It isn’t by accident that GMP Metal Products remains family owned after nearly 120 years in business—investments in longevity seem to have been a core business strategy from the start.
Even though it isn’t owned by its founders, the company still operates out of its original site in
St. Louis, MO. Early on, GMP made signs for Anheuser-Busch and running boards for the Ford Motor Company. Eventually the company evolved and expanded, establishing long-term relationships with customers, while adding capabilities and a second manufacturing facility in Humboldt, TN. “We’re constantly trying to find ways to add value for our customers,” says Dan Martus, general manager. “If that means we need to acquire a new piece of technology, we’re more than willing to do that. We’re not happy with status quo.”
This is obvious from efforts made by GMP Metal Products to support a new product being offered by long-term customer Caterpillar in the past year. Working directly with Caterpillar, GMP designed a self-contained robotic manufacturing cell to build a rear door for Caterpillar’s new skid steer. “We were able to work with their engineers on the door for manufacturability,” Martus says, “and provide a high-quality product while taking cost out of the process by making the door so efficiently.” This cell was installed in the St. Louis facility in February and went live in March.
Finding a place for the new assembly cell wasn’t as much of a challenge as might be expected, but it was well planned. “The tooling fits in with our large 1,500-ton presses, and the assembly cell is near the presses to reduce material handling,” Martus explains. “It also is close to the finished goods area, so it has a nice flow through the process. So far it’s working out great, and Caterpillar is very satisfied with the quality of the door.”
Those presses are used for more than this new cell, however. In fact, GMP has 70 presses to support its stamping operations and is well known for its deep-draw capabilities. “There’s a combination of things that you need to have for deep-draw,” Martus says. “A lot of people just don’t have the press tonnage and the technical know-how. There aren’t many manufacturers who can produce large parts with thick materials.
“We take on some difficult jobs for our customers,” he continues. “For example, the rear door for Caterpillar is heavy-gage material, and the blank weight is 173 pounds. We have mechanical manipulators that move the materials in and out of the presses, and the robot moves the door around in the assembly cell. We don’t have to handle it manually at all, and there are not many stampers who can efficiently handle big, heavy parts like that.”
In addition to its stamping capabilities, GMP also has recently invested in two 5,200-watt, state-of-the-art lasers for cutting and an 8-axis CNC brake press for fabrication. In addition to Caterpillar and other off-highway customers, GMP also serves the defense, agriculture, and transportation markets.
Equipment investments are just part of GMP Metal Products’ plans for continued success. The company recently started its lean journey, running 5S programs in both the Humboldt and St. Louis facilities with solid results. “It really has helped improve the flow of the product through the plant, free up floor space, and improve the working conditions and morale of our employees,” Martus says. “They take more pride in their workplace, their jobs, and the quality of products they produce. And the customers are totally impressed when they see it. It’s just been a tremendous benefit to our organization.”
Martus says the company is taking lean one step at a time, with its next efforts focused on quick die change for the large presses in St. Louis and kaizen training. “Our first steps were to get the place clean and organized and get folks fired up about improving processes,” he says. He also brought in a new quality assurance manager—a Six Sigma black belt—to guide continuous improvement efforts.
Working on the large presses is important because demand on that equipment is high. “It’s prudent that we optimize the efficiency and utilization of that equipment,” Martus says. “It’s a major investment, and we need to make sure we’re utilizing it effectively.
http://www.themanufacturer.com/us/profile/5485/GMP_Metal_Products
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