ff info 68 en

SUSTAINABILITY DESIGN CONVENIENCE SECURITY SAFETY

GB FlexiForce INFO magazine #68, November 2014 www.flexiforce.com

INFO

All about systems!Go for LEAN! | Proud to be FlexiForceType-2 safety light curtains | Flat-Bed pack solutions

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Content

Content • Editorial: Proud to be FlexiForce “Tour d’EMEA” 4• News: FlexiForce companies and market updates 6• DOOR AUTOMATION UPDATE: It Is All About Systems Nowadays 14• SYSTEM OVERVIEW: Garage Door Automation 16• The internet-of-things: Liftmaster and Nest 18• DOOR AUTOMATION OVERVIEW: Industrial Door Automation 20• Ultimate Safety: NEW Accesories 22• Interview: Go for LEAN! 24• NEW Products 27• SYSTEM OVERVIEW: RSC-T residential systems 28• Growing the business with FlexiForce flat-bed service 30• SYSTEM OVERVIEW: New Full vision sections 31• SYSTEM OVERVIEW: Industrial sliding door 32• SYSTEM OVERVIEW: Preferred Industrial 34

The information presented in this booklet is subject to change. We regularly update, expand our product range, offer new services. We share all our news, even daily, with you via our website, our online product catalogue (no login needed!), our YOUTUBE/Vimeo channels FF-TV, our Flickr-photo stream and through the FlexiForce social media platforms on Twitter (twitter.com/flexiforce), Facebook (www.facebook.com/flexiforce), and LinkedIn. Follow us to stay up-to-date with our news and information!

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Editorial PROUD TO BE FLEXIFORCE, “TOUR D’EMEA”

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In the last months I have had the privilege to visit all our FlexiForce subsidiaries in the EMEA region. As a kind of “Tour d’Europe”. By plane, not by car, although that would have probably made a very nice road trip (8.520km/86hours according to Google Maps). During my visits, I was often introduced to the complete local FlexiForce team and also to some local customers. One conclusion stands after this tour, and that is a strong feeling of pride, to be part of this international FlexiForce team. Julian, Julio, Mert, Johan, Jan, Imre and Hans, our local managing directors, are leading local teams of people that are all truly involved and motivated to serve FlexiForce customers in their own region.

The customers that I spoke to, confirmed that they are in general very happy with the service of FlexiForce in their country or region. Of course, we make mistakes. Not all products are in stock when you need them. Sometimes our truck is arriving later than promised. Or products are sometimes damaged or missing. But I am convinced that in general we do a very good job. Our reliability and our consistency are a good support to the everyday business of our customer. Most important is, that when something does go wrong, we fix it. The fact that Julian and I were driving to the harbour in Gandia to add some late products to the container leaving for the Canarias Islands, is only one example of our dedication. I was very happy to get that confirmed from the

customers I met during these visits. It showed to me that our “close to the customer” strategy, with local warehouses and local people in place, is helping our customers in keeping their business flexible and competitive.

What also impressed me a lot were the various ways that our customers approach the door business. I was visiting an end user showroom in Italy, an innovative door company in Turkey and a smart high volume garage door production in Spain. The wide variety of market approaches show that the independent door market is alive like never before and real entrepreneurs still find ways to secure and grow their businesses.

FlexiForce has a renewed focus on the EMEA market and is able and willing to sit down with all our customers to find local, specific and often personal solutions. Tell us what you need and I am convinced that our local teams will do everything they can to serve you. Growing the mutual business!

In this INFO#68 magazine you will find more examples of how our teams in the Netherlands, Poland, Spain, Italy, Turkey and Hungary work for you. And information on future improvements and other developments. We have some interesting information on how “LEAN” can improve your business. A big part of the INFO is reserved on presenting our residential and industrial systems to you. Do not hesitate to contact me personally for any ideas or comments that you might have. I would like to hear from you, so please, get in touch! And, enjoy reading this magazine.

Best regards,

Frank GoedhartManaging Director FlexiForce EMEAE: [email protected]

nl.linkedin.com/in/nlfrankgoedhart

Editorial (Frank Goedhart)

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“… when something does go wrong, we fix it!”

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News

News FROM FLEXIFORCE COMPANIES AND MARKET UPDATES

Honouring our long term relationshipsGoing through the ancient FlexiForce order books, it is satisfying to see that customers that ordered from us more than 25 years ago, still order today! Of course, we lost customers that were not able to keep their business going, or customers that were acquired by others, but the lists clearly shows that we are all about long-term relationships. We are happy with the trust that customers give us. And happy that apparently, we can grow our mutual business by doing something right! In our visits we will confirm our gratitude and how much we value the 25+ years relationships with a nice gesture.

Boys will be boys: New FlexiForce trucks!It is not only the fact that the boys in FlexiForce are mad about trucks with our logo on it. Apart from that, we increase efficiency and transport quality by arranging it with our dedicated trucks. In Poland and Italy, new “milk-run” trucks started delivering our hardware to our customers. “We now have three FlexiForce branded trucks driving different weekly routes to our customers in Italy”, says Julio Gonzalez, MD in FlexiForce Italy. “I cannot help but feeling very proud when the truck leaves our warehouse on its way to for example our customers in Sicily. And our customers like it just as much!”.

Patents granted!We are proud that our hard development work has lead to two new patents in our name. For the 656S -series of residential spring break devices a patent was granted for the design. This device stands out for easy installing (two click connections), reduction of parts and high efficiency in its safety function. Now this design is protected against copying by others. Jildert Gaastra explains why this product is his favorite: “It is very exciting to get a patent on your own design. It kind of confirms that you have done a good job. Of course, not just me personally but the team I worked with on this 656S-series”. (see the video!)

The second patent was granted for a spring tensioning device, which will be introduced Somewhere in 2015. We are very proud on our R&D team!

youtube.com/�exiforce

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News

Johan Keizer

Product configuration and customer E-orderingPer October 1st, we have appointed Johan Keizer as Manager Product Configuration and Customer E-Ordering. Johan, as former IT Manager of FlexiForce BV, is a veteran in the FlexiForce organization. In his new position he can fully focus on what we think is vital for our business: the digital communication and integration with our customers.His main objective will be creating a complete new online product configurator which will replace the current FF-Logic configurator. He will also further develop our online spring calculation (SpringForce) that currently not only performs web based torsion spring calculations but also enables our customers to fully integrate this functionality in their own software applications using it as a web services. The configuration of garage doors with Create as well as configuring full vision sections are, for the time being, the last components of the product configuration portfolio.

All these product configurations will be integrated in our web store in order to enable easy and seamless ordering. For those customers who would prefer to place orders directly from their purchasing software we are creating EDI interfaces.The pressure on Johan is high, to make sure that we come up with online solutions that will help you in making your business with FlexiForce easier, more efficient and flawless. We will keep you posted!

Our business model, being a technical wholesaling company, offering a wide and deep product range in components for doors, makes us ideal for setting up an online web store. Not a standard web shop, where customers need to re-enter each order that comes out of their own company software system, but a smart one that allows fast and easy ordering. We are finalizing the last phase of testing and we will contact launching customers to try the convenience of this system. After a full set-up for the customers of FlexiForce Netherlands, we will roll out the System to all our subsidiaries.

Shop online! FlexiForce Web Store 2014

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News

FF-TV new videosThere are two online channels through which we display our movies: YouTube and Vimeo. Subscribing yourself to these channels will give you instant email updates on when we launch a new video. We hear from our customers that videos and movies are an easy and visual way for explaining new products, installations, market/door related information and more. Of course, we will also announce and present these videos via Facebook, our website news and Twitter. Recently we presented:

• FlexiForce Favorites: A new series where somebody in FlexiForce explains about his/her favorite product• FlexiForce Product Of Today, season 2: Johan van de Linde shows in 1,5 minute all details on application of products.• RSC flatbed service

Hungarian Email: Switched to [email protected] are in the process of changing our worldwide email extensions to [email protected]. Today already, all our @flexiforce.hu addresses have been changed into [email protected]. Please change this in your mailing lists.

FlexiForce Favorite FF Product of the Day RSC Flatbed Service

Bienvenue! Equip’Baie 2014, Paris, Nov 18 - 21, 2014!In the third week of November, Paris will not only be the “cité d’amour”, but also the city of sectional overhead doors. In the Portes de Versailles exhibition halls, FlexiForce will present her new products and systems on stand number Q18, in Hall 1. Christophe Walschaerts and Lydie le Peltier will be, amongst others, your hosts: “We invited all our customers for a coffee or champagne. We will personally introduce you to all the news!”.

Herzlich Willkommen! R+T 2015 Stuttgart. When filling in your 2015 agenda, make sure you mark the dates “February 24-28, 2015” for a visit to our booth at R+T 2015 in Stuttgart. Known as THE international European door exhibition, this is an event that you simply cannot miss! FlexiForce will be present on booth number A37, Halle 4.


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News

The proof is in the testing!Last year we started an intensive testing project to learn all the facts about torsion and tension spring life span, relaxation and production characteristics. Our test-bench for torsion springs, is testing 8 springs at the same time, until they break. Same for the new testing equipment for tension springs. We can now say, that we are even more true experts in torsion and tension springs. What is in it for you? Our testing has shown that our spring calculation is still very much on the safe side. Meaning that our springs are better compared to what we specify to you. Last year we already adjusted our calculations in SpringForce to the new test-outcomes and we received positive feedback from our customers on this.

Bert van de Hazel, testing engineer at FlexiForce R&D in the Netherlands is almost only dreaming about springs: “After all testing that we have done in the past months, also on tension springs, which were new to us, we have learned so much about the spring characteristics. We now know exactly when a spring breaks, where it breaks under which load and what the relaxation is.”

The FlexiForce tension spring selection sheet will be adjusted to match these results. This will make our springs even more competitive while still being extremely good in life span quality! “You cannot imagine how much know-how is incorporated in a spring. And it is a vital part of the experienced quality of the total door!”, concludes Bert.

Investing: Spring production efficiency in the NetherlandsSince we started producing torsion springs in the Netherlands, our production capacity has kept up with the yearly growing demand. Especially the “fixed-to-size” spring service to bigger customers is a big part of this success. To make the next step in keeping up with demand, we will invest in our heat-treatment installation at end of this year. New burners, new air ducting, more springs per meter on the conveyor line and a longer time the springs will spend in the oven will not only increase our capacity; it will also improve the quality of our powder coated springs. The standard lengths (3.250mm etc.) springs will be treated in a new second oven. Hans Lubbers, Managing Director of FlexiForce Netherlands is happy: “Of course, I am very happy that we need to invest in our production line to be able to keep up with customer demand. After this upgrade, we are more flexible and able to serve even more customers with our customized spring service”. Contact your sales team for more information on our torsion springs.

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Bert van den Hazel

Hans Lubbers

News

FlexiForce Poland Inspiration CenterWhen all your floor space is needed for production and warehouse, there is only one way to add new office/showroom space: UP! So FlexiForce Poland is putting a new floor in the warehouse area that will function as an Inspiration Center: Showing all our new products, systems and applications clearly to visiting customers. “We want to welcome our partners, customers and show them the hardware, panel and automation solutions that we provide, in an inspiring surrounding. That works good for mutual understanding and learning.” says Margo Kubiscik, sales manager in FlexiForce Poland. “Once we finalize our project, you are invited! We will treat you like a VIP!”.

Introducing: Emiel Mulder, sales manager FlexiForce Netherlands.We are happy to inform you that, per the first of May, a new sales manager started in FlexiForce Netherlands. His name is Emiel Mulder. Emiel has a background in the elevator business and even worked in a Dutch door company. Today he is leading the Dutch sales team, reporting to Hans Lubbers (MD) and he is part of the Management Team in FlexiForce Netherlands. “It is nice to now be a part of the FlexiForce team. Listening to our customers and to the sales people leads me to believe that we can build and expand on solid relationships. A great start!”. We wish Emiel success in his new, challenging, job!

Introducing: Gyula Gal, sales manager FlexiForce Hungary.Catching up on what we should have done in the previous INFO magazine, that is, introducing our Hungarian sales manager, Gyula. “Being part of a well known international organization and leading a small, but hard working group with whom we can make (FF) customers satisfied. It still makes me happy... even after 18 months.”

Ordering and invoicing in FlexiForce Netherlands.In FlexiForce Netherlands, we have recently started sending order confirmations fully automatically. This means that the format of the email containing the order confirmation will be different from what you are accustomed to. The sender of the order confirmation is [email protected] and you can send questions or comments about the confirmation you receive to [email protected]. The order confirmation lists the articles and quantities and the accompanying price and date of delivery. To avoid misunderstandings it is advisable to check the details as soon as you receive the confirmation. We are planning to send invoices in digital form as well as the order confirmations. We also request, if you are not already doing so, that you transfer the invoiced amounts to our IBAN numbers. Thank you in advance for your cooperation! Please contact your sales representative if you have any questions about the above.


INFO

Margot Kubiscik

News

CO-CREATION! New approach in R&DAs we speak, FlexiForce is pre-testing a new tool with a number of selected industrial door companies. This tool that will make installing a door a lot easier! We intend to increase that “CO-CREATION” approach, because it will help us to introduce a product that is from the start ready to meet market demands. Listening to customers in a pre-introduction phase. Soon more news on this device.

In FlexiForce Iberica and FlexiForce Turkey, we started to offer efficient distribution of “third party door panels” to the market. This kind of service has already been offered for many years by FlexiForce Poland. Now we provide an answer to the demand for panel coming from our customers in Turkey, Spain, Portugal, North Africa and Canarias Islands. “The recent disappearance of a local supplier, has left a big gap in our market”, explains Julian Lopez, Managing Director of FlexiForce Iberica. “The need is clear: For smaller door producers it is hard to keep stock of all the panels that you need to supply, especially, garage doors. That is why we now keep these panels in stock. Our customers can order panels in smaller quantities or in shorter lengths.”. This is fully in line with the consistent FlexiForce mission to keep the small to midsized door producers

competitive in their local markets. “The first customer reactions are positive!”, claims Julian. “Ordering panels, hardware and door openers from us is now very easy!”. Contact Julian or Pablo Escriva to learn about pricing and product range! “In Turkey, custom duties, cash payments and more hurtles make it a struggle for Turkish door companies to import products. FlexiForce makes it easy by taking away all worries and offering hardware, automation and now also door panels from stock in our Gebze warehouse”.

“Easy and appreciated!” smiles Mert Kaptan, Managing Director of FlexiForce Turkey.

New! Panel service in Iberica and Turkey

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Mert Kaptan

Julian Lopez

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Industrial hardware set installation manualA complete new approach to manuals is being taken by putting our industrial door system in a 3D model, cut that into modules and, in the near future, link those pieces to our configuration system. That way, you will get exactly the manual that you need for the configured door. Expect the new manual on our website by the end of this year!

CE-ITTR: Updates?It is already some time ago that we initiated the whole Initial Type Testing Report project, which enabled you to certificate your door, with the testing work that we, and operator- and panel suppliers, have done at SP in Sweden. Of course, years down the line, the products in the report are often out-dated. The hardware products were added and updated regularly, but the panels and operators have not always done so. We have invited our partners to re-do a lot of testing with today’s product. We will keep you updated on the progress and actions.

FlexiForce industrial hardware sets production switchWe take our own advise, “outsource your worries”, seriously in FlexiForce Netherlands. A brand new production facility in Hungary, combined with very efficient logistics, made it possible for us to move the production of industrial hardware sets from Barneveld to Debrecen. All relevant customers have been informed about this step. Tibor Barsy, Plant Manager for the new Debrecen factory in Hungary: “In short term we see efficiency benefits, but in the longer term, we will upgrade our configuration, features and quality of the hardware sets to a new level. We see our international hardware sets customers as true partners. We will be proud to now also start serving the customers in Western Europe”.

Pizzas and beer sessions: “The Domino Project”Under the pressure of day-to-day product development projects, we run the risk of losing out on smart, creative or “just different” solutions for future garage or industrial door products. That is why marketing and R&D of FlexiForce get together every month, spending an evening on trying to define real innovations. “We call it the Domino Project, inspired by our pizza supplier” says Ton Peterse. “It is remarkable to see how creativity is boosted when you have time to discuss, draw and present ideas and bright thoughts”. Expect no immediate result. More pizzas will be needed!


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CE-certification

1035RES rubberEU member states

Liftmaster Evolution

LM80E

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Residential ITTR

CE

-marking

LM60E

V EN 13241-1

Declaration of Performance

Tibor Barsy

News

20mm!Door panel producer and partner in the FlexiForce ITTR, Epco, will be introducing a new panel to the market: With a panel thickness of 20mm! Where the previously introduced 60mm panel is an answer to the demand for upgraded, highly insulated garage doors, this new 20mm panel will be ideal in those markets where opening price point doors are needed to seduce the end user into the showrooms. The panel weight reduces with over 25%, which leads to the selection of light hardware and (tension) springs and also has an effect on the transport costs of the doors and panels. FlexiForce is, of course, tooling up to have all needed hardware for this panel available in Q1-2015. RSC-T 20mm coming soon!

Garage door historyThe leading door magazine in the US, Door+Access Systems Newsmagazine, has published a very interesting review on the history of our business: “The first comprehensive history of the American garage door industry”. All milestones and nice-to-knows are written down in this publication, from the start in 1921 up till today. Compliments to Tom Wadsworth, chief editor! “Even though evidence indicates that the upward-acting sectional garage door existed in 1900 or earlier, the era of mass manufacturing sectional garage doors likely began in 1921. That’s when C.G. Johnson of Detroit, Mich., started Overhead Door.............”. Find the article online on www.dasma.com.

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Door Automation Update

It is all about systems nowadays


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Door Automation Update

How different is that today, driven by market changes, legislation and modern logistics. We now design our products, starting at the door level, after which we break down the door design into systems and then the systems into components. In this way, every single part we offer, belongs to a system. Systems with Initial Type Testing Report in place. Systems with clear installation manuals and certificates. Systems that can be configured online with dedicated software. Systems ready for installation and use. So today, it is all about hardware and automation systems. FlexiForce offers different systems. As our customer, you have of course the freedom to decide how you want to make optimal use of these systems in a way that suits your specific business best. Buying in bulk is still possible. Pre-assembled track sets, pre-assembled springs is one “value added” level up. And of course, the ultimate level of service is provided to you by our complete industrial and residential hardware sets. The advantages of ordering our sets are clear: Low pre-financing strains, flexibility in your cost level (fixed costs become variable) and the security that all the parts for that one door are in the box. Convenient, professional and very efficient (now we are selling!). Up to you.In the following pages, we give you a complete line up of our main systems in hardware and automation. To help you find your way in the selection and configuration of your doors. Let us know if you need more information or details!

In the early days, FlexiForce did not offer any installation manuals with her products, because the customers themselves knew perfectly well how to apply and install the offered components. And that was what we offered: components. In bulk packaging. FlexiForce customers selected product by product. Exactly what they wanted to apply in their own door design.

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SYSTEM OVERVIEW: Garage Door Automation

It is remarkable to see how the market has embraced the Liftmaster Evolution garage door opener product line. Since the introduction, we have been very successful in convincing customers that this nice design opener, with its advanced technology, silent operation and green energy use, was really what the market was waiting for. The traditional sales channel is however still a bit reluctant to offer MyQ internet access to the consumer. We are convinced it is just a matter of time until all our homes will be full of internet connected devices. Better to be leading the way instead of following others. Below an updated overview of our line of operators and the wide range of accessories for Evolution.

SYSTEM OVERVIEW:

Garage Door Automation

770E Photocells

128EVOPush button NEW!

773E Photocells NEW!

747EVOKeypad NEW!

1034-OSEPass door switch, wireless

LM60EVO - 600NLM80EVO - 800NLM100EVO - 1.000NGarage door opener


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SYSTEM OVERVIEW: Garage Door Automation

OSE-PDSK-RES Kit pass door switch

828EVO Internet gateway

TX2EVOTX4UNIHandtransmitter

9700V12-24 keypad

MyQSmartphone remote app

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8003EVOReciever 3-channel

1702EVOOutside release kit

829EVO Garage door monitor

THE INTERNET-OF-THINGS

THE INTERNET-OF-THINGS:

Liftmaster and NEST


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Internet access through myQ and the 828EVO gateway are only the very beginning of a phenomenon called ‘connectivity’. Today myQ might be considered a gadget but sooner than we all think the garage door opener will be part of an integral home automation system. Together with heating system, electronic door locks, sun awnings and even refrigerators, etc.. LiftMaster’s co-operation with NEST Smart Thermostat underlines this future. Instead of focusing on the garage door the focus can be shifted to the user and to the car. All of this is early stage now but we’d rather be too early than late. Currently we are working on some very simple initiatives to increase the number of gateways (828EVO) sold. The Evolution line of garage door openers is a great success but the real benefit to the home owner lies in the connection with the internet. You or the installer are the direct link to the home owner and can benefit from the desire and demand that is clearly there. We believe that offering this will distinguish your proposal from any other that is just quoting the best price for a regular door opener. Liftmaster is ready, FlexiForce is ready, are you?

MAKING LIFE EASIER

„For us, one thing was obvious: Whenit comes to Garage Door Openers,we will go for the Number 1.“

Want to make sure you provide your customers with world-class quality

and peace of mind? Your customer will love the comfort and security you will

give them when installing one of the LiftMaster garage door openers.

Trust the # 1

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smartphone compatible

Easy-to-install

Silent

Standby Power

0,8W

LED

Speed

200 mm/sec

Warranty

7Years

Up to 7 years of warranty

Environmentally friendly

Long lasting LED

High performents radio technology

Intuitive installation

Monitoring andcontrolling from anywhere

Impressively silent

Fast & secure

MyQ technology enables your customer to simply and securely monitor and control the garage door... ...anytime, anywhere.

STYLISH

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Chamberlain GmbHAlfred-Nobel-Strasse 4D-66793 Saarwellingenwww.liftmaster.eu

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SYSTEM OVERVIEW: Industrial Door Automation

SYSTEM OVERVIEW:

Industrial Door Automation

Soon after the introduction of our force100XQ/C line of industrial door openers, we initiated the next steps in completing this advanced product line. The forceIQ control system not only offers unique and visual control of new installations, in 230V (single phase) or 400V (three phase) it also proved to be a very efficient after sales solution, in replacing control boxes of almost any other brand at much lower costs. Today our line of units is complete and the line of available “plug-’n-play” accessories is almost limitless.

forceOSEOptosensor kit NEW!

FLA1-LEDFlashing light NEW!

forceTLR /G/RGTraffic light NEW!

924WLKITPull switch wireless


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SYSTEM OVERVIEW: Industrial Door Automation

NEW! FORCE70XQ: The latest addition to the force line of sectional door operators is the single-phase force70XQ. Same high end quality as you have grown accustomed to with Kostal encoder for absolute precision and forceIQ control box with all features.Available from stock in our warehouses at a list price of € 625,--

773E Photocells NEW!

forceLC2 Light curtain NEW!

forceLDLoop detector kit NEW!

forceRX4 Receiver 4-channel

forceIQ Controlbox

forceTX-4 Hand transmitter NEW!

forcePSE Optosensor kit NEW!

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forceTLG green light

forceTLRGgreen/red

forceTLR red light

SPECIALIZED IN ALL SPARE PARTS… …FOR ALL DOOR BRANDS

PARTS, PANELS, SPRINGS, DRIVES, CONTROL BOXES: IN STOCK, FAST DELIVERY

Order online 24/7 on: www.iddparts.nl | Call us: 0031 342 490 990

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forceLC2 Light curtain NEW!

forceLC2

ULTIMATE SAFETY: NEW Accesories

ULTIMATE SAFETY:

NEW AccesoriesforceLC2 type-2 light curtain! Until now light curtains were not self testing. In real life this means they could only be used in combination with another safety device (safety edge). We are happy to announce to you that those days are over with the launch of forceLC2, type 2 light curtains. Main advantages:• easy to install in the vertical tracks• very unlikely to get damaged• for doors up to 10 meters wide• the absolute safest solution (non-contact)• connection on the OSE inputs so no programming!And last but not least: extremely cost effective with a list price of euro 359,- !One model fits all, active height is 2550 mm. and IP67 protected so suitable for rough and wet conditions. Compliant with EN-12978 and EN-12453. Available in our warehouses now!

New! Traffic lights!With the increasing emphasis on safety in mind we decided to focus more on passive safety as well. Next to the FLA1-LED warning light (see previous pages) a line of traffic lights has been added to our product range. Use at industrial doors, gates or docking installations. Energy efficient LED technology, good design and very simple but effective. In stock now!

New! FLA1-LED: Safety at gate and garageAs experienced door professional you all know about safety devices (for example light curtains that are featured in the following pages). However, the best safety device is still: awareness. Therefore we have added a very simple, energy efficient and universal warning flash light to our range. Works on most major door automation brands. Another up-selling opportunity (at good margins!).

FLA1-LED Flashing light NEW!


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forceTLR /G/RG Traffic light NEW!

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INNOVATION THROUGH TRADITION IN DOOR PANELS PRODUCTION

METECNO ITALIA S.R.L.Via Nazario Sauro, 80 - 33090 Travesio (PN)Phone +39 0427 591311 - Fax +39 0427 90168

[email protected]

WE WILL BE PRESENT AT R+T STUTTGART FAIR24 – 28/02/2015HALL 4 – STAND 4B31WE ARE WAITING FOR YOU!

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interview: Go for LEAN

Go for LEAN!


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Our business world is changing rapidly. Competition is tough and markets are becoming more transparent and open due to the internet. Margins and sales are continuously under pressure, while customer demands on delivery times and quality are increasing. To survive under this pressure, the role of the supply chain, that is, the way we buy, produce, install and distribute our products, is becoming increasingly important. Here is where LEAN comes into the picture. LEAN is defined in short by taking away losses and by shortening throughput times. Ronald Koenders, our recently appointed operations manager, is a LEAN expert. We hear him out in this interview.

Hi Ronald, could you summarize the origin of LEAN to us?Yes! LEAN originated in Japan, where after World War II, Japan was rebuilding her economy. The United States were big in production of cars, like the T-Ford. People of Toyota wanted to do better than Ford, but they faced two limitations: they had no money and they lacked space to build a big factory. They needed to build a car very rapidly and the cars had to leave the factory as soon as possible to generate the needed cash flow. Their solution was to keep the car in continuous flow movement during production, which turned out to be very productive. The Toyota team was continuously focused on reducing throughput times, prevent waste and scrap and take out useless steps in the line.

So this was the start of LEAN?Toyota called it: “Toyota Production System” (TPS). But when Americans adopted (or copied) this way of producing, they wanted to avoid to use the Toyota name, so they came up with: LEAN Manufacturing.

Can any company switch to LEAN?LEAN is not a technique or system that you can teach. LEAN is more of a philosophy. It is about changing behaviour, culture and thinking. A complete new way of looking at our production processes. As I said earlier, LEAN is about

reducing waste, shortening production time. Everything that has no added value will be eliminated from the process.

Can you give us an example of that?Well if you walk around in any factory or warehouse, and you start asking a lot of “why?” questions, you will see waste and loss of time immediately. When a LEAN consultant visited FlexiForce in the Netherlands, he looked at our industrial hardware collection point and he asked: “Why does this guy pick up the hardware box at this point, places the box 5 meters away to the hardware set and then walks back? Sometimes even two guys, with a heavy box. That is two times 5m, by two guys. You know how much time is lost per day? Is the customer paying you for this “walking” time?” Now in the new set-up we have eliminated the 5 meters and we are more efficient.

Is it really that simple?It takes more than just walking around and ask questions to do LEAN. There are plenty of books written on the subject which I can recommend to you. Just-in-Time, Kanban, Kaizen, 5S, Jidoka, Heijunka and other parts of the structure will be too much to explain now. But, once you dive into it, you become easily addicted to finding savings. It’s like a game.

INTERVIEW Ronald Koenders, COO FlexiForce Group

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Any concrete examples of the waste you talked about?There are eight “losses” or “wastes” listed within LEAN. I will say something about the most important ones:• Over production: often companies produce just a bit more products than they

actually need. Often this overproduction ends up as scrap or dead-stock into the container after one year of collecting dust. You might think about producing to order only.

• Inventory: Inventory slows down throughput times, it costs space, money and it locks-up your cash. It can get damaged or even lost. Finally it can end up as dead stock. In general, inventories hide the problems of an organisation. Measure your Material Through Put Times (MTPT) carefully, since cash is king! Hardware sets from FlexiForce will drastically decrease your inventory. Both of components and of finished product.

• Defects. Rejections and repairs. “Do it right the first time” is a wise saying. For door companies, as an example, at first sight, it may seem more expensive to go on site and take dimensions of the door yourself but afterwards it might save you lots of money.

• Unnecessary motion. Take the time to look at your production process and see how people move around. Which of these motions really add value? Taking a box from one point to another. Needing a fork lift truck to pick up a pallet and move it 5 meters. Counting steps, really counting the number of steps people take during their tasks. This sounds obvious but is often ignored. I would be happy to visit some customers and make an analysis together with them.

• Transport. Over the years, your production process may have grown bit by bit or has expanded fast. A new machine was added but there was no space in the existing line, or other reasons that result in a non-logical lay-out of your production floor. Leading to compensation by internal transport. Draw on a piece of paper the route that a product takes during production and often you will see a spaghetti diagram. In day-to-day practice, transport time is more than 5-times the theoretical determined time for it. Check you fork-lift truck movements, including picking up pallets that are blocking the paths and picking up products from locations too far away from the production process. When the door is ready: where is it? Close to your despatching area, or does it have to go all the way through your building?

• Skills. Improvement projects only succeed when your people really change the way they work and think. The factory workers often exactly know what can be done to improve, but not always management asks them or listens to them. “I told management many times to change this, but if they don’t listen, I give up”. If a person feels appreciated and involved in improvement projects, he will engage in the LEAN process and he will come up with creative ideas and solutions.

That is all?No! There is so much more to learn on LEAN. In FlexiForce we have assigned so-called “LEAN ambassadors”. Through the sales team a meeting can be arranged. We would love to share! Our conclusion is that LEAN is a very simple and logical way to improve processes, eliminate waste, increase the quality, reduce costs and....have production workers involved and empowered to influence their own job. A benefit for all.

“ ... everything that has no added value will be eliminated”

LEAN - The game. Simulation of "production" of 20 cups filled with two Lego bricks, through 5 desks forming the different working stations, and two persons walking in between the desks as imaginary "fork-lift trucks". After several LEAN improvements, production time was reduced to 50% with 20% reduction of personnel.

LEAN - walking around. “Why is that 4th spring machine not in the same line as the other 3? Watch how many fork-lift trucks movements you need to compensate for that. This is wasting production time!”


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New products

773ENew is this IR protection photocells kit, to be used on garage doors or industrial doors, needed in case the door is operated from a distance. Safety first! Universal for any kind of operator (NB! Not for Evolution) and unique because of the turn-able lenses, up to 90 degrees, which means you can install these photocells into or in front of the door opening. The maximal range is 20m!

New products!

New Stainless steel windowsWe have improved and expanded our range of stainless steel square windows. The choice is now wider than ever before. 2435R1 and 2435R2 feature new framing (high quality!) and a double acrylic window cassette. The price of this version is very attractive. For customers that love to have “real glass”, we also offer 2435RS1 and 2435RS2, with a double safety glass cassette. Both versions will also become available in a version with sand-brushed (SB) glazing. Check out our online catalogue for the latest updates.

661HDReplacing our 322BAS bracket, this new Heavy Duty version is used for adjusting the heart distance for spring break devices (670etc) between 86-152mm. Order separately: 2 x Bolt M10 (1058B) and 2 x nut M10 (1058F).

Shhh! Silent roller carrier slides!423SZB, 450SZB are the article codes of our new roller slides, featuring a silencing plastic filling. No more squeaking or scratching, just silent run of the rollers in the hinges. Available soon!

421AC Adjustable bottom bracket for garage doorsThere are different ways to fine-tune the cable length of garage doors. Now we offer a solution to people that prefer to adjust at the location of the bottom bracket. A light and price efficient solution, available in Q1 of 2015.

422H304, 422R304 Stainless Steel hinges for EpcoStainless steel hinges, 70mm wide, for the finger-safe panels of Epco. Now available! Check pricing online!

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SYSTEM OVERVIEW: RSC(-T)

SYSTEM OVERVIEW:

RSC(-T)

Per September 1st, FlexiForce has introduced RSC-T. An expansion on our well-known residential system, Reliable - Secure - Convenient, now with Tension spring technology. For doors up to w x h = 3.000 x 2.250mm, door weight to 75kg. We offer a unique new system to the market, where the (double) tension springs are integrated into the vertical track system. Unique is the drive through opening height (-50mm) of our system, easy installation and reduction of components. Find all technical details, such as installation manual, spring selection table, bill of materials and a explanatory video on our website. NB! On RSC-T the vertical track is not a closed “C”, but traditionally “open” again (215V).See our overview of all dedicated components:


INFO

ACCCable clamp

915VSX2253 Lintel profile

SYSTEM OVERVIEW: RSC(-T) INFO

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K24-....TSLifting cable set

LM50EVO Garage door opener500N

TSS...-..Tension springset

TST2PR Pulley bracket

LM60EVO23 Garage door opener600N

RSCTV10etc Vertical track set

RTSH05etc Horizontal track set

Tutorial

" RSC(-T) FLAT-BED SERVICE WORKS FOR ME"

Of course, FlexiForce is also offering you this residential system in the smart and efficient Flat-Bed packaging. Configure your set online via Create and order it digitally to your FlexiForce contact. The Flat-Bed will arrive when you need it, complete and ready for shipment to your customer! We have asked some of our customers to review on their experience with the RSC(-T) FlatBed approach so far.

Mr. Wouter Van Bosstraeten, Vabo Belgium: “It works in day-to-day practice just as well as it was promised in theory: So, good!”

Mr. Christian Bunse, BBS-Bauelemente, Germany:“We order the FlatBed packaging because: • It is easy stackable, so saving warehouse space • All parts are protected against damage and dirt,• We put the FlatBed together with our sealed panel

pack, it forms an optimal transport pack,• The wood reinforced packaging allows simple

loading and moving with fork-lift trucks.These are the main advantages why we are happy with RSC(T) FlatBed Packaging.”

Marius Skullerud, Topit AS, Norway:“For us the products from FlexiForce has lifted our company in the eyes of our customers, and we are now stronger positioned in the Norwegian market. We order the FlatBed-packing and the hardware kit arrives at our door already packed, and ready to be shipped out to our customers. With other components and panels combined with it, we send out the complete set, so that the complete door arrives at the customer in one piece. Handling is easy and because of the strengthening inside the package, the hardware system is well protected and arrives at the customer looking as good as it is supposed to, even after being handled with a fork lift numerous times. We look forward to expanding even more in the future, and the products from FlexiForce are an important part of that.”

Mr. Samuel Lagarde, Alsanext, France“The development of FlatBed solution is a critical step in optimizing our supply. The integration of our own configuration in a proven packaging allows us to increase efficiency and to dedicate ourselves to all other production tasks that generate more added value than the collection of hardware parts only.”

Mr. Jonas Nord Rappe, VD GarageCenter, Sweden“The FlatBed finishing is THE solution which has solved problems we didn’t even know we had. Because of the flat design we can fit >200 sets in a trailer and second off all the width is the same as the packaging of the door. In a joint effort with FlexiForce we have managed to put together a cut-to-size GarageCenter RSC-set which all fit our door sizes. In one word: Great!”


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SYSTEM OVERVIEW: New Full vision sections

SYSTEM OVERVIEW:

New Full vision sections

We have informed you a couple of times on our full vision sections (alu-glazed sections) set-up. You can either buy the profiles and assemble the sections yourself. Or choose for ordering the complete section, assembled to order by FlexiForce in Hungary or in Poland. Which will save you a lot of hassle and time. Below you will find an overview of our new system for industrial and residential doors. A revolutionary system that we will introduce in Q1-2015. It deserves your attention, given the significant savings we achieved in the use of aluminium in combination with a very nice and sharp design of the section. The complete elimination of glass laths makes this system easy to produce while giving it a high-end design appearance. On top of that, it opens up interesting after-sales opportunities for door producers. More information soon!

Phase 2: Thermal break designWhile we are finalizing the process of this design and bringing it into our catalogue and warehouses, we are already working on phase II of this project, that is: full vision sections/profiles with an integrated thermal break feature. Of course, as an answer to the growing market demand for better U-values on doors. We will keep you posted on our planning in this!

INFO

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SYSTEM OVERVIEW: Industrail Sliding Door Hardware

SYSTEM OVERVIEW:

Industrial Sliding Door HardwareExpanding your business with sliding doors, could be an interesting opportunity for growing revenues in two ways:• industrial sliding doors are a new potential business

for you now that FlexiForce can offer you easy access to parts

• you are already producing this door type, but now FlexiForce can be your easy direct supplier of these parts.

We have started by entering a compact, limited range of hardware parts for top hung straight sliding doors weighing up to 360kg. These systems are suitable for industrial and commercial applications such as warehouses, factories and agricultural settings.We focus on allowing a door blade made out of standard sectional door sections (since these are in your stock already available). For bigger doors, the panels can be assembled “on-site” to a door blade, which makes logistics a lot easier. Two versions:• Panels framed in an aluminium U-profile

for doors <100kg• Panels framed in a partly welded steel frame

for doors <360kg.The parts for these doors are available in our warehouses in Europe today!

H89FPFloor guide

H17STDoor stopper

H89U4000U-profile


INFO

SYSTEM OVERVIEW: Industrail Sliding Door Hardware

H31RAHanger/roller

H31SNSuspension bracket

H31-6000Horizontal suspension track

H31EB Rail end bracket

1016B30Bolt

1016MNut

H40UBCorner bracket

H31ARail hanger

H31ACRail end connector

H31RC Hanger/roller

H31ST Rail stopper

H53B6000Brush

INFO

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574RESRoller

450STRMounting strip NEW!

415CZTop roller bracket

440S Cable break deviceadjustable

9VDAngle vertical

30B20-3000Angle perforated

670RSpring break device

450CZ Side hinge

force70XQOperator NEW!

VL/R-PP and 1065PVC3000 Torsion springs with spring filler

SYSTEM OVERVIEW: Preferred Industrial Hardware

SYSTEM OVERVIEW:

Preferred Industrial HardwareThe beginning of next year, we will release our online configuration software for industrial doors. Which will allow you to create your own door system with all the products that you prefer, selecting from our wide range of industrial door hardware products. For people whom tend to get lost in our product catalogue, we have selected what we think could be your “preferred industrial solution”. Often more cost effective alternatives that are not known or maybe overseen by you.


INFO

718CSpring bumper

705GBShaft

1036DTop astragal

3152CBearing plate

FFNL18Cable drum

3086SEnd bearing plate

708S90Coupler

1027N7 1027N7BParo clamp plate

2400-90Window rectangular

642BLHandgrip kit

668BLLock kit

SYSTEM OVERVIEW: Preferred Industrial Hardware

SYSTEM OVERVIEW:

Preferred Industrial Hardware

INFO

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[email protected]

Anticipating on smart homes......with Evolution

garage door openers!

It will not be long before your home refrigerator will order its own food

supplies from an online food retailer, simply because it knows you will run

short of milk and cheese soon. The “internet-of-things”, where home

appliances and devices are connected and controlled via the internet and

with that via your smart phone, is already in place today. Liftmaster Evolution

garage door openers are enabled (ready) for internet access. Made very easy by just

ordering the 828EVO gateway from FlexiForce, install an App on a smart phone and connect. With

this unique feature, you are able to sell more than “just another garage door opener” to your home

owning customers! Allow us an introduction!

ff info 68 en

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