Case Study: AXYZ Machines Empower RP Signs to Elevate Production and Quality

Company Overview: RP Signs

Founded in 1988 as a division of Recognition Plus, RP Signs has steadily grown from a modest one-person operation into a thriving business with a team of 20 skilled employees. Operating out of a 25,000-square-foot facility in Charlotte, NC, the company specializes in the design and manufacture of both interior and exterior signage. Over the years, RP Signs has built a solid reputation for delivering high-quality, custom signage solutions that meet the unique needs of a diverse range of industries, including healthcare, multi-family developments, universities and corporate offices.

The Need for Advanced Technology

As RP Signs expanded, they encountered a growing demand for larger, more complex signage when their existing laser cutting capabilities could not efficiently handle. Their laser cutter, while effective for small-scale jobs and certain materials, struggled to handle larger signs and a broader variety of substrates. Specifically, the need to process materials like Alumacore, PVC and laminates in-house became a priority. This bottleneck led to increased outsourcing, which not only added to costs but also extended turnaround times and reduced their control over the quality of the final product.

Faced with these challenges, RP Signs recognized the need for a more versatile and robust powerful cutting solution that would enable them to bring more of their production processes in-house. This would enable them improve efficiency, increase production volume, reduce turnaround times and maintain the high standards of quality their clients expected.

What stood out was the router’s ability to handle a wide range of materials and its potential to significantly increase our production volume” – Gary Ferrell, Director of Operations.

The Solution: AXYZ 4010 Router

In 2012, RP Signs made a strategic decision to invest in their first AXYZ 4010 router. This decision was driven by the need to bring more of their production in-house, particularly for cutting larger signs and handling a wider variety of materials. The introduction of the AXYZ router allowed RP Signs to significantly increase their production speed and capacity, effectively eliminating the need to outsource these tasks.

Why AXYZ?

RP Signs discovered AXYZ while attending the ISA Sign Show, where they were introduced to the 4010 router. The team at RP Signs was immediately impressed by the machine’s robust build, advanced features and the competitive pricing offered by AXYZ. Along with their reputation for reliable machines and strong customer support this further solidified their decision to adopt this technology. “What stood out was the router’s ability to handle a wide range of materials and its potential to significantly increase our production volume”, said Gary Ferrell, Director of Operations.

Impact on Production and Efficiency

The integration of the AXYZ 4010 router into RP Signs’ operations brought about a dramatic transformation in their production process. With the ability to cut larger signs and work with diverse materials like acrylic, PVC and aluminum, the company was able to drastically reduce the need for outsourcing. This shift not only saved time and money but also allowed RP Signs to maintain greater control over the entire production process, ensuring consistent quality across all projects.

The router’s capabilities went beyond just cutting materials. It played a crucial role in producing individual letter sets, cutting coroplast with a tangential knife and creating precise templates for installing letter sets and other signage elements. The machine’s precision also enhanced the quality of the finished products, especially in tasks that required exact measurements and intricate cuts.

“The time savings and ability to keep more work in-house have certainly increased our profitability. The automation provided by the AXYZ router allows us to complete processes such as cutting aluminum and drilling holes with greater precision and efficiency,” explained Gary Farrell. This increase in efficiency translated directly into a better service for their clients, with faster turnaround times and improved product quality, lower production costs and less material waste.

The INFINITE ROUTER

The INFINTIE 4010 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.

Overcoming Initial Challenges

Like any new technology integration, the adoption of the AXYZ router came with a learning curve. RP Signs had to experiment with different feeds and speeds for various materials. However, the transition was smoother than expected. With the training provided by AXYZ and support from their technical team, these challenges were quickly overcome, allowing the company to fully leverage the capabilities of their new machine.

Employee Reception and Workforce Impact

The introduction of the AXYZ router was met with enthusiasm from the RP Signs team. The automation of previously manual processes not only reduced physical labor it also allowed employees to focus on more strategic and creative aspects of their work. This shift in workload was seen as a positive development, leading to higher job satisfaction and a more motivated workforce.

To ensure the continuous operation of the AXYZ router, RP Signs hired a dedicated operator and provided cross-training to other team members, enabling them to step in as needed. This approach not only safeguarded against potential disruptions but also fostered a more versatile and skilled workforce.

Maintenance and Long-Term Reliability

RP Signs has taken a proactive approach to maintaining the AXYZ 4010 router, following AXYZ’s recommended preventative maintenance schedule to ensure the machine’s longevity and optimal performance. Regular maintenance visits from AXYZ technicians have proven invaluable in keeping the machine in top condition, allowing RP Signs to avoid unexpected downtime and continue delivering high-quality products to their clients.

The Financial Impact: Increased Profitability and Cost Savings

The financial benefits of integrating the AXYZ 4010 router into RP Signs’ operations have been substantial. By bringing more production in-house, the company has been able to significantly reduce outsourcing costs, which in turn has improved their profit margins. The automation of processes such as cutting aluminum and drilling holes, which were previously done manually, has not only sped up production but also reduced the potential for human error, further enhancing the quality of the final product.

Moreover, the ability to produce high-precision cuts and templates has allowed RP Signs to take on more complex projects with confidence, expanding their service offerings and attracting new clients. The cumulative effect of these improvements has been a noticeable increase in profitability, positioning RP Signs for continued growth.

Looking Ahead: Future Plans for Automation and Growth

As RP Signs looks to the future, they are keen to further integrate automation into their operations. The success of the AXYZ 4010 router has sparked interest in adding another router to their production line, which would further increase their capacity and efficiency. Additionally, RP Signs is exploring opportunities to upgrade their existing machine to take advantage of the latest advancements in CNC technology, ensuring they remain at the forefront of the signage industry.

Conclusion: A Partnership for Success

The partnership between RP Signs and AXYZ has been a resounding success, transforming RP Signs’ production capabilities and enabling them to deliver higher quality products with greater efficiency. The adoption of the AXYZ 4010 router has not only improved their operational processes but has also positively impacted their bottom line, setting the stage for continued growth and innovation.

As RP Signs continues to expand and evolve, they remain committed to leveraging advanced technology to meet the ever-changing needs of their clients. With the support of AXYZ, they are well-positioned to maintain their reputation as a leader in the US signage industry, delivering exceptional products that meet the highest standards of quality and precision.

For press enquiries or more information on R P Signs, please contact:
Web: rpsigns.net
Phone:+1(704) 344-8552

For more information on the AXYZ range of routers contact us today or visit our website.
Web: www.axyz.com
Email: enquiries@axyz.com
Tel: +1 (844) 927-3538

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