Sixty Years of Machines, Part XX: Cyber Success

Before the Cyber Saw was introduced, I saw its PLC “brain” control the machines on a GM assembly line. From the conference room at General Electric’s PLC factory, I was able to watch a live display of the automation systems it powered. While most were “Greek” to me, I understood the digital readout counting the cars exiting the plant. This told me that a PLC could do a lot more than it was doing on Omni or Easy Set 3000 saws. And I was happy to find out that, even back in 1995, PLCs were already proven technology. I proceeded to the GE factory floor to learn more.

The largely female workforce was putting together two types of components: flat green boards a little longer than a shoe box lid, and various modules about the shape of a pack of cigarettes. The boards were called “backplanes” and had multiple sockets that resembled those on the back of the original desktop PCs. [For images, see PDF or View in Full Issue.] The backplane would become the rack upon which the various modules would be hung. The modules themselves were all the same size but were being loaded with different electronics, depending on their functions: as power supplies, processors (CPUs), and input/output devices. From this visit I learned that PLCs were clearly in the mainstream, and that their modular design enabled easy upgrades. I left with high hopes that this device would greatly simplify the maintenance and operation of the Cyber Saw. But I was still wondered if CMs were ready for this level of technology. I found out shortly.

The growing backlogs at truss plants altered many CMs’ views on purchasing new equipment. Both large and small manufacturers set aside their attachment to older equipment and became willing to take a chance on automation. The best exemplar of this transformation was Brent Holcomb at Shoffner Industries[1], the dominant CM in the South, with 16 identically equipped, “cookie-cutter” (but totally manual) plants. Brent was convinced he needed to update his entire production system, but worried that, “He’d lose his job if automation didn’t work.” At the other end of the spectrum was a small-town plant, Better Living Components. When I suggested that an Easy Set 2000 could easily handle their cutting load, John Nunley, the owner, stated, “Why would I want a saw that isn’t fully automated.” Clearly, we manufacturers had great opportunities ahead, but we would need to overhaul our entire infrastructure to exploit them. The design of the saw itself would prove to be the least of our concerns.

The Cyber Saw’s major components were built on solid ground. The DePauw-inspired mechanisms had proven themselves in hundreds of installations. The electronics were new, but had the backing of GE, one of America’s most revered companies. Troubleshooting was expedited with the PLC’s on-screen diagnostics, that had been lacking with the Easy Set saws. Operator training was minimized by a highly graphical and user-friendly interface. And longevity was assured since GE guaranteed their support for at least a dozen years ahead. This assurance was critical during an era in which PCs became obsolete within 2 to 3 years. Yet with all this capability, one key factor wasn’t yet in place: maintenance support. Unfortunately, this wasn’t an immediate concern.

The first Cyber Saws were shipped early in 1996 to customers like Henry Chambers and Heart Truss & Engineering, who had gained familiarity with the Easy Set 2000 or 3000 saws and were anxious to continue automating. The next several Cybers were shipped around the world and were functioning well. The most important factor in the success of these early installations was their thorough commitment to saw maintenance. These CMs embraced automation electronics and had learned how to care for it. Unfortunately, this capability was in short supply across our industry, and would prove to be our biggest challenge going forward with the Cyber.

Leading up to the 1996 BCMC, the performance of the first Cybers in the field would be critical to the perception of show goers. When Heart Truss was able to cut over 2000 pieces with 500 setups in a single shift, we were able to bring a credible testimonial to the Show. And BCMC didn’t disappoint. The Show had returned to Louisville featuring a full complement of equipment after a two-year hiatus. The Show’s tagline, “Discover the Change,” subtly stoked CMs’ interest in changing equipment, that had already been stimulated by booming truss sales. The result was a highly successful launch of the Cyber, yielding sales that would strain our limited support capabilities, and compel us to borrow another page from the Koskovich playbook.

When Jerry Koskovich sold an Auto-Omni, he required that the saw operator and maintenance person come to his facility for training. There he familiarized them with the unique features of the Omni that otherwise might trouble them. With this innovative approach, he considerably shortened their learning curve and greatly aided in the Omni’s success. Just as importantly, he secured a personal bond between his support people and Omni users. And finally, ingeniously, he had them disassemble their own saw for transport.

Not long after BCMC, Cyber #12 was purchased by Glaize Components in Virginia. They deployed it in their newly purchased plant in rural North Carolina, 400 miles away. Upon delivery, plant personnel rebelled, having played no role in the purchase, and they were able to handicap its successful operation. After multiple (expensive) warranty service calls, we were compelled to rectify this situation. We took our best saw technician, Dennis Kelley, and dedicated him to a training class at our plant. Dennis had been servicing MiTek saws since the DePauw acquisition, and was ultimately able to train an army of qualified Cyber maintenance technicians. And like Jerry Koskovich, we made the training in our plant mandatory. But this was only the first step. To professionally address the coming wave of automation, we made untold investments in facilities, engineering, installation technicians, and help desk staff. Over the succeeding years, the Cyber was upgraded to an Advanced Technology model, the CyberAT, that continues to be shipped today.

Now, 25 years after its introduction, with nearly 700 installations, the Cyber Saw has become the most successful truss machine in the history of our industry. The same modular GE PLC continues to power it, a remarkable distinction for any electronic device. Though the linear saw has risen to achieve a nearly equal role in truss production, the component saw still excels in actual throughput. And further innovation will continue to secure its place in the truss plant of the future.

Next Month:

The Birth of the Linear Saw

Since 1970, Joe Kannapell has worked as programmer, Chief Engineer, Marketing Manager, and Sales VP for MiTek, plus 7 years at truss plants, retiring at the end of 2020.