Maximize Your Profit and Avoid Hidden Troubles

January 19, 2018 | Filament Winding, GRP Pipe Production

Maximize Your Profit and Avoid Hidden Troubles

In this article, I will reveal how much money you could profit-taking only one decision and eliminating hidden troubles forever.

I know that it may seem strange to you to hear about something in your company that is not visible, something that consumes your profit and even causes problems to everyone near the worksite.

During my visits to different manufacturing plants and pipe installations, I have seen such situations several times and, unfortunately, also their negative effects because the team in charge didn’t act in time. After seeing the consequences, I have decided to fight it back, investing all my time to eliminate the source of such harm.

In order for you to be able to cope with this issue, I will provide with the explanation of this danger.

As you probably know, one of the main continuous tasks performed by your workers in the fiberglass plant or pipe installation is the manual cutting. Yes, it has always been a problem that you thought you need to solve due to its low efficiency, being the most expensive and labor-intensive task in the supply chain or installation process.

If you think that low efficiency is the only reason I believe this to be true and that there is no other way to do the job, I have to tell you something: the danger is already there but it is hiding very well.

Performing the cutting manually is not only inefficient but it also poses hidden dangers that could make you ill and result in you losing a lot of money.

After installing the FCS, you will get the following benefits:

  • Through its diamond cutting system, you will see how it is possible to cut a larger pipe in minutes. The efficiency of your fittings department will immediately increase by more than 50%.
  • The desired cuts can be programmed by drawing in a CAD – CAM software supplied with the machine or by importing the data directly into its Numerical Control so the marking task is not needed anymore. No more complicated templates to mark the pipes, while amazing precision and matching will become your daily routine.
  • The software of the FCS can repeat the same profiling jobs as many times as desired by the operator, whereby the repeatability is 100%. All the cuts will be exactly the same and the efficiency will increase amazingly.
  • The water spray system of the FCS controls the fiberglass dust so you and your workers will be safe from such a destructive threat.
  • The software of the FCS performs the cut without the need for an operator. Since you are away from the cutting zone, there is no possibility of being injured by such a task. The cutting process will thus become simple and carefree.

I shall illustrate this with an example of a fiberglass pipe with a diameter of 2500 mm.

To perform the manual cutting, these are the activities your workers need to perform:

ACTIVITY NUMBER OF WORKERS TIME REQUIRED (min)
Preparation of the template for the required cut 1 60
Marking of the cut on the pipe 2 60
Manual cutting 2 75
Correction of the manual cutting 1 30

Now we are ready to analyze the same task using the Fittings Cutting Station (FCS):

ACTIVITY NUMBER OF WORKERS TIME REQUIRED (min)
Preparation of the template for the required cut not needed 0
Marking of the cut on the pipe not needed 0
Automatic cutting 1 15
Correction of the manual cutting not needed 0

FINAL COMPARISON FOR THE ND 2500 PIPE CUTTING

Manual cutting:                                                 225 minutes – irregular cutting

Fittings Cutting Station (FCS) cutting:        15 minutes – perfect cutting

Multiplying the average industrial costs (direct and indirect costs) of a medium-size manufacturing plant with the overtime due to the manual cutting, we are talking about savings of more than 500 euros per 1 piece.

Considering that in one month, a fitting plant would need to produce 30 pieces, the result would be a saving of more than 15.000€/month (of course, not considering all the costs related to injuries and health hazards associated with the manual cutting).

I am sure that it is clear to you by now that the Fittings Cutting Station (FCS) enables you to save a lot of money.

Perhaps you are asking yourself: “But what if I have to perform curvilinear cutting? Is it possible to cut any type of fiberglass pipe? What about the pipe thickness?”

I can answer you right away: You will be able to cut any types of fiberglass pipes, regardless of their thickness, rectilinearly, curvilinearly, at every possible angle, precisely and within minutes.

Before I conclude this article, I would like to give you another good piece of news.

The FCS may be customized to fit different cutting ranges, so you don’t need to worry about whether your production range is too small or too big. We can cut pipes of up to 4000 mm easily. Imagine how you would feel knowing that you are increasing your profit immediately after installing the solution by means of which you can avoid potential injuries and health hazards related to the manual cutting.

Would you not want to avoid unexpected events during the delivery of a very demanding project?

It is very simple: you can request a telephone appointment (or a Skype call) by simply clicking on “REQUEST A PHONE CALL“.

A page with a contact form will appear on your screen. Leave me your details and I will get back to you within 48 hours.

For better understanding, let me state some facts.

  • Your team has difficulties assembling the GRP components due to uneven cuts
    The GRP pipes with unevenly cut ends and cutouts are difficult to align and position. The job that your workers do daily to close the gaps is very difficult and time-consuming, especially with big diameters. Such a task often involves resin dripping inside the pipe or the movement of pre-assembled pieces, all resulting in the extension of time taken for the assembly and, consequently, in a big loss.
  • Your workers may get injured
    Manual cutting in fiberglass industry is a cause of a large proportion of work-related injuries, and we are all familiar with their enormous cost. But if you think that injuries and health hazards only affect your workers because they work with a manual grinder, you are simply wrong.

There is another threat, and it is the trickiest aspect of this story because its consequences cannot be seen immediately. This destructive threat appears in the form of fiberglass dust that is generated all around you.

Your workers cut, chop, saw or trim fiberglass, and the dust produced contains small fibers. These fibers can come into contact with their skin and eyes, causing eye injuries or serious skin problems.

But what happens if you or your workers inhale such fiberglass dust?

Unfortunately, when the fiberglass dust is inhaled, larger glass particles may be trapped in the upper airway but smaller fibers may go deep into the lungs. Imagine for a moment these small particles flying around, entering your lungs and remaining inside forever. Not a pleasant picture, isn’t it?

The possible harm that the dust may cause is mostly determined by the amount of dust present in the air and the time of exposure to it. Anyone who is exposed to high levels of fiberglass dust may be affected – the longer you breathe in the dust, the greater is the chance that it will seriously affect your health.

There were several studies published in the British Journal of Industrial Medicine that explored the pulmonary effects of exposure to fine fiberglass, and the conclusion was that the exposure to fine fiberglass appears to produce human disease similar to asbestosis.

Don’t worry, luckily for you, you’ve come to the right place.

In this article, as I told you in the beginning, you will learn how to eliminate this threat and immediately increase your profit.

You can make your GRP cutting safe, hazard-free, efficient, rapid and precise, saving time and money through the application of the FCS (Fittings Cutting Station).

The FCS is designed for high precision fiberglass cutting, slabbing and profiling.

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