Fine tuning for production
A new high speed saw helps a guitar accessories manufacturer cut through a production backlog.
A capotasto, better known as a capo, is a small device designed to quickly change the pitch of a stringed instrument. Used by virtually every musician, from famous touring professionals to campfire players, a capo is an essential tool for every kit.
Kyser Musical Products, founded in 1980 by Milton Kyser, has made a name for themselves as the worldwide leader in capo manufacturing. Kyser has distributed their product throughout the world of music and into the hands of many well-known musicians. From George Strait and Katy Perry to John Mayer and Bon Jovi, Kyser-branded capos are a staple for guitarists, bassists, banjoists, and other musicians seeking to increase command of their instruments.
Handmade in the U.S.A, every capo starts as two cross-sectional aluminum extrusions, each with a different profile. The extrusions are sliced into narrow pieces which are then joined together to make the final clamp-like product.
When David McClung, Director of Safety and Maintenance at Kyser Musical Products, realized production was not keeping up with demand, it became apparent that their sawing equipment just wasn’t cutting it. Their current machine was delivering less than 50% of required volumes, as the saw simply was not fast enough, accurate enough, or consistent enough to get the job done.
McClung needed a solution, but this wasn’t as simple as choosing a new supplier and moving on with production, this was an important capital equipment acquisition. David needed to make an investment, and a good investment requires research. He needed a piece of machinery that would be efficient, dependable, and hold tight tolerances.
Informed decision
When the product you are buying is a critical investment, the value of an informed decision cannot be underestimated. McClung spent a year on research alone, sending out parts, talking to different people, and comparing equipment in his search for a machine that could stand up to his demands.
Kyser searched in many corners of the industry for a machine that could replace theirs and such a venture proved difficult, as McClung explained that he struggled to find a saw that could check off all of his boxes. “The findings were always the same, either they could not cut our smallest parts or they could not get the finish we were looking for,” he explained.
High-volume meant it needed to be fast. Tight tolerances meant it needed to be precise. The saw needed to minimize downtime and waste, while improving the overall quality and consistency of the product.
During the hunt, McClung came across Behringer Saws and he made the call. Within a week, a sales rep had gone out to visit Kyser, which was a first throughout McClung’s year long process with other companies. The sales rep familiarized himself with Kyser’s process, took samples of their materials, and was on his way back to Behringer to begin testing.
With this information in mind and having run tests on every one of Kyser’s materials, Behringer was able to recommend the VA-L 560NC, a circular cold saw specifically geared towards aluminum and tailored to Kyser’s specific production needs. “We can control RPM, feed rate, oil spray, PSI on the grippers, which allows for the best possible finish”, McClung pointed out. A few months later, McClung and his team were headed to Behringer with more samples to see the machine in action.
Behringer demonstrated the saws capabilities, showing off the versatility and ease of controlling the equipment, and proving that the saw was up to the challenge. With Behringer’s Control System, it made it possible to get precision and speed. The systems are freely programmable and allow for several different piece number and length combinations during a single run, which suited Kyser’s need for flexibility.
High speeds
Capable of running at speeds up to 800 – 3400 RPM, the VA-L 560 was able to improve production by up to 75%, according to McClung's team. When asked what has made the biggest difference, Waylon Alexander, Director of Operations, answered, "the speed and output without the sacrifice of quality. Less down time has put us in a position to run the saw less [sic] hours in the work week".
But a good investment in capital equipment is more than the quality of the machine itself. A testament to the retained value of a Behringer saw is seen in the continuation of technical support nationwide, for the lifetime of the machine.
Almost as important as the machine itself is the ability to rely on experienced technicians who can help when the equipment needs servicing. As with every purchase of a Behringer saw, a tech was sent out for the week to assist Kyser with setting up the equipment and training its employees on how to properly operate the saw.
“The company that we had purchased from previously could not or did not know how to fix any problems that had developed over the few years”, notes McClung. “Behringer’s customer service, by far, is above all others”.
Now, while celebrating their 40-year anniversary, Kyser Musical Products is well-positioned to support their continued growth and to satisfy the needs of their musician customers!