Bell Equipment Increases Fabrication Productivity by More than 200%

Bell Equipment is a global original equipment manufacturer (OEM) serving the mining, construction, forestry, and agriculture industries. Operating in more than 80 countries and employing over 3,500 people worldwide, the company depends on efficient fabrication processes to meet customer demand and maintain production schedules. When bevel cutting became a manufacturing bottleneck, Bell Equipment turned to Hypertherm plasma technology to dramatically improve throughput and productivity.

CHALLENGE

Eliminating a bevel-cutting bottleneck to support growing production demands

Bell Equipment's weld-preparation process had become a significant production constraint. To avoid slowing its XY plasma cutting tables, the company relied on an oxyfuel track burner for bevel cutting. Parts were manually positioned and rotated to create bevels on multiple sides, resulting in lengthy setup times and inconsistent throughput.

Some bevel-cutting work was outsourced to keep pace with demand, increasing both cost and lead time. Even with outsourcing, production delays persisted due to slow oxyfuel cutting speeds, extensive grinding requirements, and rework caused by bevel-angle inconsistencies and dross buildup.

SOLUTION

Deploying two robotic plasma cutting cells powered by Hypertherm technology

To eliminate the bottleneck and improve manufacturing efficiency, Bell Equipment developed two robotic cutting cells. One cell was equipped with a Hypertherm MAXPRO200^® plasma system, while the second utilized a Hypertherm Powermax105^® system. Learn more about robotic plasma cutting.

Each cell features three worktables, allowing operators to fixture up to 15 different parts at a time. This configuration supports continuous loading and unloading, maximizing equipment utilization and enabling higher production output.

ADVANTAGE

Tripled weld-preparation productivity while eliminating a critical bottleneck

By combining cutting and weld preparation into a single automated operation, Bell Equipment transformed a formerly labor-intensive process into a streamlined manufacturing workflow.

Compared with the previous oxyfuel process, robotic plasma cells:

• Deliver more accurate bevel cuts

• Operate 3 to 5 times faster than the previous process

• Reduce grinding, cleanup, and other secondary operations

• Produce many parts that are ready for welding immediately after cutting

• Improve labor efficiency and operator safety

The results were substantial. Bell Equipment estimates overall productivity has increased by more than 200%, while weld-preparation productivity has tripled. Improved production flow, reduced reliance on outsourcing, and the proven reliability of Hypertherm systems have positioned the company to support future growth with confidence. As Bell Equipment evaluates additional robotic cutting capacity, Hypertherm remains a trusted technology partner.