For a manufacturer of aluminum off-road motorcycle and bicycle accessories, precision, efficiency, and cost-effectiveness are essential. Serving the fast-paced powersports industry, the company produces high-quality parts in production runs of around 100 pieces per SKU. To stay competitive, they sought a solution to overcome labor shortages, reduce costs, and streamline operations. Visit Enduro Engineering’s Website
The Challenge: Labor Shortages & Production Inefficiencies
- Before integrating automation, the company faced significant obstacles:
- Difficulty finding qualified staff for three shifts, including weekends.
- High labor costs associated with manual loading across multiple machines.
- Inefficient production processes leading to delays and increased expenses.
The Solution: VersaBuilt CNC Automation
With rising labor costs threatening product affordability, the company turned to CNC automation. Initially, they weren’t sure if an off-the-shelf system could meet their needs, but after testing a VersaBuilt system, they quickly realized its potential.
- Versatility & Ease of Use: The system required minimal training and adapted seamlessly to their high-mix production environment.
- Customer Support: VersaBuilt’s team provided assistance during the initial setup, making the transition smoother.
- Scalability: The company started with one system and, due to its success, now operates seven VersaBuilt systems in their facility
The Implementation: Quick Setup & Immediate Impact
Installing the first VersaBuilt system took about 10 days to fully optimize. The company managed the setup in-house with some guidance from VersaBuilt’s support team.
- Faster Changeovers: The MultiGrip technology simplified job setup, allowing for small production runs with minimal downtime.
- Extended Lights-Out Operations: The system runs completely unattended from 3:30 PM to 7:00 AM, significantly cutting labor costs.
- Maximized Efficiency: Materials can be stacked for longer run times, and finished parts drop directly into a basket, reducing unnecessary handling.
The Results: Significant Cost Savings & Higher Productivity
The ROI on VersaBuilt automation was nearly immediate.
- Eliminated the need for 3 full-time operators across all shifts and weekend overtime.
- Lowered cycle times with uninterrupted production.
- Reduced manual labor costs while maintaining high-quality output.
Looking Ahead: Expanding Automation Capabilities
Building on its automation success, the company recently installed a VersaBuilt system on a mill equipped with an automated side window, optimizing flexibility between unattended production and operator-run prototyping during the day.