TOPS SOLUTIONS

Overview

- Modular, expandable, integrated, flexible
- Best cost-performance ratio in the market
- Time-proven reliability of systems
- Most popular CAD-CAD package in use today
- Optimized parts flow with minimum handlin
- User friendly interface from machine to machine, easy for cross-training operators

Presentation

What is TOPS ?

TOPS stands for Thibaut Optimized Production Solutions. It is a new manufacturing approach that includes production modules arranged in such a way as to greatly improve your shops’ throughput by reducing material handling between processes. The same system can also improve quality and reduce waste by software nesting and process controls. Proper input at the start of the process eliminates processing errors down stream, and offers consistency of quality.

How does TOPS achieve its aims ?

TOPS owe its success to the concept of direct and continuous feed-through of the materials from their raw stage to their complete transformation into a finished product. This is done while keeping flexibility at each stage of the process : slab quality control and optimization of the cutting plan, choice of process methodology (face up/face down), machining setup while processing, unloading of the finished product with a minimum of equipment idle time.

Alternate processes can also be introduced in the chain of events with practically no interruption in production. For instance, long pieces or backsplashes can be diverted to a dedicated edge polishing machine; the following piece would then proceed towards the CNC center as usual. The diverted piece can, if necessary, be re-injected in the line, passed on to a manual work station for touch-up or simply stocked for eventual shipment.

A Flexible Solution

TOPS can grow with you

TOPS is a modular system, and each of its components can stand on its own without becoming obsolescent. Therefore as you needs grow and/or when your budget allows it, your system can be expanded. Inventory control can also be achieved through the use of bar-coding.

TOPS is flexible

TOPS can be customized to your personal requirements, i.e. two bridge saws, two CNC centers in tandem sharing common ancillary equipment etc. The TC04 Numeric Bridge saw, for instance, is free standing, requires no foundations and can therefore be relocated to suit any new situation.

The links of a Chain

Templating and Layout

At the heart of the system is TiboCAD, a dedicated software for drawing kitchen layouts and that can be fed by any of the several templating systems that can produce a .dxf file. Traditional physical templates can be digitized directly on the equipment for cutting.

Available options include a camera mounted over the saw’s tilting loading table. This takes a digital photo of the actual slab on which any defects can be marked with a grease pencil. The CAD drawing is then superimposed onto the photo and the cutting plan adjusted to both avoid defects and to maximize slab yield.

Programming

TiboCAD‘s integrated package enables programming all the elements of the proposed job, including, in addition to the various shapes, assignment of the individual tools for the CNC center. From this file, a CAM file is derived to drive the actual machines.

Sawing

TOPS feed-through system aims at speeding this critical stage of the job with less lifting of the pieces. A separate tilting loading table precedes the TC04 Numeric CNC bridge saw. This is where the cutting plan is optimized (initial quality control, imaging) before being fed to the saw. Since this operation can be done as the saw is processing a previous cutting sequence, handling time is reduced and actual sawing time is greatly enhanced.

From the saw, the cut pieces are transferred to an exit table where the waste is segregated from the cut elements. Following this table the pieces can be flipped over (for working face down) and directed to an optional dedicated straight edge polisher, or passed through to the T818 M5 CNC Machining Center.

The Thibaut TC04 Numeric is a space saving bridge saw. No foundations are required for its installation. The table is fixed; angle cuts are performed by interpolating the saw’s X and Y axes, while the blade can rotate 360º (“C”-Axis). This arrangement also permits cutting outside radii as small as 10”. The “walls” of the saw are open to permit pass-through of the slabs/cut pieces. This is a tremendous time saver as the slabs are loaded on an external tilting table with rollers, while the saw’s table is used only for sawing.

The TC04 Numeric Bridge saw can be followed by an optional flipping table; this system is used for turning the cut pieces over in order for them to be worked “mirror side down”, useful when slabs vary in thickness.

The transfer between the machines is made thanks to roller conveyors.

CNC Machining

The Thibaut T818 M5 is also built on the “pass-through” principle, with a setup table. This table is equipped with a laser to accurately position the vacuum pods and is located ahead of the machine. Again the result is optimized “machine time”: when the pieces have been machined, they are simply transferred to the unloading table, where they are stripped of their suction pods and directed to shipping or to hand touch up. The freed suction pods are then carried back to the setup table.

The T818 M5 is the result of a comprehensive R&D study and CNC user input. This machine is available with a tilting table and adjustable spindle pressure for surface polishing. It comes standard with 45 tool emplacements, and, with corrosion protection all around and an industry standard software package, it is a logical choice. The table measures 3375 mm x 2040 mm (11 ft x 6 ft-7 in.) with useful stokes of 11-1/2 ft x 7-1/2 ft (X and Y axes) and a vertical movement (Z-axis) of 400 mm (15-1/2 in.)

Edging

While most of the edging can be performed by the T818 M5 CNC, long, straight edging is best done on a dedicated edger (back splashes).

Thibaut’s T55 Advance edge polisher uses flat tooling for all convex shapes such as bullnoses, but will also use CNC tooling, thus ensuring uniformity. The T55 Advance is equipped with an automatic tool changer which houses complete shaping/polishing sequences (up to 16 tools), whether convex (bullnoses) or concave/convex (ogees). All tools are mounted on BT 40 cones, the same as used on all of Thibaut’s machines.

Inventory Management

Using a bar-coding scheme, with readers at the various processing stops, it is also possible to instantaneously keep track of any job, from slab selection, work in progress to finished inventory and shipping. The information can also be useful in the customer file and help in installation scheduling. Similarly, the raw slab inventory can be kept up to date. As this is basically a software upgrade, it can be added upon availability.