Automation Streamlines Production, Slashes Costs

Time is money. That’s true for every link in the manufacturing chain from receiving raw material through quality control.

Our customers need parts processed quickly – in some cases on demand. To meet their need, we respond by fabricating components as efficiently as possible and maximizing machine uptime. Our investment in automation delivers dependable repeatability 24 hours a day.

Automated production at Max Velocity

The centerpiece of Estes automation is its Max Velocity automated sheet metal fabrication cell. Powered by Salvagnini, the Max Velocity cell contains an automated MV Warehouse, a CNC Shearing/Punching Center, CNC Fiber Laser Cutter, and CNC Panel Bender. The MV Warehouse doesn’t just store the material, but allows our work centers to have seamless transition between jobs, because we know that every second counts!

The MV Warehouse inventories, stores, schedules and transports work material through the entire production process from intake through completed part. Using a picker crane equipped with a telescopic fork that runs throughout the cell on a rail, raw materials are moved to the appropriate machine at the proper sequence for an unattended production environment for maximum efficiency.

With every machine within the cell being fully automated, Max Velocity allows Estes to provide customers faster fabrication, shorter lead times and on-time delivery. The high level of repeatability that comes with automated manufacturing improves overall quality, and that reduces costs for customers.

Estes also uses the latest in robot-assisted technology for speed, accuracy and lights-out production. As a pioneer of laser welding light gauge sheet metal for superior welds and reduced production times, we quickly adapted to lightweight laser welders such as LightWELD that can operate in automatic mode while connected to our Fanuc CRX 25iA collaborative robot (cobot). Laser welding with LightWELD is two to three times faster than MIG welding and four times faster than TIG welding because the rapidly moving cobot is able to move from weld to weld with no hesitation.

Innovation driven by passionate people

Though automation and advanced metal forming technology drive the shop floor, it’s the high character of our people who take personal responsibility for customers’ results. Michael Bruns is the most recent addition to the Estes team and a steward of our customer-centric approach.

As Estes’ new sales manager, Michael focuses on building and maintaining relationships internally and with customers to bring the best results possible. A graduate of Purdue University with a bachelor’s in professional flight, Michael is a licensed pilot holding multiple ratings. In addition to acute attention to detail, Michael has spent his career in leadership positions focusing on relationship development. It’s his unwavering commitment to excellence and hard work that makes Michael a key component to our customers’ successes. You can get to know Michael more or provide him an inquiry directly by emailing him at [email protected].?

At Estes, we continually evaluate how we can do things better for our customers. Investing in the latest sheet metal fabrication technology and automation innovation is just one way we stay ahead of the manufacturing curve. See how Estes automation and design expertise slashed customer cost by two-thirds and reduced manufacturing operations from 11 to three on its cabinet door assembly in this case study.