Case Study: NCS Fabrications Ltd and AXYZ Routers

Company Overview NCS Fabrications Ltd has been a leading name in the signage industry since its inception in 1988. Originally specialising in manufacturing noise control enclosures, the company diversified into signage in the late 1990s. Over the years, this transition has resulted in signage becoming the dominant aspect of the business, now accounting for 98% of operations. By focusing on high-quality signage production, NCS Fabrications Ltd has built strong relationships with clients, delivering innovative and customised signage solutions to meet the evolving demands of the industry.

Adoption of AXYZ Routers NCS Fabrications Ltd has been utilising AXYZ routers since 2005, when the company first invested in the 6014 3x2m router, this increased the company’s processing capabilities on aluminium, a material widely used in the sign industry for large exterior signage. The decision to invest in AXYZ technology was driven by the company’s desire to take full control of its signage manufacturing process. Initially, the business outsourced certain aspects of production, but as customer expectations for intricate signage designs grew, it became evident that in-house cutting solutions were necessary to maintain quality and efficiency. AXYZ routers provided the precision and automation required to elevate production capabilities.

Due to the success of the first router and the increase in business, NCS Fabrications Ltd invested in their second, the replacement for the 6000 series, the IFINITE with the ATC (Automatic Tool Changer) facility. The INFINITE router is a highly configurable CNC machine that is suitable for one-off, small batch production as well as high volume and high productivity applications, including woodworking, plastic fabrication, engineering plastic machining and so much more. For a wide range of routing operations, one can choose from high-speed spindles ranging from 5HP to 15HP. For knife cutting, choose from a tangential knife, which can be used for creasing and folding applications or an oscillating knife which can be used to process soft goods material.

Client Base and Industry Focus NCS Fabrications Ltd operates as a trade-only signage manufacturer, supplying a wide range of front-end sign companies. By partnering with well-established brands, the company ensures that its high standards of signage production are maintained across different industries. From corporate branding and retail signage to bespoke displays, NCS Fabrications Ltd plays a crucial role in bringing high-quality visual branding to life for a diverse range of clients.

Why AXYZ? “The choice to work with AXYZ as a preferred machine supplier was based on multiple factors. AXYZ has a long-standing reputation as an industry leader in CNC router technology, offering reliable and high-performance machines. Additionally, the support provided by Chris Perry and the AXYZ team has been instrumental in ensuring a seamless experience. Their expertise, responsive customer service and willingness to assist in both procurement and troubleshooting have made AXYZ an invaluable partner to NCS Fabrications Ltd.” Said Kieran Spiers Managing Director

Enhancing Production with AXYZ Machines The integration of AXYZ routers into the manufacturing workflow has significantly enhanced production capabilities at NCS Fabrications Ltd. These machines play an essential role in cutting ACM (Aluminium Composite Material) panels, which are a fundamental component in signage production. In addition to ACM, the routers efficiently handle materials such as aluminium, acrylic and polycarbonate, enabling the creation of complex and customised signage solutions. The precision of AXYZ machines ensures that intricate designs are executed with consistency, reducing material waste and improving overall product quality.

Impact on Productivity and Efficiency The initial implementation of AXYZ routers led to a noticeable increase in productivity. While these machines are now fully integrated into daily operations, their impact continues to be significant. The introduction of Tool Changers in the latest AXYZ machines has been particularly beneficial, automating the tool-switching process and reducing manual intervention. This feature has led to considerable time savings, especially when working on intricate signage projects that require multiple cutting tools. The ability to switch tools seamlessly ensures greater efficiency and faster turnaround times.

The choice to work with AXYZ as a preferred machine supplier was based on multiple factors. AXYZ has a long-standing reputation as an industry leader in CNC router technology, offering reliable and high-performance machines. Additionally, the support provided by Chris Perry and the AXYZ team has been instrumental in ensuring a seamless experience. Their expertise, responsive customer service and willingness to assist in both procurement and troubleshooting have made AXYZ an invaluable partner to NCS Fabrications Ltd. – Kieran Spiers, Managing Director

Employee Adaptation to Automation The workforce at NCS Fabrications Ltd has responded positively to the automation introduced by AXYZ machines. Employees, particularly younger team members, have embraced the technology, recognising its ability to enhance efficiency and improve job quality. Brad, who operates the routers, highlights the benefits of faster processing times and higher precision in production. “Automation has not only streamlined workflows but has also enabled staff to focus on more complex and creative aspects of signage production, rather than spending time on repetitive manual tasks.” Explains Brad Machine Operator

Maintenance and Operational Reliability Ensuring the longevity and optimal performance of AXYZ machines is a priority at NCS Fabrications Ltd. The company has implemented a structured maintenance program, overseen by Shaun, the facilities manager. Regular servicing and timely repairs are carefully logged and executed to prevent unexpected downtime. This proactive approach helps maintain machine reliability, ensuring that production runs smoothly and deadlines are consistently met.

Challenges and Cost Savings Although the initial challenges encountered during the integration of AXYZ machines are difficult to recall, NCS Fabrications Ltd acknowledges that these routers have played a pivotal role in increasing efficiency and reducing costs. By eliminating the need for outsourcing certain processes, the company has gained greater control over its production schedules, leading to cost savings and improved profitability. The reduction in material waste, coupled with the enhanced accuracy of AXYZ routers, has further contributed to cost efficiency.

Quality Improvements and Competitive Advantage The ability to produce high-quality signage with precision-cut materials has strengthened NCS Fabrications Ltd’s competitive edge. The integration of AXYZ routers has allowed for greater consistency in manufacturing, ensuring that every sign meets the exacting standards expected by clients. The speed and accuracy of these machines have enabled the company to take on more complex projects while maintaining quick turnaround times. This ability to efficiently meet client demands has reinforced the company’s reputation for excellence in the signage industry.

Future Plans for Automation Despite the many benefits of automation, NCS Fabrications Ltd recognises that full-scale automation is not currently feasible due to the bespoke nature of its products. However, the company remains open to exploring advancements in CNC technology that can further optimise its processes without compromising the flexibility required for custom signage production. The continued partnership with AXYZ ensures that NCS Fabrications Ltd has access to the latest innovations in router technology thereby keeping the business at the forefront of industry advancements.

Conclusion The introduction of AXYZ routers has been a game-changer for NCS Fabrications Ltd. From increasing efficiency and reducing costs to enhancing product quality and employee satisfaction, these machines have become an essential component of the company’s production process. With a commitment to maintaining high standards and embracing technological advancements, NCS Fabrications Ltd continues to thrive as a leading signage manufacturer. As the industry evolves, the company’s strategic investment in automation and precision machinery will remain a key driver of its ongoing success.