“The quality and the reliability of the TRUMPF machines (comprised) 80% of our decision to stay with (that line of) equipment. The remaining 20% is that TRUMPF has such a good reputation in the marketplace. TRUMPF is similar to Champ in that we both believe that a (close) relationship with the customer is critical,” says Ryan McClelland, sales and purchasing manager with Champ Industries.

Since installing its first TRUMPF machine-a Trumatic 3030 laser system-seven years ago, Champ has installed a number of other TRUMPF machines at its facility in Winnipeg including a Trumatic L4050 laser system, a Trumatic 2020R turret punch press, two V Series press brakes (V85 and V200), and a Trumatic 6000L laser/punch combination machine. In addition, the company has installed a 4030 laser system and a V130 Series press brake at its recently opened facility in Jamestown, North Dakota. Another 2020 punch press was installed in the Jamestown facility early this year. In total, Champ has invested between $5 to $6 million in TRUMPF equipment.

Champ, which began operations approximately 30 years ago, has 85 employees at its 58,000 sq. ft. facility in Winnipeg. The firm has another 18 employees based at its 10,000 sq. ft. facility in Jamestown. The company also anticipates it will be moving to a new 30,000 sq. ft. facility this year.

The firm specializes in custom metal fabrication for various original equipment manufacturers in a variety of markets including transportation, agricultural, commercial, health care and more. The company provides an extensive range of services including laser cutting, punching, bending (both sheet and tube), welding, and assembly services.

Champ, which is ISO 9001-2000 certified, works with a variety of flat sheet materials including carbon steel, stainless steel, and aluminum. Typically, the firm is dealing with material thicknesses ranging from 3/8 in. to 20 ga. In general, the company’s part runs range from 10 to 50 pieces.

According to Lise Baker, general manager of Champ Industries, the 6000L laser/punch combination machine including a SheetMaster automation module is the newest TRUMPF machine that Champ has installed. All of the TRUMPF equipment was supplied by Advanced Fabricating Machinery Inc., Mississauga, ON (afmcanada.com).

“We installed the 6000L in 2007 to add production capacity and additional process capabilities to our operation. At the time, we had inklings of a large new contract coming on board and we needed more capacity to handle the work,” she explains.

Adds Baker, “Also, we were looking towards growth and the 6000L laser/punch machine would attract larger customers and allow us to become more efficient and therefore more competitive.”

Because Champ is fabricating many different families of products in low volumes, enhancing production flexibility was a critical goal in installing the 6000L laser/punch combination machine.

“We do approximately 12,000 different part numbers and reduced setup time was a major factor (in installing the 6000L). With the 6000L laser/punch combination machine we have the best of both worlds-the speed of punching the holes as well as laser cutting,” says McClelland.

The Trumatic 6000L laser/punch combination machine features a 3,200 watt laser and 30 ton punching capacity. Standard contours such as round or rectangular holes are produced in one stroke by the punching unit, as are threads or other forms. Delicate, intricate inside and outside contours are laser cut with smooth, burr-free edges. The Trumatic 6000L offers a maximum hit rate of 900 strokes/min. In marking, hit rates as high as 2,800 strokes/min. are attained. Since all tools can be rotated, tool requirements are reduced to a minimum. Threads are produced at a C-axis rotation speed of 330 rpm.

The 6000L has provided Champ with a variety of benefits, notes Baker. “Because of the machine’s ability to do both laser cutting and punching along with other functions such as tapping and countersinking, it has definitely led to increased efficiencies and reduced costs.”

Adds McClelland “We see installing the 6000L as a move towards the future giving our customers different design options and competitive pricing.”

The TRUMPF laser/punch combination machine has also enabled Champ to eliminate secondary operations on certain parts. “With the 6000L, we have been able to take different operations out of the process. For example, you don’t have to deburr the part after it is done on the laser,” says McClelland.

In addition,  he points out that the 6000L’s SheetMaster automation system has also improved the surface quality of the material being used because of the significant reduction in material handling.

According to McClelland, because of Champ’s previous experience with punching, training on the new 6000L unit was a relatively simple and straightforward process. “There was a bit of a learning curve on the automation side but training was fairly easy.”

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