No two fabrication shops operate exactly alike. Even identical bending machines develop different wear patterns depending on the shop. Yet many service contracts take a one-size-fits-all approach.
As fabricators push machinery harder to keep up with demand, they also need to protect their investment – ongoing maintenance support is just as important as making the initial purchase. Recognizing a need for more flexible care offerings, Bystronic Inc. developed ByCare, a tiered group of service packages.
Matthew Opela, national customer relations manager at Bystronic, says ByCare offers tailored flexibility, which means customers can choose from individual modules to match specific requirements. But it goes beyond remote maintenance and warranties; centralized digital support and employee training bring added value. And for those focused on improving their service packages related to bending, Bystronic has them covered.
“In recent years, Bystronic has developed a more focused approach to maintenance agreements,” Opela says. “With the launch of our Bending program, we see far more value and flexibility.”
Training the workforce
High-tech machines are capable of improving productivity, but the machine is only as productive as the person running it. Avoiding downtime, achieving high accuracy and improving throughput have as much to do with the operator as the machine they are running. While machines today are built with ease-of-use in mind, there remains a gap between the trained and untrained workforce. Bystronic’s ByAcademy brings the ongoing education piece to the forefront.
Operators can select courses through ByAcademy that meet their needs, such as B100, which covers press brake operation, programming and determining bend sequences. Upon completion of the course, operators will know how to start and stop the machine, recognize various hazards, and be able to define and execute bending programs without assistance.
“Our training offerings are built to better support our customers’ needs and employee base,” Opela says. “With a balanced approach of practical and classroom education, each training focuses on the needs of the operators in each class. As each operator certifies, they gain additional knowledge to advance machine capabilities.”
Bystronic also recognizes that some fabricators need to know more than the basics, which is why they offer training for maintenance staff as well as shop managers. From essential training, which covers basic machine functions and programming, to advanced training, which brings a deeper understanding of bending systems, operators can fine-tune their machines and are empowered with insights and optimization potential.
Digitalization advantages
Fabrication machinery generates a constant stream of data, but without proper analysis, it provides little insight. Shops, however, can track machine conditions and performance trends and convert that information into action. Timely access to machine data can help identify potential problems sooner and inform decisions that prevent downtime.
Bystronic’s eProactive service ensures maximum technical availability through machine condition monitoring. Bystronic can identify machine needs by continuously collecting and analyzing data through its cloud-based Care Console. The benefits include increased production security, shorter repair times, more efficient repair processes and optimized machine use.
“Our digitalization initiatives, such as eProactive, allow the machine to monitor itself and notify Bystronic if there are any issues,” Opela says. “This one-way, cloud-based program initiates communication in real time so technicians can begin running through troubleshooting decision trees or speak with a hotliner to determine the best path forward. Pairing eProactive with the myBystronic portal perfectly melds self-help and remote support to minimize downtime.”
Another component of Bystronic’s proactive approach is the 360° Customer Advisor, which is an on-site service designed to sniff out concerns and schedule maintenance to prevent disruption. This includes an A-to-Z service offering that examines critical machine components and auxiliary equipment. The examination will help determine if the machines are being maintained correctly and if the operators have the skills necessary for success.
Services like this provide a customer with a full picture of their machines’ conditions, and because a Bystronic advisor reviews the findings, the customer receives a real conversation about next steps rather than just a report.
Portal assistance
Keeping machinery running is crucial, but so, too, is managing machine documentation, service records, technical support and replacement parts. These are all addressed in myBystronic – the company’s portal that serves as a central digital cockpit for customers. Opela says the goal with the portal is to simplify the customer experience.
The portal includes three central areas, including myProducts, which allows customers to keep a close eye on their information, parts and technical documents. Another is mySupport, which offers full transparency related to service matters, allowing customers to optimize their service management and view their service history while also providing self-help tools. The third area, myParts, is the company’s online shop for spare parts where customers can order what they need 24/7 and then access delivery times, shipment tracking, order history and more.
“The portal allows for a fully transparent picture of past and present service issues,” Opela says. “This allows a customer to determine in real time how we handled something in the past and how we are handling a service call in real time. The portal also allows a customer to view their service calls, troubleshoot through decision trees and order parts. It truly is a one-stop shop for all after-sales activity.”
Effectiveness and value
Improving overall equipment effectiveness (OEE) starts with avoiding downtime and consistently producing good parts. What gets in the way of improved OEE includes gaps in maintenance that result in breakdowns or operator mistakes, delays in diagnosing problems and trouble achieving swift technical support.
Opela says Bystronic’s approach to engage customers remotely enables them to do the troubleshooting and bring a level of support previously unavailable.
“Many job shops completely trust their operators and staff,” he says, “so our goal is to embrace that trust and push our services to their limits to ensure that machines are always running. The proactive nature of our services has the singular goal of turning the unexpected into the predictable. Reaching out to the operator early when there are service issues helps us plan and address issues quickly. This relationship is key to any success.”
Dig deeper into how new technologies improve how press brakes are used in fab shops today by visiting our press brake archive.
