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Dino
09-24-2011, 12:06 AM
Few years back a solar panel company asked ez to come up with a setup
to save all the damaged panels. 5K + wasted money every day due to manufacturing defects on the panels.

The problem was that the panels was very long 20-40 feet?
and the fusion of many extruded small tubes (3/8") to the mailn pipe (2")
some times wasn't perfect and the entire panel was...recycled for scrap plastic.
An entire warehouse was dedicated to storage the defected panels
in order to use grinders and labors to recycle the plastics.
More labors and more wasted money that required more machinery....

After trying many traditional machines and ways one young engineer call
eurekazone looking for an EZ solution.
The tool was build in 2-3 days ( a simple custom powerbench with a b-300)
and delivered to the factory, setup and performed few test cuts ...EZ.
The cut was perfect and the damaged main pipe was replaced with a new one.
What made the cut perfect and possible was the thin kerf blade ( Diablo)
We only had (+-) 1/32"-1/16" margin of error in 40"-50" cross cuts.
Our test cuts was within the play of the saw blade and the arbor of the saw.
Because the sawblade and arbor play is he same (in full circle) the accuracy was dead on.



the cut was right at the fusion point ( where the small tubing was welded to the main pipe ( perpendicular) the small tibing was 2" lower than the main pipe
and the simple answer was to build a two level table right at the cut line
while removing 1"? from the sawbase to allow the blade to cut 1/8" next to the main tube. ( I will try to find some pic's and post them here)

Today, I saw that Solyndra's waste was 100K daily.
I believe that the answer to the problem was very easy and simple if they knew about this forum and post a challenge???:rolleyes:

more to follow as soon as I can find the time to find few pic's.
Here is a video of that setup before delivered.

http://youtu.be/X4Jgr-RGFYQ

tx

toollovingschultz
09-24-2011, 08:57 AM
dino I like this pbb and it also shows how the ten inch malita has no power problems. did they put this tool to use?
Andy

Dino
09-24-2011, 09:40 AM
dino I like this pbb and it also shows how the ten inch malita has no power problems. did they put this tool to use?
Andy

Thanks Andy.
The long supporting and positioning table was taken back due to high price.
I transform the long table into something else.
a multi setup cutting and routing system.
I will post a video.

The main powerbench was start saving 10K of panels the very first day.
Look at the outfeed system. drop down table with adjustable fence to apply pressure against the main 2" pipe and keep everything perfect.
The cutting lline was the very edge of the table.

I think this is a good example of positioning the work piece instead of
trying to take the panels for a ride to a spinning blade.

I visited many extrusion, injection and formed plastic plans.
I saw very unique applications for the ez and we build few problem solvers
over the years. even a table with three twin bridges to cut multiple aluminum extrusions 10 times faster and easier than Pistorius (10K)? double miter saws.

One day, I like to have a team to build super ez problem solvers to help manufacturing plans.

Another place was cutting plastic extrusions to size using two miter saws.
A long table with 5 movable b-100's was build and the production was increased by 500%
allowing the factory to get more contracts by lowering the prices and the same time offering total safety and easy
to the guys using the ez system.

tx

sean9c
09-24-2011, 01:27 PM
Was the company you made the bench for Solyndra?

Dino
09-25-2011, 08:38 PM
Was the company you made the bench for Solyndra?

No. That was a NJ company.
Solyndra had 100K manufactuting loses a day...
from manufacturing damages?

The NJ company ( much smaller ) was in the same situation ???
but a young guy cared enough to call us and trusted ez to deliver a solution.

After all they had nothing to loose because the deal was to set the setup and due few test cuts.
First one by me and 10 more by anyone at the factory.

The idea here is that the biggest problems usually have the easiest solutions
IF we forget what is readily available and start from nothing.

The ez system is all about material positioning and support.
The cut is the last thing to worry.
With what we have in the market is the other way.
First we have to worry about the cut and for 100 years we keep using
a table and a saw that was invented by luck?

Sean, we made few unique setups after all other tools don't pass the tests.
Microsoft lab and teaching shop ordered 2 custom powerbenches and just about anything else that we offer.
The US dept. of energy and defence choose EZ for their shop.
Many universities, industrial design schools and few factories.

Yesterday, I received a nice bottle of wine.;) from a pro cabinetmaker.
after all. he saves 6K every month ...only from rent.
Imagine all the other expenses that come with running a big shop?

Burt's EZ package ( the cabinetmaker Pro ) was his favor.
He paid for it by selling only one SLR ( straight line rip saw)
but he saves every day by not housing one purpose traditional machinery.

good to see ez delivering better ways for better lifes.
good to see people looking for solutions and don't take no for an answer.;)

Like you.

Burt
09-25-2011, 09:59 PM
No. That was a NJ company.
Solyndra had 100K manufactuting loses a day...
from manufacturing damages?

The NJ company ( much smaller ) was in the same situation ???
but a young guy cared enough to call us and trusted ez to deliver a solution.

After all they had nothing to loose because the deal was to set the setup and due few test cuts.
First one by me and 10 more by anyone at the factory.

The idea here is that the biggest problems usually have the easiest solutions
IF we forget what is readily available and start from nothing.

The ez system is all about material positioning and support.
The cut is the last thing to worry.
With what we have in the market is the other way.
First we have to worry about the cut and for 100 years we keep using
a table and a saw that was invented by luck?

Sean, we made few unique setups after all other tools don't pass the tests.
Microsoft lab and teaching shop ordered 2 custom powerbenches and just about anything else that we offer.
The US dept. of energy and defence choose EZ for their shop.
Many universities, industrial design schools and few factories.

Yesterday, I received a nice bottle of wine.;) from a pro cabinetmaker.
after all. he saves 6K every month ...only from rent.
Imagine all the other expenses that come with running a big shop?

Burt's EZ package ( the cabinetmaker Pro ) was his favor.
He paid for it by selling only one SLR ( straight line rip saw)
but he saves every day by not housing one purpose traditional machinery.

good to see ez delivering better ways for better lifes.
good to see people looking for solutions and don't take no for an answer.;)

Like you.

Dino,

You are certainly correct. A straightline rip saw normally costs in the $10,000 plus range.

A simple setup like an EZ One with a couple little add-ons can handle all the tasks needed for a cabinet shop.

I'm waiting for someone with limited space to make a shop that just has the EZ One and a deep set of shelves . WHen you are using the tool, put it on the EZ One. When you are finished put it back on the shelf. Even a drun sander like the Jet 10-20 or a lunch box planer could be mounted on sliding modules and easily installed or removed.

Burt

Dino
09-25-2011, 10:19 PM
Dino,

You are certainly correct. A straightline rip saw normally costs in the $10,000 plus range.

A simple setup like an EZ One with a couple little add-ons can handle all the tasks needed for a cabinet shop.

I'm waiting for someone with limited space to make a shop that just has the EZ One and a deep set of shelves . WHen you are using the tool, put it on the EZ One. When you are finished put it back on the shelf. Even a drun sander like the Jet 10-20 or a lunch box planer could be mounted on sliding modules and easily installed or removed.

Burt

Burt, the ez-one is a lifesaver for our shop.
I even ordered custom designed, special aluminum panels ( honeycomb)
for my ez-one. So far so good. Why not save more space with special setups and sliding modules? I will send you a piece to "play" with.
Because the aluminum panels are super flat, strong and easy to lift...
I have few tools waiting to be setup.
Good not to have the need for joiners. SLR saws, panel saws, miter saws, tablesaws,
radial arm saws and routing tables, dublicators and so many jigs...
More room for more CNC's to be able to keep up with
the ripsizer/ez-one/ssrk combo.;)

My ez-combo supplies 4 CNC's, the 3 headed ( Dumore) drill, the green monster drill with few multi spindle heads
and one dedicated ( flycutting ) milling machine with 7-1/2" flycutter.
Wasted space? Nothing. If needed the ez-one becomes a table with the pbb to stk kit.
Thanks to ez we don't have to waste money on wasted space.

tx.

Philphoto
09-25-2011, 11:31 PM
I really have to wonder about the business that has 100K reject or manufacturing losses daily. I would have shut the line and looked for a solution! As a student of manufacturing processes, I really get surprised at the stupidity of some of these "executives." I had to turn around one company that had 15% ACCEPTANCE of delivered product. That was one of my easier jobs.

I always look for the novel way of processing, and if you tell me it can not be done -- watch me prove you wrong. I have been told that is an annoying fault of mine.

My favorite manufacturing process writers are Eli Goldratt and Shiogi Shingo. Incredible brains! I suppose that is why I am so impressed with EZ system tools. There is a better way. Guys like Dino and this forum group are my kind of thinkers. I have to admit that I admire the thinking here.

Phil

cutncrown
11-20-2011, 10:03 PM
I remember when we had a 5% defect rate and our manufacturer was going crazy trying to figure out why, it was the first month of testing and before we even starting shipping product they had it figured out. A simple change in the injection point and problem solved. Thanks for sharing this story, crazy how bad solyndra squandered our tax dollars. http://cutncrown.com

Dino
11-20-2011, 10:12 PM
Nice video. I learned something from your video.
why not starting a new thread how to install crown moldings?

welcome to the forum. now teach us something..;)