African Fusion August 2016

SAIWmember profile: Stainless Precision Engineering

SPE’s AMADA Astro robotic bending system has a 130 t capacity along a 3 000 mm length. The system’s robot picks up a part, measures it and then transfers it to a manipulator on the bending brake, where the part can be repositioned as many time as necessary to compete the bending processes.

To support the higher volume parking systems’ work, welding assembly is supported by three Fanuc/Lincoln electric robotic welding systems: a two-robot cell that includes a 4.0 t manipulator and two multi-axes turntables and a second robot for sub-component assembly.

the company on the welding side. “Our ISO 3834 welding quality sys- temwas built fromthe ground up, with pro- cedure development and training at the root of implementa- tion. It was a mindset change for the fabrica- tion team on the shop floor, to first look for the procedures that applied to the job and then to routinely apply them. On the other hand, welders had to get used to not doing any work that they were not yet qualified for.

procedures and then training them to do what needs to be done.” In keeping with its belief in state- of-the-art machine tools, welding as- sembly is supported by three Fanuc robotic welding systems. The largest is a two-robot cell that includes a 4.0 t ma- nipulator and twomulti-axes turntables. A second Fanuc robot is employed as a sub-component assembly station. Both systems use Lincolnwelding equipment and are supported by Pretoria-based Robotic Innovations. “The robot system is used exten- sively for our ongoing parking systems’ work. The two-robot cell welds the fin- gers that rise up from the ground at the boom gates to prevent non-payment. The turntable allows the whole part to be rotated for better access to all of the welding required. Boomgates and park- ing system consoles have long been our flagship capability andwemanufacture these for a number of different OEMs,” says Diedericks. “On the manual side, we use mostly theMIG/MAGwelding processwith some TIGwelding.We alsohave five spotweld- ing machines and a stud gun,” he adds. Returning to welding quality man- agement issues, Diedericks says the quality at source approach runs through every aspect of component manufac- ture. “On the welding side, we do a before, during and after inspection, with our welding inspector taking primary responsibility. Then, after grinding, we apply a visual inspection and sign-off stage to 100% of the assemblies. Since very early in its inception, SPE has been ISO 9001-certified, but since Diedericks’ arrival, ISO 3834 certifica- tion has been implemented to further enhance the quality and creditability of

SPE is currently fabricating high voltage cubicles and traction converter cabinets for South Africa’s railway rejuvenation projects.

age cubicles and traction converter cabinets for one of the SouthAfrican rail- way rejuvenation projects. We are also making the frames for 2.0m locomotive radiators for a railway sub-contractor and, in aluminium, we have started to fabricate the driver control panels for railway climate control solutions,” Die- dericks reveals. “We are aiming to become a railway specialist, hence the need for ISO15085. We expect to be audited during August andwehope tobeCL2-accreditedbefore the end of this year,” he tells African Fusion . “SPE is constantly striving for prod- uct excellence by keeping up-to-date with the latest technologies and trends in the sheet metal Industry. We guaran- tee excellent service to all our clients with timeously delivered, quality- inspected goods that are certified to international quality standards,” he concludes.

“Our welders were willing to learn, though, and they applied the new system with enthusiasm. The whole team has gone out of its way to make ISO 3834 work for us, to improve weld quality and production performance,” Diedericks notes. “Quality gives us a competitive advantage: We now offer excellent quality on the welding side and this is appreciated by management and cus- tomers, resulting in new contracts and in significant growth. So much so that we are having to extend the workshop space to accommodate the additional work,” he adds. Due to the significant increase in railway contracts being awarded to SPE, the company is also gearing up for ISO 15085-accreditation for the manufactureof railway components and structures. “We are currently involved with Bombardier, fabricating high volt-

7

August 2016

AFRICAN FUSION