Kovatch Mobile Equipment Corporation, headquartered in Nesquehoning, Pennsylvania, builds custom-designed fire trucks, rescue trucks, industrial foam vehicles and aircraft refuelers. CEO and spirited visionary, John "Sonny" Kovatch began his business as a modest two-car repair shop in 1946. Since then, with eleven manufacturing plants at this facility, annual production reaching 300-325 units and orders flowing in from around the world, this family owned and operated company stands as the largest privately held manufacturer of customized specialty vehicles in the United States.

One-of-a-kind manufacturing challenges are KME’s specialty, and that’s just what keeps things exciting. "Everything is interesting here because everything changes," said Ernest Smith, Shop Supervisor, who oversees the facility’s fabricated part production. "Take the cab on a fire truck," he explained. "Even with a fairly standard design, fabrication becomes a never-before-seen challenge when the customer decides to raise the roof thirteen inches (330mm)."

Offering customers over 300 fire cab configurations, flexibility and a "can do" attitude are part of the KME ethos. When shopping for a new press brake, the company needed a system that could handle short runs, complex parts and unwieldy, over-sized materials –diverse challenges that are certainly the nature of the beast in custom manufacturing. With their older press brakes needing forty-five minutes to one hour preparation in order to achieve one 90-degree bend, they were understandably eager to reduce their set-up time as well.

Searching through a veritable maze of equipment manufacturers, Smith stated that performance was only part of the equation in KME’s hunt for the perfect press brake. "We shopped around for weeks," Smith said. "We visited several press brake manufacturers throughout the country to see what they offered. More often than not, manufacturers were focused on their machinery; they were not concerned about us and what we needed."

According to Smith, the direction became clear following his visit to Bystronic’s facility in New York. "Sure we were impressed by what we saw in terms of technology. But we were utterly amazed by their level of commitment --in terms of training, customer service and support-- to their customers." Smith continued, "They actually took time to understand our business," adding that Bystronic’s sales and service team took him under their wing.

"They really examined our needs," Smith commented. "Then, and only then, did they demonstrate how the Beyeler PR press brake could handle our challenges." The KME team then visited Bystronic’s customers in New York and New Jersey to see the press brake perform in an active, demanding environment. "When we saw these systems in action, hands down, we were blown away," Smith said.

KME purchased two Bystronic Beyeler PR Series press brakes, both with a 6 axes backgauge. Smith was pleased that the after-sales service was just as comprehensive as the attention he received prior to purchasing the systems. "Our Bystronic sales representative, Fred Weber, was really hands-on. He examined our prints and jobs that we’ve done to figure out exactly which tooling would work best for us. What Bystronic recommended fit the bill perfectly. I’m pleased to admit," Smith added, "that I haven’t had to buy another set of tooling yet."

Following their installation in October, 2003, the two Bystronic systems were up and running at full capacity in two weeks. The new brakes process vehicle body parts out of 3/16" (4.76mm) aluminum with pieces running up to 153"-236" (389-599cm) in length. The increase in productivity at KME is impressive, to say the least. On their older machines, it would take six to eight people two hours to form one side sheet. Now processing that same side panel takes two people (with some assistance from the CNC lifting aids on front of the machine) just thirty minutes. "It used to take two full days to form four individual truck bodies; it now takes just four hours." Smith continued, "In fact, our throughput has increased so much that I cannot keep enough jobs on the floor to keep my press brake operators busy!"

With such productivity gains, Smith shut down four of his older press brakes-- machines that were running all day, six days a week. Six press brake operators were moved over to different facilities in the company. "It is just incredible what these two press brakes have done for us in terms of reducing our part run-time, operating costs and man-hour costs," said Smith.

Set-up time reductions have been another significant advantage of the new systems. Whereas typically it would take an operator up to one hour just to set up and pack the die with shims on the old machines, now it takes five minutes to do ten pieces. Smith added, "The crowning system works just great for us. It saves us a tremendous amount of time and helps us get a dead-on, 90-degree bend quickly and easily."

Smith admitted that his favorite features are the CNC controls and Bystronic’s easy-to-use offline programming software. "Not only is our set-up time reduced, but the part is done fast and done right the first time." Off-line programming figures out the bend sequence so the user can see graphically how the part will be handled. It also demonstrates if there are any potential collision points. Smith said, "We just punch in the material thickness into the program and then put the piece on the machine. After that, the piece is done!"

The facility’s downstream processes seem to have benefited from this new technology as well. It was not uncommon to get waves all along the finished part when forming a 90-degree bend in a 3/16" (4.76mm) sheet that is 170" (432cm) long. "Now, with the new brakes," Smith boasted, "you can visit any of our other plants, and there is not a single issue concerning part straightness or consistency. Even on our large bodied trucks that carry extra long side panels, the sides are perfectly straight and uniform."

Process optimization for a better end product

In the manufacturing world, the Holy Grail of productivity is process optimization. The high level of part accuracy generated by the new press brakes has allowed the company to rethink its manufacturing processes to streamline job flow and generate an even higher quality end-product. For the past three months, Smith’s team has been forming parts that are longer and wider than ever before. In bending parts for the sides of trucks, traditionally there were four pieces that were individually formed and then welded together. Now, in place of theses four small parts, there is just one large panel. "This," Smith explained, "has minimized assembly time and increased product quality considerably." Firemen take exceptional pride in their equipment, so aesthetics and structural integrity, welding and fitting are critical on a fire truck. Smith states that customers are happier as there are fewer panels (and therefore less welding) on their trucks.

Amidst the humming of machines and the ever-growing pile of finished parts around the Bystronic Beyeler press brakes, it is hard to ignore the pervasive, happy atmosphere at Kovatch. Smith stated, "Morale in my shop has gone up 100% since installation." Recently, a press brake operator told Smith that when he worked on the older press brakes he used to report to work feeling miserable. He felt chronically stressed and overwhelmed. He was frustrated in spending hours forming difficult parts that never really ended up quite right.

Since working on the Beyeler PR press brake, the operator told Smith that he actually likes coming to work. He is happier because the machine is accurate and simple-to-use, and this, in turn, makes it easier for him to do his job. "My operators are actually having fun." Smith continued, "Before, difficult parts got shoved to the side, and now they actually fight over who is going to get the next piece to form."

Smith and several operators took part in a four-day training course at Bystronic’s Hauppauge, New York, facility. Smith found the training helpful. He explained that it was very thorough in teaching the programming system as well as the actual press brake and its capabilities.

"Surprised by this level of service and support…"

"In terms of service and support, when I call they are immediately on the phone with me, walking me through whatever challenge I may have. Should they not have the answer on hand, they call back with a solution in less than two hours." Smith added, "I have been dealing with other companies for decades, and I was actually surprised by this level of service. My experience has been that many manufacturers continually push off your requests for assistance and service. But not Bystronic! If there is ever a problem, there is someone from their service department out here the very next day."

Looking to the future, it is apparent that Kovatch stands ready for any challenging order that may come his way. Wearing a broad smile, Mr. Smith seems to have absorbed his press brake operators’ enthusiasm. As rows of specialty vehicles stand gleaming in the sun behind him, one thing becomes clear: in some places in this world, happiness and productivity go hand in hand.

As shown in:

Man (Modern Application News), August 2004

Canadian FAB Canada, February 2005