With cost & productivity being primary concerns, Mark and Trey made sure to monitor tool life and the time needed to complete a project. Using both the cost of the tooling and the operator’s time, Chisum and Frederick were able to determine Metalforms’ cost per expansion. The Hybrid Series Rapid Hawk showed positive results almost immediately, compared to their previous rolling method. “As a result of the changes we made with the Rapid Hawk we can say that our cost to expand a tube has dropped by more than 50%,” Chisum explained. This was primarily due to the system’s reach and mobility, making it easier for the operator to complete the job. In addition to cost savings, Metalforms saw a significant decrease in the amount of rework needed on their heat exchangers. “We have over 280,000 expansions on the Rapid Hawk, with the capability of 360 expansions per hour, with 0 tube joint leaks due to the system, and with 0 downtime,” Chisum stated.
The reduction in time spent rolling not only benefitted their customers, but it also made a positive impact on operators. The ergonomics of the system alleviated unnecessary operator stress. After only four hours of use during the first trial day, one of Metalforms’ lead operators commented: “I can’t remember a time where my shoulders weren’t hurting by now.” The new ease with which operators were able to complete the job, made them eager to use the machine. Their enthusiasm and willingness to use the Hybrid Series Rapid Hawk helped Metalforms transition their team to the new system more quickly.
Overall, Dave Hearn was impressed with both the results generated from the Rapid Hawk system, as well as, the customer service provided. “In the competitive environment we are in, Metalforms is always looking for ways to reduce our costs, improve our quality, and improve our safety. It is good when we can find a supplier that can do one of those really well. We are impressed when a supplier can do two of those. Elliott Tool was instrumental in helping us with all three!” Dave Hearn said. After purchasing two additional Hybrid Series Rapid Hawk systems, Metalforms, Ltd. is confident that they can maintain their competitive edge within an increasingly competitive environment.