132 -MAY 2006 No. 127

WWith the most innovative processingtechnologies for laser cutting andwelding, Verona Lamiere is currently

responsible for large scale semi-processed partsorders made from metal sheets. “This definitionimplies that we don’t just manage the cut andbent sheet, but we also cover the entireproduction process for semi-processed parts”explains Mr. Remigio Lucchini, owner of VeronaLamiere. “For example, we are starting tomanufacture a very important order to make60,000 doors that we will supply already finishedto customers. So, we are talking about laser cut,formed and assembled parts in metal sheets,and we also manage varnishing and gluing ofthe glass with outsourced partners. Thereforethe customer receives the finished product,packaged, labelled and ready for the storagewarehouse. For us, this means being responsiblefor the order: or rather also managing theoutsourced activities, interfacing with the clientto follow and support him in all his needs, bothin terms of service quality and goodsmanagement; in short, coordinating every singletask”. A supporting element of the philosophy followedby the company is in fact based on thespecialisation in various processing stages, thereason for which it avails of collaboration withtrustworthy partners who ensure professionalismand a quality product for the production ofaccessory or complementary parts. In this sense,a series of business partnerships were set upwith companies working in the Veronese

hinterland to complete the service offered tocustomers. Valid support already at design phaseThe concept of partnership that Verona Lamierealso, and particularly, extends to its customers,to ensure valid support already in the designphase, serious attention to qualitative requirementspecifications and the study of optimal technicalsolutions to minimise production costs, as wellas joint analysis to determine an optimalquality/cost ratio based on specific needs. “We are working a lot to create ever-closercontact between our technical office and thatof our customers – explains Engineer GaetanoCarcano, General Manager of the company –also because it is now fundamental from astrategic point of view, especially for those

[ ]Experience

Automation and laser are the key words

Verona Lamiere is part of Finluc Group whosevarious businesses areactive in the market ofboiler manufacturing, heating systemconstruction and sheetprocessing for third parties.In particular, VeronaLamiere was established in1989 as a company mainlydedicated to sheet cuttingand bending.

by Fabrizio Garnero

Verona Lamiere is currently responsible for largescale semi-processed parts ordersmade from metal sheets.

companies without internal skills in metal sheetprocessing and that ensures our experienceand our contribution gives guaranteed success. In some cases, in fact, we get rough, generaldrawings, with instructions on how the part mustbe made but it is up to us to industrialise it, orrather, analyse it from a technical/economicaspect and optimise the design based on theactual feasibility with our machinery. Recently,for example, we designed a line of ad hoccabinets from scratch for a customer; in thiscase, we got a general sketch from the plannerused as the basis for the actual design andproduction”.

Differentiation forend marketsThe main end markets for Verona Lamiereprocesses are the boiler, vending machines,office furniture, white goods in small quantitiesand the production of semi-processed structuralparts for operating and industrial machinerysectors. “With such a wide-ranging market – explainsMr. Lucchini again – our strategy is to favourorders characterised by medium to highquantities. Having seriously invested inautomation and laser technology, it is best tohave as little machine downtime as possible,the reason for which our batch limit is onehundred parts. Given today’s low profit margins,it is fundamental to always have the laser cuttingsystems moving; this is why we prefer bigbatches, even if we are always willing to workwith smaller quantities”. The various end sectors for Verona Lamiere alsoincludes that of small quantities of electricalappliances, intending for example kitchens forcommunities with thousands of pieces per year

or machines to distribute beverages and coffee.Another important sector is heating becauseICI Caldaie, also part of Finluc Group, passesall its boiler processing and heating systemorders to Verona Lamiere. “Another interesting sector for us - recallsCarcano – is industrial machines such as forkliftsor the transport sector, where we work for leadingcompanies on the market. In this case, highstrength steel sheets such as Domex andWeldox, even if we generally work more withcarbon steel. However, we process all types ofsheets, from polished to galvanised to stainlesssteel and aluminium and we always purchasehigh quality materials, since we consider thisan important part of our successful processes”.

In the workshop, twelve automatic lines process the sheetsVerona Lamiere is convinced the key unbeatableif you want to be competitive on the sub-contractor's metal sheet processing market isthe continuous modernisation of the systemspark and technological innovation. For thisreason, as previously mentioned by Mr. Lucchini,

MAY 2006 No. 127F O R M I N G

The laser cutting cell withthe Platino system installed inVerona Lamiere.

The 3D Rapido laser system by PrimaIndustrie installedin VeronaLamiere.

134 - MAY 2006 NO. 127

the automation of processes and lasertechnology are the characterising elements ofthe company’s business which found in the PrimaIndustrie Platino and Rapido laser cuttingsystems two reliable systems enablingconcentration on certain cutting andcutting/welding activities. However, it is best to

proceed in an orderly manner and give a generalframework of how the company is organised interms of production. In fact, the Verona Lamiere workshop isorganised into four macro-divisions: a divisiondedicated to cutting operations, which worksover three shifts; the bending division whichworks over two shifts and mainly in manual modedespite having a robotic bending cell; anassembly division, which conducts typicallymanual operations such as punching and worksover one shift; the moulding division, with pressesinstalled up to 500 t and working, according tothe work load, over one or two shifts. “The most automated part of the company -explains Carcano – is definitely cutting andpanelling, a division with 12 automatic linesinstalled for sheet processing, with punchingcells, laser cutting systems and panellingsystems. Despite the high level of automationhowever, our philosophy is to avoid, as feasiblypossible, working completely unstaffed; sincewe have 12 automatic machines, having at leasttwo or three operators present seems justified

Automation

of the

processes

and laser technology

are the characterising

elements of

Verona

Lamiere

business.

The most automated part of the

company is definitely cutting,

a division with 12

automatic lines installed for sheet

processing, including punching

cells and laser cutting systems.

Being responsible for an order alsomeans managing the outsourcedactivities, interfacing withthe client to follow and support him in all his needs, both in terms of service quality and goodsmanagement

Flash“Being responsible for

an order not only means wemanage the cut and bentsheet, but fully manage theproduction procedure of thesemi-processed part.”

[ ]Experience

MAY 2006 NO. 127 - 135F O R M I N G

because if there are faults or malfunctions theycan ensure extremely fast reaction times andreduce risk of loosing precious hours of work.This is the reason why having one or twooperators always present in production isjustified”.Laser, winning and revolutionary technologyAs we have seen, one of the technologiesassisting Verona Lamiere's business is lasertechnology, which is mostly applied by thecompany in cutting processes, even if, thanksto the Rapido system the company was also

introduced to the laser welding market, but we'llget back to this later. What is however importantto highlight is the strategic aspect that theintroduction of this laser technology has hadon the company. “Laser in fact - explains Lucchini– has allowed us to increase operational flexibilityand reach the “famous” 50 parts that we referredto before and especially to create more complexproducts to give added value to the companyand the “imagination” compared to what isfeasible with more traditional processes suchas punching and shearing. Overall, this expandsour reference market also thanks to the possibility

The Platino flatlaser

cutting system

installed inVerona Lamiere

specifically for cutting average

thicknesses, i.e.8, 10 and 12 mm.

The bending division works over two shifts andmainly in manual mode despite having a bending robotic cell.

The moulding division

has pressesinstalled

up to 500 t thatwork, based

on the work load,over one or two

shifts.

Verona Lamiere avails of an assembly division, where typically manual operations are conducted over one shift.

of helping the customer to make his productmore appealing”.

The purchase of each machine is due to a specific requirementA particular aspect of Verona Lamiere is thatthe machinery installed is fairly wide-rangingboth for the type of machinery and the namesof the machinery manufacturers. “Even ifmachines today are all fairly similar, they alwayshave different characteristics, whether good orbad, from one another. Since we have quite alot of machinery, because there aren’t that manysub-contractors in Italy with twelve automaticsystems to process sheeting, from the very startwe have always tried to take advantage of thepositive features of each machine, trying toorientate it and dedicate it to applications thatbest adapt to its specific peculiarities andpotential” says Mr. Lucchini.Based on contingent needs when making thepurchase, Verona Lamiere chose the mostsuitable machine indicated to meet specificrequirements, independent of the manufacturerand from that moment the machine will be mostlydedicated to a precise application. “Rather thanan initial, precise choice, that of dedicatedmachinery, it is a philosophy matured over time”explains Carcano. “When an order is launched,it is decided where to manufacture it, also basedon the various machine loads, but we are alwayscareful to ensure that certain types of materialgo on certain systems for which they are moreor less dedicated. Therefore, all thin sheets arealways on one type of machine and all stainless

steel on another system, and so on. Among other things, we realised that suchmanagement leads to more regular system wear.In fact, if for example a machine is dedicatedonly to stainless steel, this will definitely be aless worn machine compared to one used tocut carbon steel, since the cutting process forstainless steel is decisively cleaner”.

Experience cannot be bought and must be gained over timeInstallation of the Prima Industrie Rapido three-dimensional system is exactly what thisphilosophy is about. “In this case - recallsLucchini – there were two reasons for ourpurchase: firstly, a request by one of our important

Verona Lamiere takes advantage of the positive features of eachmachine while trying to orientateit and direct it to the applications thatbest adapt to specific peculiarities andpotential.

By simply assembling the welding head set up by Prima Industrie, Rapido allows you to even meet welding requirements on profiled parts.

136 - MAY 2006 No. 127

[ ]Experience

Flash“Given today's

extremely low profit margins,it is fundamental to alwayshave the laser cuttingsystems moving; thereforebig batches are preferred,even if we never refusesmaller quantities”.

Laser welding requires templates that guarantee an extremely precise approach to the parts to weld

The HOW welding unit enables welding from a distance over 100 mm, thereby avoiding interference with equipment.

customers, but especially our willingness toevolve and start diversifying our business whichwas purely flat cut based. It also often happenedthat the work conducted using the Rapidocontributes to increasing the work of the othermachines because three-dimensional processesare a great sales pitch”. “Another aspect, but none the less important,is that the Rapido, by simply assembling thewelding head developed by Prima Industrie,allows us to also meet welding requirementson profiled parts. We would like to work morewith this sector, since it is extremely “fertile”ground with enormous potential, but there isstill a lack of culture and mentality and laserwelding is frowned upon. One limitation is definitely costs given the processrequires templates to guarantee an extremelyprecise approach of the parts to weld and that,

therefore, require certain willingness to invest.We are however convinced that laser weldingwill play an important role in the future, especiallyto increase the added value of orders. Theobjective is therefore to saturate the Rapidosystem with other cutting activities but especiallywelding. For over a year now, we have beenworking in the professional sector of laser weldingwhere the aesthetic appearance of the bead isimportant”.

MAY 2006 NO. 127- 137F O R M I N G

138 - MAY 2006 NO. 127

Experience

“Lastly, I would like to add - interjects Lucchini– that the choice of 3D laser made three yearsago favoured Prima Industrie particularly dueto their experience already in this type of systemcompared to that of other competitors. Eventhough the other manufacturers were seriousand reliable, I am fully convinced that experiencecannot be bought and has to be gained overtime”.

Welding at a distance over100 mm from the surfaceThe HOW welding unit, the name of the headdeveloped by Prima Industrie, enables weldingat a distance over 100 mm, thereby avoidinginterference with the equipment. It is particularlysuitable for welding in sections (stitch welding)and is easily inter-changeable with the cuttingunit.

The HOW unit includes a coupling flange onthe machine head, an air and gas connection,a mirror (with focus length 200 mm) to focusthe ray on the part to process and cross-jetprotection of the optics.A removable tube enables coverage gasadduction and plasma elimination and can beassembled in four different positions, based onthe advancement direction. The HOW unit also

For over a year Verona Lamiere has been working in the professional sector of laser weldingwhere the aesthetic appearance of the beadis important.

The HOW welding unit assembled on the Prima IndustrieRapido system.

FlashThe objective is

therefore to saturate theRapido system not with othercutting activities butespecially welding. We havebeen working for over a yearin the professional sector ofaesthetic laser welding.

[ ]

MAY 2006 No. 127 - 139F O R M I N G

includes self-learning programming equipment.

A reliable flat laser system specifically for mediumthickness cuts“The second Prima Industrie system – continuesMr. Lucchini – was instead installed simplybecause we needed a reliable flat laser systemspecifically for medium thickness cuts, i.e. 8,

10 and 12 mm, and the Platino, while also cuttinghigher thicknesses, seemed most suitable forthis operation thanks to the excellent mechanics,as well as the machine with the best quality/priceratio. Another reason that influenced the overall choicewas the possibility of having front access to thework area of the machine because, even thoughthe machine has a vertical sheets warehouse,the sheets often have to be loaded manually,especially when making slightly profiled parts.In this case, we need to supply them by handbecause when just a few parts are beingmanufactured automatic loading and unloadingis pointless. This is definitely a big convenience and one ofthe reasons why we preferred the Platino to othersimilar systems”.

�

One of the reasons

why the Platino system was

chosen is the possibility ofaccessing the

machine work area from

the front.

FlashTo be competitive on

the sub-contracting, sheetprocessing market, you needa continuously updatedsystems park andtechnological innovation.

The Platinosysteminstalled inVerona Lamiere is equipped with a vertical warehouse.