Issue n. 4 - September 2005Download pdf - BLM GROUP

INSPIRED FOR TUBE
THE TUBE PROCESSING TECHNOLOGY
No. 4 - 9/2005
UK

Contents
INSPIRED FOR TUBE
2
INSPIRED FOR TUBE
Edited by:
Area Comunicazione
BLM GROUP
Emanuela Colombo
Antonio Farese
Cristina Guzzetti
e-mail: pr@blm.it
tel. +39 031 7070 200
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6
8
10
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14
Contents
INSPIRED FOR TUBE
Also available in pdf format on:
www.blmgroup.com
Produced by:
BLM GROUP
Via Selvaregina 30
22063 Cantù (CO) Italy
www.blmgroup.com
Number
INSPIRED FOR TUBE
Nr. 4 - 09/2005
Lasertube - Sub-Contracting
Three “Laser tube”
generations
Cells - Motorcycle
The “5S” of the Kaizen
Lasertube - Sub-Contracting
First time quality
Lasertube - Farm equipment
Same day delivery
Bending - Automotive
When the tube bender becomes
a star performer
BLM GROUP SA - The Group
The Rainbow Nation
Graphic Design
Studio Grafico Page
Vincenzo De Rosa
Fabrizio Santini
Printed by:
Intergrafica Verona S.r.l.
Verona
Photography:
Aeffe
BBR
Reproduction of all or part of
articles or illustrations published
in this edition cannot
be used without prior authorisation.

Opinion
Paolo Colombo, Anna Mascheroni, Pietro and Emanuela Colombo.
People make the real difference
As a manufacturer of high technology machines
and systems for tube processing, on a daily ba-
sis we must confront the challenge of a constantly
changing market. What we offer today is the product
of past decision and what is being developed
today should foresee future market needs. What
is beyond doubt is that all the related decisions
and actions will be taken by people: hence it can
only be people that can make the real difference.
In BLM GROUP human resources have always
been highly valued: 12,800 hours were dedicated
to training activities in 2004 involving more than
65% of our employees. The entire sales and service
network took part in training programs, including
our subsidiaries abroad who face the extra
dimension of fulfilling customer demands
locally and independently from the HQ.
Human resource is one of three pillars of BLM
GROUP’s strategy together with innovation and market
development. A long established BLM GROUP
principle is that over 5% of our turnover must always
be invested in R&D, additional initiatives in 2005 include
the support of market development with our
sales and after sales service teams empowered
to ensure we are meeting and exceeding customer
expectations by regular personal contact.
BLM GROUP’S latest innovations for the market
are focused on increasing added value to tube
processing operations and include:
• New ALL-ELECTRIC ranges of Tube benders
and Endformers to complement our established
market leading hydro-electric ranges.
• New laser cutting options to process open sections
as well as tube.
• A new version of the ADIGE CM502 combined
sawing and machining centre, now covers a much
wider range of machining applications.
Added to this is the new product philosophy we
are successfully establishing on the world market:
“Processes...Combining and Integrating Multiple
Operations into Competitive Solutions” which
we introduced during INTUBE 2005 in May, the
last BLMGROUP Open House.
To fully support this philosophy and to meet the
growing customers’ demand for customised
working cells and integrated manufacturing
lines, a separate ‘Production Systems Department’
has been established, dedicated to the
design and supply “turnkey” machines and systems
for tubular applications, based on the specific
technologies and demands of the individual
customer.
Human resources, technological innovation, customization,
on-site evaluation of customer needs
and new markets are our daily routines. They determinate
our decisions and make us look at the
future with a positive outlook, because we work
so closely with our customers sharing winning
ideas and winning solutions.
Pietro Colombo
BLM GROUP, President
INSPIRED FOR TUBE
3

INSPIRED FOR TUBE Sub-Contracting
4
Three laser tube cutting systems of different
generations work side by side.
Three “Laser tube”
generations
That fortune favours the brave is a matter of fact
at Metrio in Ense-Hohingen. Despite being located
in Nordrhein-Westfalen, Germany, an area
overflowing with laser cutting sub-contractors,
Metrio have established a market-leading position
in only six years by specialising in the laser
tube processing. At the beginning, this was truly
a gamble for the two founders Wolfgang Peuker
and Ulrich Duser. “We started up from zero
in December 1998 - without any customers or
contracts - but pretty confident our idea would
get a positive response from the market, which
needed an operation like Metrio”.
The Laser tube revolution
Wolfgang and Ulrich clearly remember the early
days after taking delivery of their first laser tube
cutting system; the LT651 from ADIGE in Italy. “In
the first six months, when time was available, we
literally “played” with the machine, to enable us
to discover and exploit the potential of the laser
tube cutting technology, and to really get to grips
with even the most obscure features of the machine.
We did not want to make our customers
promises, that we could not keep and we wanted
to give them the optimum benefit of this then
ground-breaking technology,” says Ulrich.
“Our first customers were from the lighting, furniture
and sports equipment industries” explains
Ulrich. “With us they found what they had never
had before: high flexibility and fast deliveries.
The next step was to establish both ourselves
and the massive potential of the
“revolutionary” (at the time) laser tube technology.
We arranged an open house for potential
customers, to highlight the differences between
laser tube cutting and traditional
machining. It was not just a matter of how laser
tube cutting could radically improve product
design and manufacture and final-assembly;
but mostly how it eliminated old and cost-inefficient
processes such as tube, sawing, milling,
punching, notching, deburring etc”. This convinced
even the most sceptical customers.
A unique know-how for tube
After this provident start, Metrio saw the possibility
to win new customers in the automotive
industry, who, along with the usual accuracy
pre-requisite, demand the ultimate in on-time
delivery.
“The need of another machine was at once clear
- explains Ulrich – and this happened in the year
2000 (less than two years from the first machine

eing installed). The choice was again ADIGE,
this time the new model LT652, and not only because
of the excellent service.
“Our experience with ADIGE has been positive
in all respects: firstly, we always have the same
contact point, which provides the necessary support,
and let’s not forget the prompt delivery of
spare parts, usually received within 24 hours from
BLM GROUP Deutschland GmbH, a subsidiary
of BLM GROUP, or directly from the ADIGE Headquarters
in Levico Terme”.
“Moreover” - adds Ulrich - “BLM-ADIGE possesses
a unique know-how for tube processing,
which is very important for quickly resolving
any application problems. ADIGE regularly
draws on customers’ experiences to develop
innovative and efficient solutions, which are then
implemented in the new machines to make our
work easier”.
Special and irregular profiles
With new contracts undertaken for the automotive
and motorcycle industries, the two laser tubes
were soon filled with jobs and working three shifts.
In 2004, three new people joined the company
staff, which now totals twelve.
In the same year came the third new machine,
the latest generation ADIGE LASERTUBE LT712D,
with a customised selection of accessories to also
handle and process irregular shaped tube and
section.
“We now have three laser systems, of different
generations, working side-by-side 24-7, producing
components in stainless steel and mild steel
in batches from 1 offs, to 30,000 pieces per
month.” The first machine the LT651 is still going
strong, working all-day, every-day” says Wolfgang
Peuker. “We recently replaced a key part
of the machine, which had worn, and although
the machine has been out of production for five
years, the part was available from stock and was
fitted immediately, it was as if it had been manufactured
in Germany”… praise indeed.
Metrio GmbH
Metall- und Laserbearbeitung
Auf der Breihe 5
59469 Ense-Höingen
Tel. 02938/97982-0
Fax 02938/97982-9
E-Mail: info@metrio.de
www.metrio.de
No. 4 - september 2005 INSPIRED FOR TUBE Sub-Contracting
5

INSPIRED FOR TUBE Motorcycle
6
TMC Supplies tubular components directly to the assembly
lines of Italian Honda with a very low defective level.
The “5S” of the Kaizen
Going through the doors of TMC S.r.l. in Vasto, it
would be easy to believe you were entering a
Japanese factory: at the centre of the workshop
you can clearly see a large, dominant poster with
the famous “5S” of the Kaizen, continuous improvement.
Mr Gabriele Tumini, who runs this Italian company,
decided some years ago that in order to
supply the Japanese successfully, it was necessary
to find a “common denominator”.
And the “continuous improvement” culture became,
at once, the principal practise at TMC, enabling
them to become one of the few firms which
supplies Italian Honda and which guarantees the
supply of components with a defective level of
0,0015 – 0,0019 ppm (parts per million). A good
result, achieved thanks to reliability (on time delivery),
quality (ISO9001, ISAO 14001 and Vision
2000 certification) and efficiency (good quality to
price ratio).
100% inspection of all components.
TMC s.r.l. employs around 90 people, producing
tubular components ready for assembly and metal
component. The tubular components are used
in the motorcycle sector (handlebars, stands,
frames), in high quality furniture, and sports equipment.
With its wealth of expertise in tube manipulation,
TMC carries out all the aspects tube fab-

ication: cutting to length, bending, end forming,
welding, finishing and 100% inspection of all
components, and then delivering, just in time, directly
on to the Honda assembly lines. Included
amongst its other customers are Fiat, Sevel, Pilkington
and Denso and Knoll.
1.2 million pieces every year.
Visiting his workshop, it is evident that Mr Tumini,
has reached these results by investing in the most
advanced BLM tube forming technology.
In fact, they have installed two BLM fully automatic
working cells. The first one is capable of producing
1.2 million pieces per annum and works
on three shifts, with an integrated robot continuously
loading and unloading between a BLM
Swing Tube Bender and a BLM Tube form Endformer.
Such has been the success of this first cell; a second
has been recently installed.
Many of the major advantages these BLM manufacturing
solutions have provided were not so
self evident.
Obviously there are the traditional benefits of reduced
cycle times and the possibility to work lights
out.
However TMC now find they enjoy a workflow with
almost perfect optimization, rejects have been reduced
to acceptable levels, the management flexibility
of the cell for batch work has eliminated other
non-efficient machines/processes from the
production cycle, there are no pallets of semimanufactured
components (work-in-progress)
around the workshop and the peak efficiency of
the welding lines has been greatly improved.
But Mr. Tumini’s greatest satisfaction is taking the
development of his company to a higher level
or competency, with partner suppliers with the
same work belief, and customers who recognise
the value of good work.
The fundamental given is that of trust in the customer
and the acceptance of an equal supplier/customer
partnership not just of supplier exploitation.
TMC s.r.l.
Zona Industriale Punta Penna
66054 Vasto (CH)
tel. 0873 3108.1
fax. 0873 3108.228
e-mail: info@tmcvasto.com
No. 4 - september 2005 INSPIRED FOR TUBE Motorcycle
7

INSPIRED FOR TUBE Sub-Contracting
8
From steel stockholder to a sophisticated
laser tube processor.
First time quality
Hierros Lleopart, S.A. in Barcelona, Spain, was
established in 1962 selling iron and steel, but
in the last 12 years there has been a radical
change, transforming the company into a high
value-added processor of steel tube with three
Adige laser tube cutting systems working 24-7.
With around 25 employees and managed by
the two brothers Jorge and Jaime Isert (second
generation), the past of Hierros Llopart lies only
with the name. With spirit, investment and dedication
to service, the company has continuously
changed during the years, growing day
by day with the most up-to-date technology
available on the market.
Hierros Llopart typical customers are involved
in industries such as lighting, metal furniture,
agricultural machinery, tubular frames and motorcycles.
Over the years the company had purchased
several Adige Production Saws and felt
very comfortable with them. Then in 2001 they
decided to take a massive step upwards in the
value-added chain by investing in their first Adige
Laser Tube Cutting system, so successful
was it that a second followed in 2003 and recently
a third, the very latest generation Adige
LT712D.
Finished semi-manufactured products.
Of course the change was not so easy but starting
with their existing customer base, the brothers
Isert then started to widen their sphere of action
so that nowadays the old customers are just
a small part of the total clientele.

HIERROS LLOPART S.A.
Carretera Nacional 150, km 3,7
08110 Montcada i Reixac
Barcelona, Spain
tel. +34 93 594 48 60
fax. +34 93 594 48 61
e-mail: lasertubo@hierrosllopart.com
www.hierrosllopart.com
The company itself has undergone a deep transformation
to establish the culture of high technology
tube processing, engaging skilled employees
for programming and operating
high-technology machinery.
Rather than just a cut piece of tube, their customers
now receive a semi-finished product,
ready for final assembly or welding, to the highest
degree of accuracy without any high fixed
investment cost ie. the benefit of a laser cut
product without the cost of investment in the
machine itself.
Customised service
The “customer orientated” culture springs from
the old trade of iron and steel days and continues
to develop. Hierros Llopart is a true partner
supporting their customers throughout the total
process from the CAD engineering (with four dedicated
employees), to product design and manufacture.
We don’t just look at the parts to be
made, we genuinely involve ourselves in our customers
total manufacturing process and product
design - only then can we make legitimate suggestions
on how best we can utilise our vast laser
tube cutting expertise to our customers’ ultimate
benefit in terms of overall cost and quality improvements
- a truly personalised package.
Quality and service are factual for Hierros Lleopart,
both are assured through the reliability and
performance of their three Adige Laser Tube Cutting
Systems running continuously on three shifts.
Being aware that customers are the key of success,
Hierros Lleopart will continue to lead in innovation,
purchasing the very latest high technology
to exceed customers’ demands and to
improve their tube laser processing and customer
service.
No. 4 - september 2005 INSPIRED FOR TUBE Sub-Contracting
9

INSPIRED FOR TUBE Farm equipment
10
Embracing the very latest “laser tube cutting” technology guarantees
unbeatable floor-to-floor times and the lowest possible component cost.
Same day delivery
At RIMA SPA of Montichiari, nothing happens unexpectedly.
Their strategy of controlled growth
and the strictest attention to customer satisfaction,
are the clear business drivers of the company
run by Mr Giorgio Zonta.
RIMA s.p.a. founded in 1972, specialises in the
manufacture of vehicles and equipment for construction,
agricultural and industrial use. In particular,
parking jacks, lifting gear and wheels, as
well as hydraulic components including cylinder
and bearings.
The 8000m2 factory in Montichiari, production
units in England and Rumania, and other strategically
positioned business offices enable us “to
be near to our customers” adds Mr Zonta.
The company has around 170 employees and
rapidly increasing exports account for 40% of
turnover.
The development strategy revolves around two
principal concepts: the differentiation of the products
(hydraulic components) and opening up new
market areas (industrial vehicles and construction
equipment).

The added-value technology is kept
within the company
“Our production – Mr Zonta explains – is characterised
by medium-small batches and increasing
product-customisation/differentiation. So to manage
the variability and variety of the demand in a
flexible and efficient manner, it was decided to retain
within the company, all manufacturing considered
strategic and with a high added-value, for
example, the complex tube machining involved in
many of their products along with welding, assembly
and finishing.
13 job changeovers per shift
The machining of RIMA’s tubular products is now
carried out on the Adige LT652 Laser Tube Cutting
System, which enables them to finish-machine the
product on one machine, in one operation, automatically.
As RIMA use mostly thick-walled heavy
tubes, the consequent elimination of handling between
former traditional machining processes. By
utilising the Adige LT652 Lasertube, has been greatly
appreciated. The versatility and capability of the
ADIGE LASERTUBE has given rise to amazing pro-
ductivity gains, 70% in some cases. Remarkably
the whole machine can be changed from one job
to the next in typically 3 to 4 minutes.
“With the very fast and multi-purpose manufacturing
capability the ADIGE LASERTUBE provides –
Mr Zonta explains again – it is realistic to manage
efficiently and cost-effectively small batches (20
pieces or less) and quickly accommodate any product-customisation
(or even design changes). Very
often there are occasions when job changeovers
on the ADIGE LASERTUBE, exceed 13 times per
shift. With the total flexibility and production capability
of the ADIGE LASERTUBE the advantages
are self-evident and numerous.
Previously in the production cycle we would have
used four or five traditional machines and transferred
the semi-finished product between these machines,
inspecting at each process to try and minimise
the accumulative error associated with
consecutive traditional machining processes. Now
its all done on one machine, the LASERTUBE and
RIMA can turn around customer orders in the very
same day they are received!
RIMA S.p.a.
Via Sigalina a Mattina 32
Località Ro
25018 Montichiari (BS)
tel. +39 030 962161
fax. +39 030 9961397
www.rimaspa.com
e-mail: info@rimaspa.it
No. 4 - september 2005 INSPIRED FOR TUBE Farm equipment
11

INSPIRED FOR TUBE Automotive
12
CNC controlled tube benders boost the processing of tubular
components for the automotive industry.
When the tube bender becomes
a star performer
Giflo Engineering specialises in manufacturing
tubular type components for the automotive industry,
products include the smaller water, oil and
fuel pipes, the larger bull, roll, nudge and side impact
bars and tubular rear bumpers.
Other components include roof racks, seat frames,
dipstick tubes, breather tubes, hood supports,
various mounting brackets, protectors, spare
wheel carriers, chassis frames, and stainless steel
aesthetical components. Located in northern Pre-
toria, South Africa, in the Ga-Rankuwa Industrial
Park, the company has steadily increased its collection
of BLM CNC tube bending equipment,
strongly improving their tube manipulation process
and capability. They now have four machines with
a fifth shortly to follow.
Italian Origins
Giflo Engineering was established in 1972 by two
Italian immigrants, Alfonso Benassi and Livio Floresco,
to manufacture jigs and fixtures for Alfa
Romeo and FIAT in South Africa. The third partner,
Dante Altieri, who had been working for Nissan
South Africa, joined the company in 1984.
The majority shareholding of Giflo Engineering
was sold in 1996 to Argent Industrial Holdings, a
company listed on the South African JSE Securities
Exchange.
The Argent group has 18 operations, 17 in South
Africa and one in the US, and Giflo is one of the
stars of the group. With over 340 employees and
headed up by MD Jan Taljaard, Giflo now supplies,
the majority of the OEM’s in South Africa, including
Daimler Chrysler, General Motors and
from this year, Toyota pickup vans.
The next time you find yourself driving on the road
behind a pick up van, take a look at the steel back

umper because it is almost certain to be an Argent
group product.This is because Giflo supplies
virtually all pick up van back bumpers and
a large majority of their roll bars.
Combining fixed and variable radius
bending.
Giflo mainly process tube diameters 44, 63 and
76mm, though products range from tube diameters
8mm up to 130mm. Productivity depends on
the orders flow and varies from 50,000 pieces per
year for the small components, to 18,000 per year
for the bigger ones. Such volumes demand the
output and reliability associated with the four BLM
tube benders and the AST80NC end-forming machine,
the pride and strength of their tube pro-
cessing department.
Giflo Engineering purchased the first tube bender
in 1983, when it won a contract with one of
the local OEMs, and is now waiting for its fifth BLM
Bender, a Dynam3, to bend tubes up to OD
63mm. Designed for four stack bending or for
four tool stacks; using formed clamp jaws to bend
components where there is little or no straight between
bends; and where combined fixed and
variable radii bending is required on the same
component. This machine will complement their
much bigger BLM Dynam 8 a 5-axes CNC tube
bender with a capacity 130mm diameter. Their
other BLM CNC tube benders include: NC880,
capacity OD 80mm, the NC832, capacity OD
32mm; and the NC863, capacity OD 63.5mm.
Giflo Engineering (Pty) Ltd
Stand 245, 4th Street
Industrial Site
Ga-Rankuwa,
North West 0208
South Africa
+27 12 703-3346
+27 12 703-3347
No. 4 - september 2005 INSPIRED FOR TUBE Automotive
13

INSPIRED FOR TUBE The Group
14
BLM GROUP SA assure local support
with its own staff.
The Rainbow Nation
GROUP SA people:
Ian Hutchinson Service Engineer
Cesare Caccia Managing Director
Alan J Turton Sales Manager
Kerry Palmer Book Keeping/Secretary
Tiziano Zanardo Service Engineer
Eight years ago, BLM GROUP took the opportunity
to set up a subsidiary company in the
emerging market of South Africa. At the time, it
seemed a risk but now the establishment of BLM
GROUP South Africa has turned out to be the key
of success.
The first aim was to make BLM GROUP and its
products better known in an area where previously
our coverage had been fairly marginal. From
the beginning, we sought to establish relations
based on the credibility of BLM GROUP as a leading
global player in tube processing machinery,
and on the confidence customers feel when they
can deal with the manufacturer directly. With fully
trained, product dedicated engineers, ensuring
the highest standard of after-sales service and
customer satisfaction – even when 10.000 km
away from Europe, surrounded by the whole
African continent.
Two strategic locations in the territory
As the leading specialist in machines and systems
for tube processing, BLM GROUP SA is now
enjoying a reputation of reliability and significance,
which is unique in the South-African market. This
is a direct result of the continuous total-support
offered to customers by an experienced staff,
comprised of five South-Africans, two being service
engineers and offices in Johannesburg and
Port Elizabeth. The Port Elizabeth office was established
in 2004 so we could be on the doorstep
of our customers in this heartland of manufacturing,
thereby ensuring the best response time and
service support.
Nowadays BLM GROUP SA is considered a
first class partner with unrivalled state-of-theart
technology, offering innovative manufactur-

BLM GROUP SA PTY LTD
Unit 12 Meadowdale Park.
Dick Kemp Street.
Edenvale 1609
P.O.Box Postnet Suite 129
Private Bag X4 - Bedfordview 2008
Tel. : +27 (011) 454 0037
Fax.: +27 (011) 454 2753
Email: blmsa@iafrica.com
ing solutions as well as a skilled and timely after
sale service.
Customer’s satisfaction
The South-African tube processing market fully
embodies the spirit of the “Rainbow Nation” with
a unique variety of companies, ranging from family-owned
furniture companies to multi-national
manufacturers of automotive components. BLM
GROUP SA has developed its own character and
skills to be a flexible and considerate partner, able
to offer a service to meet the different demands
of such a diverse market.
BLM GROUP SA is unique in its capability to offer
both stand-alone solutions and totally integrated
production cells. The after-sale service is completed
by a show room equipped with machines
for “live” demos and by a spares warehouse.
The future actions of BLM GROUP SA will be
based on its complete competence and on our
ability to transfer the know-how and the technological
solutions that BLM GROUP amasses from
its worldwide presence and deep experience, together
with extreme attention to the customerpartnership.
The aim is always the same: customer’s
satisfaction.
No. 4 - september 2005 INSPIRED FOR TUBE The Group
15

INSPIRED FOR TUBE
16
Via Selvaregina, 30
22063 Cantù (CO) Italy
tel. +39 031 7070200
fax +39 031 715911
e-mail: export@blm.it
TUBE BENDERS
TUBE END FORMERS
CUTTING DEBURRING AND WASHING
CUTTING AND END MACHINING
LASERTUBE CUTTING SYSTEMS
LASER CUTTING FOR SHEET AND SHEET&TUBE COMBINED
MATERIALS HANDLING SYSTEMS
3D MEASURING AND INSPECTION
PRODUCTION CELLS
NON CONTACT MEASUREMENT SYSTEMS
PROCESS CONTROL SOFTWARE
Also available in pdf format on:
www.blmgroup.com
Via dei Campi, 4
38050 Novaledo (TN) Italy
tel. +39 0461 720007
fax +39 0461 720214
e-mail: sales@adigesystems.it
Via per Barco, 11
38056 Levico Terme (TN) Italy
tel. +39 0461 729000
fax +39 0461 701410
e-mail: export@adige.it