.

One of Metalcraft Technologies key investments is punch press tooling, but the investment goes beyond the tooling itself. Metalcraft Technologies trains its operators in its use and utilizes the tooling supplier’s to maximize these tooling resources. When it started in 1997, the company standardized on one tooling style, Mate Ultra Tec®, and has stayed committed to it for 18 years.

Unusual to commit to one tooling style? Not in Metalcraft Technologies case. Investing in the best from the start, learning everything it can do and then sticking to the formula has paid off with greatly reduced tool setup times, increased productivity, longer tool life and top quality products, according to Ferroz Abdulla, customer support/lean manager.

Metalcraft Technologies “Professional Team” Approach Builds Customer Loyalty
“Metalcraft Technologies began in 1997 with a team of 10 professionals,” reports Mr. Abdulla, son of founder and president Azim Abdulla. “We consider ourselves a professional team in all respects because of the overall quality of our people, technology and the way we operate. We’ve recently invested over $2.5 million in automated fabricating equipment including adding more Mate Ultra Tec tooling which we’ve used from the start.”

“By having the latest and finest technology, training and cross-training for maximum technology utilization, we’ve become a valued supplier to leading Canadian and US manufacturers’” Mr. Abulla stated. “We’re successful because of our professionalism with the result that we have grown to a team of 30 professionals. We’ve achieved that despite the difficult economy and depressed manufacturing environment. Our customers needs continually change and we’ve learned to quickly adapt to those changing needs,” reports Mr. Abdulla.

Quantity requirements often are a challenge, according to Mr. Abdulla. “We get orders now for just one fabricated part and other orders for as many as 20,000 parts. Customer inventories are minimal so we’re are asked to meet just-in-time requirements even if it means setting up for a part run of just one, five or 20,000 pieces. Materials also vary a lot, from different grades of steel, aluminum and stainless in very thin to thick plate. With such a variety in small  to large quantities, planning jobs for maximum machine utilization – including efficient programming, tool setup, automation and tool maintenance – is an ongoing challenge, according to Mr. Abdulla. Punch press tooling plays a major role.

Tooling Choice Made Because Of Superior Design Features
Tooling selection has been important to Metalcraft Technologies ongoing success, according to Mr. Abdulla. “We’ve had a long relationship with Peter Storey of Mate who started us with Ultra Tec. He’s helped us maximize the benefits of the tooling system through many projects. The Ultra Tec design is such a superior concept because its fully guided design has so much more to offer. From the start, we wanted to be able to operate our Amada presses at top speed – 350 hits a minute depending on material and thickness – with the assurance that the tooling would perform well delivering top quality.”
Insuring this top performance requirement is Ultra Tec’s tooling design. It features a self-contained spring canister assembly that maintains uniform stripping pressure and a hardened guide to maximize turret bore life at all press speeds, even the highest. The punch is manufactured from M-2 high speed steel with a minute back taper and near polished punch flanks to reduce friction and extend tool life. The strippers, which slide into the guide, include a recess, which creates an extra 3.00 mm of grind life. This feature alone, by conservative estimates, can add many thousands of additional hits to the tool’s useful life. This was very important in Metalcraft Technologies’ initial decision to go with Ultra Tec.

Set-Up, Length Adjustment And Die Features Enhance Productivity
Equally important are Ultra Tec’s easy set-up features. The tooling incorporates a hardened guide assembly with internal and external lubrication grooves together with a quick length adjustment device and quick change stripper mechanism. Punches are made from high speed steel. Stripprers have a 2.00 mm recess and locate into a spring loaded lock ring on the guide. This design makes assembly and length adjustment easy and fast, using a minimum of set-up tools.

The dies for the Ultra Tec system are made of A-2 5% chrome air hardened tool steel that provide optimum balance between the opposing conditions of hardness and toughness. Mate’s unique Slug Free® die geometry guarantees effective slug discharge after every punch cycle. By clearing the slug after every cycle, the possibility of slug pulling is eliminated, improving piece part quality.

Auto Indexing Multi-Tools Loaded With Ultra TEC–Boosts Press Capacity And Flexibility While Reducing Setup Time
Metalcraft Technologies maximizes turret press punching features with two auto indexing Multi Tools loaded with special form tools to punch louvers, knockouts, card guides, embossed and many other special features.
With widely varying part runs, the transition from one type of material and thickness to another can get complicated and time-consuming. The auto indexing stations with Multi Tools help shorten the tool setup process for job changeovers. While the bulk of the tools in the turret are standard tools and do not change, the Multi Tools are loaded with special application tools to punch the formed features.

“Changing these Ultra Tec tools is really fast,” reports Mr. Abdulla. “The tools pop apart with just a touch of a button and go back together just as fast. They are easy to adjust and assemble visually. The punch, guide and other components are easily disassembled by hand and lock up correctly and quickly With Ultra Tec, our operators set tool length in just 5 seconds. No shimming needed. The tooling’s push-button design allows for fast and easy setting of overall length and die penetration in precise increments (0.006 inch for a ½-inch A station tools and 0.008 inch for larger station tools) without the need for measuring tools.” (Photo Three)
Mate Ultra Tec Tool Life Measured In Years Of Continuous Use

Metalcraft Technologies reports that 75 percent of its originally purchased Ultra Tec tooling 18 years ago is still in everyday use. One of the reasons for this tooling longevity is Ultra Tec’s tool steel, even when punching difficult materials such as stainless steel. That’s because Ultra Tec punches are heat treated in NC controlled furnaces using exclusive processes developed by Mate and heat treat specialists. The combination of highest grade tool steel and heat treating results in punches with superior compressive strength and high wear resistance. Punches are extremely resilient and retain size and accuracy while withstanding high operating temperatures and remain resistant to tool wear.

Ultra Tec’s fully guided design also adds to the tool’s robust design and long life. This is especially important for forming operations like cluster punching where material thickness is exceeded to punch diameter ratios and where hit balance can cause problems. Ultra Tec’s guided design prevents side-loading and twisting forces that can occur with standard tools on thick material and those that are difficult to punch like stainless, ”reports Mr. Abdulla. “While the initial cost of Ultra Tec is more, the cost per hit is far less. The tool reliability, predictability and longevity makes it a very good value.”

First Article Measurement And Automated Punched Part Handling
While Ultra Tec tooling streamlines the actual punching process, Metalcraft Technologies investment in complementary technology enhances productivity and quality even more.
FabriVISION is a recently added automated measurement and digitizing system that compares the first fabricated articles to the original CAD drawings for emailing to customers for acceptance. Using this system in connection with the punching process facilitates a faster approval of prototypes and first articles so that punching and other fabricating processes can proceed with minimal wait time. (Photo Four)
Another wise equipment investment for Metalworking Technologies is automation. Following punching, parts are moved from the turret press via robot to an adjacent press brake for bending then on to pem-setting, metal finishing and assembly.
Learning the use of this new technology is ongoing at Metalcraft Technologies. All employees participate in a full day of training every month of the year. The training varies by need with a focus on lean initiatives. Efficient punch press tool utilization and laser operations are two areas that get regular attention with Peter Storey’s input.

With both Mssrs. Abdulla and Huynh Greenbelt Certified and more certifications targeted, the company’s growth is proof that lean works. Summing it up, Mr. Abdulla says that “Metalcraft Technologies’ commitment to lean shows off both in the professionalism of our people and our equipment improvements and utilization. It’s an ongoing process of using the best and doing the best, whether it’s with tooling, training or something else.”

For more information about Metalcraft Technologies, Inc., call toll free 1-877-9817 or 604-515-1877. Email: info@metalcraft.ca  Website: www.metalcraft.ca
Or write to Metalcraft Technologies, Inc., 273 Schoolhouse St., Coquitlam BC V3K 4Y1 Canada.
For more information about Mate Precision Tooling, in USA and Canada, call 1-800-328-4492. Outside USA and Canada, call 1-763-421-0230. Email: marketing@mate.com   Website: www.mate.com
Or write to MATE PRECISION TOOLING, 1295 Lund Boulevard, Anoka, Minnesota 55303.  USA and Canada, Fax 1-800-541-0285. Outside USA and Canada,
Fax 1-763-421-0285.