Don't Fence Me In
Ask Paul B. Zimmerman, Inc.'s co-owner Mark Zimmerman why he wanted a Mazak FabriGear
150 to make cattle control fencing and he'll simply answer "To remain competitive,
you've got to automate." Mark traveled to Japan, across Europe and North America
to evaluate the 3D laser offerings of the major players in the market, before choosing
the Mazak FabriGear 150. "I went with the FabriGear because of its reputation for
dependability and its flexibility to
handle larger pieces, which are key issues
for us," he continued, "One day we might be running fence posts in the morning and
switch over to bodybuilding equipment on the second shift. We're averaging 18-20
hours per day on the FabriGear."
Although their FabriGear 150 was originally purchased to streamline their barn equipment
manufacturing division located in Lititz, PA, Zimmerman was very realistic about the investment they made. With five business partners who also happen to be brothers,
Zimmerman admitted to being a bit nervous, but confident in his decision to purchase
the FabriGear 150. "I knew we couldn't justify the expense of the FabriGear 150
with just our barn equipment, so the plan was to take on job shop work." Little did he know, the job shop potential was so great in the Northeast, that he would
be buying a second 3D laser, this time the larger FabriGear 300, in a few short
years. "We've got the area ready for the installation and a customer waiting for the first part run on the new 300!"
exclaimed Zimmerman.
One of the first outside projects Zimmerman landed was for a manufacturer of weight
training equipment, who has grown to become a major customer, utilizing services
from several Paul B. Zimmerman, Inc. divisions. "They were having trouble getting
the geometry they wanted cut from a square tube, they sent us a sample and the rest
is history. Now we're cutting all their tube, fabricating and welding the fitness
equipment, warehousing components, custom powder coating and delivering the knocked
down units for final assembly at their client's facilities," said Zimmerman. Essential
to the success has been the Zimmerman's ability to
eliminate production steps, reduce
labor and improve accuracy with the FabriGear 150. "We've minimized the handling
and cut labor costs by as much as 50% on some of the parts, but more importantly,
we've improved accuracy so when the parts go to the robotic welder we're getting
better welds faster."
Zimmerman points to the FabriGear's ability to directly import solid modeled part
files with the Mazak FG-CAD/CAM software package and cut them without error as an
exciting feature that gives him an edge over the competition. "We're working on
a project with a large number of tube components for a video screen tower and frame
for a major rock band's world tour staging. We're cutting 2" and 3" OD round chrome-molly
tubing with compound angles exactly to the design; it's a very expensive material,
so you can't afford a single mistake. We took the work away from a job shop that
had a competitive brand of tube laser, but couldn't import the files." From the
exotic to the mundane, Zimmerman has seen the FabriGear 150 impact his business
"Little things like being able to put a slot in a tube where we used to drill a
hole. It makes the end product's assembly easier while eliminating the set-up time
on the drill press. It all adds up to greater profits."
 New projects for Paul B. Zimmerman, Inc. include stainless steel hand railings for
luxury yachts and New York City's Mass Transit system. "We've gone from barnyards
to weight rooms to rock concerts to the subway and now out to sea on luxury yachts
with our FabriGear 150. I'm happy to have the ability to be diversified!" With
sustained growth capable of justifying a second, larger FabriGear, Zimmerman has
clearly hit one over the fence!
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