Custom Machinery Design and Relocation - Solutions To Keep Industry In Motion™ - Laron · 2019. 8. 15. · Laron operates a fully equipped fabrication facility with material handling

4255 Santa Fe Drive • Kingman, AZ 86401 • Phone 928.757.8424 • Fax 928.757.8995

Custom Machinery Design and Relocation

Copper State Rubber Case Study

Newly installed reengineered Spiralators

Copper State Rubber Relocation and Upgrade Case Study

Background Copper State Rubber is a manufacturer of high quality oilfield, marine and industrial hoses located in Phoenix, Arizona. Copper State Rubber has been an industry leader for over 50 years in the rotary drilling, marine, and mining industry. The Copper State rubber current facility was built in 1965 and over the years has grown into a 50,000 sf facility. Problem The Original Copper State Rubber facility was located in the path of a highway expansion project. Through the state’s Eminent Domain / Right of Way process, Copper State needed to find a new home. Much of their equipment was custom and therefore could not be purchased directly from suppliers. Also, they could not allow the production down time required for the relocation. Their only option was to build a new manufacturing line and seamlessly move production to the new facility. Copper State struggled to find a contractor capable of recreating their proprietary machinery as the original designer and was no longer in business. Previous attempts at hiring a replacement contractor had been unsuccessful. As the impending highway construction continued only blocks away, Copper State had plans for land and a building but none for its machinery and production line. Solution Through a series of shop tours and prototype designs, Laron’s CEO Glenn Thoroughman was able to demonstrate that Laron could not only replace their machines but engineer enhanced upgrades. Laron got to work and started the reengineering of Copper State’s entire production line. Utilizing nearly all specialties, Laron was able to reengineer, fabricate, machine, assemble, install and commission Copper State’s entire production line. Upgrades The new machines feature many upgrades including: 20% reduced power consumption, greater capacity, reduced waste, increased product line, decreased maintenance, better operator ergonomics and a safer and cleaner production floor.


Machinery by Laron Nearly all machinery in the new facility was redesigned and manufactured by Laron including: Spiralators, Hose Mandrels, Mandrel Racks, Hose Test Chambers (220ft long), Hose Machine Wire Tensioner, Hose Machine Material Applicator, Hose Machine Carts, Pull-out Conveyor, Crating Machine with a 72” Turntable, Crating Machine with a 168” Turntable, Hose Machine Table, Vulcanizer Pressure Vessels (5’x165’ long and 3’x215’ long), Wire Re-roll Machine, Nylon Tape Re-roll Machine , Tube Conveyor, Hose Machine Gear Reducer Heads , Spiralator Output Table (15HP motor), Wire Tensioning Clamps, PLC Electrical and Controls, Blow-off Table and Frames.

Spiralators

The Newly Laron-designed Spiralators have a 25% increased capacity and a 400% increased bobbin size for fewer load times and 75% reduced waste. What was previously done by hand measurements and manual adjustments, the on board computers calculate the lay angle automatically and the electronic gears and tensioners allow for exact timing and precise application all while reducing energy consumption by over 20% and requiring significantly less maintenance.

Old

New


Vulcanizers

After the rubber and wire is applied, a final wrap of moist nylon tape is applied to maintain shape and compression. The hoses are then placed into the vulcanizer tanks which use pressure and steam to cure the hoses. The 2 new Vulcanizers are longer and made of stainless steel to resist rusting. They were fabricated under Laron’s Code stamp and therefore are certified pressure vessels and can more reliably hold required pressures. The electronics built into the Vulcanizers allow for precise temperature control and graphing.

Old

New


Hose Machines

The Hose Machine is the device that rotates the Hose Mandrels while the rubber or vinyl is wrapped around the Hose Mandrel. This process used to be applied by hand and required 2 operators to walk down the length of the hose during application. With the newly designed Hose Machines, a single operator stands on a powered cart and interfaces with the computer that dispenses the material at the precise speed and lay angle required.

Old New


LARON INTRODUCTION

LARON has established a reputation over the past 38 years as a leader in mill-wright services, fabrication, welding, precision machining, field service, electrical equipment repair and manufacturing, control systems development, predictive maintenance, and new equipment sales. This reputation has been based on supporting the mining, manufacturing, power generation, and gas transmission and construction industries by creating a partnership of trust and confidence. Our Mission: We, at Laron provide industrial support services to established and newly acquired customers to increase the uptime of their operations. To accomplish this we build on our core values of innovation, responsiveness, first-time-quality and value-added-service. We strive to maintain a business environment that is principled, moral, and honest with our employees, customers, vendors, and lenders. Our Vision: To be the preferred solution resource for industries that provides the fundamental needs of a changing world through Service Innovation and Education. Safety: Laron has no greater priority than the safety of our employees. Our Total Quality Service Program encompasses not only the quality of our work but also the safety or our employees, customers and vendors. Facilities: Head-quartered in Kingman, Laron has four facilities located in Tucson, Kingman, Phoenix, and Salt Lake City. The Kingman facility specializes in mechanical and machine shop operations, the Phoenix and Tucson facilities are positioned in the electrical controls, new motors, drives and related controls, and equipment sales.


FACILITIES AND CAPABILITIES

Laron operates a fully equipped fabrication facility with material handling capabilities up to 100 ton. Laron has machinery on the scale and in the quantity required to accomplish a wide variety of work in the given time frame. Laron also has the experienced craftsmen who have proven their ability to be successful in the most demanding situations. One of Laron’s greatest assets is our ability to innovate and improvise to best meet the needs of our customer and offer the best value possible. The following photographs, drawings and exhibits demonstrate our capability, equipment and the kind of planning we have already accomplished to assure your company that Laron is the right choice for your company. Our four facilities, located in Kingman AZ, Phoenix AZ, Tucson AZ, and Salt Lake City, UT provide over 250,000 square feet of repair and manufacturing capability that is equipped with a wide variety of electrical and mechanical equipment to meet our customer’s service requirements. To reduce critical down time, Laron can mobilize a fully equipped staff of mill wrights, welders, machinists and electrical technicians to provide solutions for installation and repair needs throughout the Western United States. Our well stocked inventory of material gives Laron the capability of responding quickly to minimize extended lead times. Laron provides welding services for a variety of applications from carbon steel to exotic materials with fabrication capabilities up to 100 ton. Certified welders for pipe, plate and pressure vessel application: AWS, ASME, API “R”, “S”, “U” Code Stamps.


QUALITY ASSURANCE Quality is important to us at Laron that is why we hold and maintain numerous Quality certifications and programs to ensure the required quality for each and every project. While we are certified to work with nuclear equipment, Pressure Vessels, Rail Road components and many others, our quality programs can be customized to fulfill requirements. Our Quality Assurance includes the following programs and certifications:

ASME / AWS Welding Quality

o ASME Code-Sections I, II, IV, V, VII, IX and B31.1

o ASME Stamps S, U

o National Board Stamps R, NB

o Over 300 ASME compliant approved Weld Process Specifications (WPS)

o All welders qualified to ASME Section IX and/or AWS D1.1 & D1.2

o Welder Qualification processes and reporting

Nuclear NQA-1 10CFR Appendix B

o Nuclear Quality Manual – audited and published

o Nuclear Quality Procedures

o Document Control System

o MT&E Calibration System

o Non-Conformance Reporting

o Corrective Action Reporting

o Commercial Grade Dedication

o Material Handling

Electric Motor Repair

o SKF Certified Motor Rebuild Facility

o Shipping point quality inspections

UL Certified (Underwriters Laboratory)

o Explosion proof electric motors

o Electrical control panels

AAR Certified (Association of American Railroads)

o Machining and repair of Rail Road components

o Certified label and tracking system of Rail components


Commitment to Safety

Laron Incorporated is committed to ensuring our workforce safety. We continually strive to achieve a “Zero Incident Work Environment” through a process driven approach, which includes: Training, Provision of resources, Audit accomplishment. Safety is a mindset, we have a Safety Team at each facility that meets on a monthly basis to discuss concerns and design solutions. This team is comprised of employees in every department. Safety expands beyond employees and includes vendors, contractors, visitors, and customers. Laron Incorporated protects all who walk through our doors from workplace hazards. Laron has a process driven Safety Management Program including a structured Injury and Illness Prevention Program. This program is based on a common set of key elements: management leadership, worker participation, hazard identification, hazard prevention and control, education and training, and program evaluation and improvement. When applicable, we also work with our customer’s safety procedures, requirements and documentation. Topics covered by this program include but are not limited to:

Lockout/Tagout/Testout Energy Isolation

Confined Spaces

Fall Protection/ Working at Heights

Cranes/Rigging/Overhead Loads

Hazard Communication

Powered Industrial Equipment

Personal Protective Equipment

Qualifications OSHA Employees have either OSHA 10 hour or 30 Hour Construction training certificates. Laron has a certified OSHA Outreach Training Program and Instructor for Construction. MSHA Employees are trained in MSHA Surface Metal/Non- Metal, Underground Metal/Non-Metal, or Surface Coal. Laron also has several Part 48 instructors which includes an approved Surface Metal/Non-metal training plan. DOT Registered and compliant, Laron prides itself on maintaining a safe fleet of vehicles and drivers on our nation’s roads and highways.


Documents

Custom Machinery Design and Relocation - Solutions To Keep Industry In Motion™ - Laron · 2019. 8. 15. · Laron operates a fully equipped fabrication facility with material handling