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A smooth skate to faster Canadian hockey rink board manufacturing with SOLIDWORKS

Hockey rinks have come a long way since the wood and chicken-wire fence of the early days. As the preferred rink equipment supplier to the National Hockey League (NHL), Sport Systems Unlimited Corp. is leading the effort to produce rink board systems that look better, last longer, and are easier to maintain.

Sport Systems Unlimited implement SolidWorks 3D design software to drive robotic production for their Canadian hockey rink board manufacturing.

Sport Systems Unlimited implement SOLIDWORKS 3D design software to drive robotic production for their Canadian hockey rink board manufacturing.

One of the fastest-growing companies in Canada, Sport Systems Canadian hockey rink board manufacturing feature mechanically fastened anodized aluminum frames, high-density polyethylene puckboard, tempered safety glass, and stainless steel hardware.

While the aesthetics of the company’s board systems have dramatically improved over the years, production processes remained relatively unchanged until management adopted a lean manufacturing philosophy in 2005. Before then, Sport Systems Unlimited used AutoCAD® 2D design tools and manual techniques to manufacture its board systems. The manufacturer’s adoption of a lean manufacturing methodology required a move to 3D.

“We needed to take advantage of robotic automation to make manufacturing more efficient, our objective was to automate production so we could shorten cycles, control costs, and increase capacity. Achieving consistent quality and expanding into new markets were also goals of our lean manufacturing approach.”

Sport Systems Unlimited chose to implement SOLIDWORKS® 3D design software as the cornerstone of its lean manufacturing initiative because the software is easy to use and can drive the company’s manufacturing processes, automatically generating robotics and CNC code from 3D solid models. The hockey boards manufacturer also acquired DriveWorks® knowledge-based engineering software, a Certified SOLIDWORKS Gold Partner Product, to automate the configuration of customized board sizes.

“Increased capacity was the key for us,” notes David Staines, director of sales and marketing. “We believed that the move to SOLIDWORKS software would support our lean manufacturing transformation and help us grow as a company.”

Automating robotic production saves time

Using the SOLIDWORKS Visual Basic® for Applications Interface, Sport Systems Unlimited automatically creates tool paths and instructions for its CNC machines and robotic systems directly from SolidWorks software models. By automating its manufacturing processes, the company has slashed production time for custom rinks from 1,200 staff-hours per rink in 2006 to 450 staff-hours in 2009, a 62 percent reduction in production time.

“Switching to SOLIDWORKS software was a critical move in our manufacturing transformation,” Henhoeffer stresses. “SolidWorks software streams data out to our robot and CNC machine, and our line workers simply set up raw stock, punch in the SolidWorks software part code, and watch as the panel, part, or aluminum member is machined in a fraction of the previous time.”

“When we have the raw material in stock, we can deliver a rink in just three days,” Staines notes. “This allows us to shorten delivery times, which provides added value to our customers.”

Consistent quality, better throughput support sales growth

With shorter manufacturing cycles, Sport Systems Unlimited has increased throughput at its 28,000-square-foot production facility. The number of dasher board systems that Sport Systems Unlimited produces has risen steadily year after year; in 2009 their throughput was more than three times what it was in 2005. Using SOLIDWORKS software, the manufacturer has increased capacity without adding resources or sacrificing quality. In fact, because Sport Systems Unlimited has automated its processes—with tighter control of accuracy and repeatability—the quality of its products has actually improved.

Lean manufacturing helped Sport Systems to acheive a 62 percent reduction in production time

Lean manufacturing helped Sport Systems to acheive a 62 percent reduction in production time

“We can now produce more hockey board systems more efficiently with the same amount of staff and virtually no overtime, all of which sets us apart in the industry,” Staines points out. “Our sales go up year after year, and our lean manufacturing operation allows us to control costs and grow the business. We estimate that we now have 35 to 40 percent of the Canadian market, and 22 of the 30 arenas in the NHL have our board systems installed.”

Increased capacity drives entry into new markets

The transformation of Sport Systems Unlimited’s production into a lean manufacturing operation has enabled the company to not only grow its core business, but also expand its product line. “Lean manufacturing, robotics, and SolidWorks software have allowed us to branch out into new markets like indoor soccer, one of Canada’s fastest-growing sports, and even pharmaceuticals, where our partitions prevent cross-contamination of drug batches,” Staines explains.

Lean manufacturing, robotics, and SolidWorks software have allowed Sport Systems to branch out into new markets like indoor soccer, one of Canada’s fastest-growing sports

Lean manufacturing, robotics, and SOLIDWORKS software have allowed Sport Systems to branch out into new markets like indoor soccer, one of Canada’s fastest-growing sports

“The improvements we have made enable us to do more research and development into how we can apply our core expertise in other areas,” adds Henhoeffer. “Working in 3D also has enhanced our ability to visualize and develop new concepts, and then show them to potential customers. This allows us to stimulate interest and secure business without having to make significant capital investments up front.”

Challenge:

Make the production of hockey rink board systems more efficient to shorten manufacturing and delivery times, control costs by reducing errors and rework, and support expansion into new markets.

Solution:

Implement SOLIDWORKS 3D design software to drive robotic production of hockey rink board systems.

Results:

  • Cut production time by 62 percent
  • Tripled manufacturing throughput
  • Achieved 40 percent share of Canadian market
  • Expanded into new markets

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