Custom balanced door manufacturer reduces lead times with waterjet technology

Situation

Ellison Bronze Inc., based in Falconer, N.Y., invented the balanced door in 1927. Today the company produces these custom doors to architects’ requirements, which means meeting unique requests for dimensions, materials, components, and finishes. In the booming commercial building market, the manufacturer is constantly seeking new ways to maintain the highest product quality and satisfy customers while improving efficiency and getting finished products delivered more quickly to job sites.

In revisiting some of its processes, the company identified areas it wanted to improve. First, with quality control being of utmost importance, Ellison decided to keep as many steps of the manufacturing process as possible in-house, including cutting grilles, thresholds, and other door components.

Previously the company’s metalworkers either tediously machined these parts or outsourced them to third-party fabricators, which extended production time, added to manufacturing costs, and prolonged turnaround time for customers. So Ellison went in search of the equipment necessary to manufacture its doors efficiently in-house.

Resolution

The company’s research revealed the potential of waterjet technology to help achieve its efficiency and quality goals for in-house production. Ellison chose an OMAX® 80X JetMachining® Center, which cuts a variety of materials in a range of thicknesses—allowing the company to eliminate outsourcing.

“Cutting parts in-house with the waterjet has allowed us to improve efficiencies by saving on time and resources,” said Roger Overend, president/CEO, Ellison Bronze. “While it does take time to cut a component, it is a lot less time-consuming than outsourcing or machining.”

The waterjet uses only natural garnet abrasive and water in the cutting process. Ellison has cut up to 3 in. into a material, but 0.06- to 1-in. cuts are typical. This allows the company to offer fast cutting speeds with the precision necessary for the quality control its customers demand. Equipped with A-Jet®, a software-controlled multiaxis cutting head, the machine has a cutting range from 0 to 60 degrees. The cut components require no secondary finishing or additional labor.

OMAX

www.omax.com