Wrightform Ltd, based in Eye, UK, has made a name for itself with cutting-edge technology and precision work in sheet metal forming. With Arku’s straightening technology, this can now be done much faster than before – and at the same time alleviates the shortage of skilled workers.
© Arku
Eye, UK – Whether in the food industry, construction, transportation or high-tech swimming pools, metal parts often come from the small British town of Eye. This town of 2,400 inhabitants is home to the sheet metal processing company Wrightform Ltd. Right next door, sister company Wrightfield designs, manufactures and installs conveyor and food processing systems as well as movable pool floors.
Wrightform’s customer base consists of both small and large companies, including those in the food, energy, agricultural and automotive industries. As part of the service offering, customers can send their parts directly to Eye for straightening before the finished components are sent to countries around the world. They are then used, for example, as conveyor belt components in Spain or in hydraulic systems for swimming pools “down under”.
New challenges require a new way of thinking
© Arku
Wrightform currently employs more than 50 people and has two laser cutting machines, with a third due to be commissioned shortly. There are also three press brakes and a deburring and polishing machine. In recent years, however, Wrightform’s flourishing business has faced new challenges. The shortage of skilled workers in rural areas of the UK has become a major problem. Experienced employees are currently hard to find.
Steve Larkins, Business Development Manager at Wrightform, also noticed that the quality of the starting material was deteriorating: “The sheets often looked good at first. But as soon as we started cutting sheet metal parts, their residual stress was released, which often resulted in a deformed end product.” As a result, many parts had to be leveled manually by skilled workers, which was expensive and time-consuming. “As a supplier, we realized that an automated and consistent process could help us deliver high quality straightening in a reliable, time and resource efficient manner,” says Larkins.
A chance encounter
With this idea in mind, Ken Rose, Managing Director of Wrightform, and his team began looking for a suitable method to automate and speed up the straightening processes. However, most of the machines lacked the flexibility to process all the components for Wrightform’s diverse customer base. A visit to Trumpf in Ditzingen finally paved the way to the desired solution: “Until then, I didn’t know that straightening machines like the Arku FlatMaster existed,” recalls Rose. The FlatMaster quickly aroused his interest. “We were looking for a solution that would not only allow us to straighten quickly, but would also be easy to use and deliver lasting results without bending or stressing the material. Once we had all the information about the FlatMaster, we decided on it very quickly,” he says.
As Brexit was imminent on January 1, 2021, the installation and commissioning of the system was carried out under great time pressure. In view of possible import taxes, Wrightform decided to install the straightener shortly before Christmas 2020. A tight schedule, especially as the commissioning by Arku had to be completed within a few days. Nevertheless, everything went smoothly.
Straightened in the blink of an eye
© Itasse
With the FlatMaster, the parts are flat in seconds and almost completely free of residual stresses. This is a major advantage compared to manual straightening, which can take several hours. The machine is capable of straightening laser-cut, punched and plasma-cut parts and even ultra-high-strength steels (AHSS materials) with a thickness of 1.0 to 28 millimeters. Subsequent steps such as welding, bending or forming are faster and more reliable.
The positive customer feedback underlines the importance of consistent and reliable straightening. For many customers, the flatness of the parts is crucial. In contrast to the manual process, Wrightform can now straighten 10 or 15 parts in the same time and still meet the flatness specifications.
Since installing the FlatMaster, Wrightform has also benefited from time savings and planning reliability. While it is difficult to estimate the time in advance when straightening sheets manually, the automated processes are both calculable and predictable. In addition, the machine works so efficiently that it often only has to run for a few hours a day and still manages a throughput of several tons per week. In this way, Wrightform can also compensate for any shortage of skilled workers.
Wrightform offers customers to bring sample parts to show how easy it is to set up the straightener. Word has already spread about the consistently high quality: New customers are approaching Wrightform and asking for Arku technology. In addition, the optimized straightening services complement the range offered by sister company Wrightfield. Given the current order situation, it is crucial that the components are aligned. “This would not have been possible before the FlatMaster was installed,” says Larkins.
Constantly evenly aligned parts
The FlatMaster is very easy to use and saves the company lengthy training. “We can teach our employees how to use the FlatMaster within a few hours. It is very helpful to introduce new employees to automatic straightening and to ensure efficient work at all times,” says Larkins.
Arku’s ongoing technical support is a great asset for the company: “We are a family business, so trust is a key factor. It is very important for us to work with people with whom we are on an equal footing and whose quality we can fully rely on,” concludes Rose. “With Arku, we have added a new member to our family of devices.”
Stéphane Itasse, freelance journalist in 97246 Eibelstadt
Web:
www.arku.com
