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PRODUCTIVE TOOL CASE STUDY

By Jimmy Myers

As of 2022, the Solar Energy Industries Association estimates that the solar industry has roughly 263,000 employed in more than 10,000 companies. It's also estimated that in 2022 the sector generated more than $36 billion in private investments in the American economy. The growth pattern has been dramatic. Don Whitmire, a retired defense contractor, saw an opportunity around 2017 when he joined his friends at Productive Tool as chief operating officer.

Productive Tool, a Dallas, N.C.-based machine shop, had dabbled in defense contracts, which is how Whitmire struck up a professional friendship with Chris Brooks, owner, and Amy Prince, vice president. With roughly $1 million in annual revenues when Whitmire began, he set out to identify growth opportunities, and he knew solar could be incredibly lucrative for the company.

The research paid off, as the 7,000-square-foot shop has grown into a 36,000-square-foot facility that produces aluminum framing upon which solar panels are affixed. Whitmire says the growth, culminating in the company processing around a million pounds of raw goods per month and annual revenues of $20 million plus, wouldn't have been possible without implementing automated sawing, tapping, and drilling solutions custom-made by Pat Mooney Saws.
“Right now,” Whitmire says, “in our production space, solar occupies 100 percent of our total capacity. The industry is growing, and I don't see that ending in the next 36 months. Solar is an effective way to collect energy, and it's moving its way across the country.”

INITIAL INVESTMENTS

There is a lot of pride associated with buying American-made products, but because of international competition, many challenges must be overcome to be profitable. Whitmire knew that for his company to compete against China, India, and Vietnam, among others, automation would be the key.
“That was the only way we could do this work,” he says. “We can't compete dollar to dollar with labor, but we can compete with technology. We knew we would have to make an investment on the front end to allow us to do this.”
In the beginning, Whitmire attended trade shows, researching technology that would give them a fighting chance to produce parts at volume and be profitable. Eventually, he developed a vision where an automated process involving as few touchpoints as possible would efficiently turn out a high-quality product. His research led him to Patrick Thornton, Vice-President at Pat Mooney Saws. During that first conversation, Whitmire told Thornton he needed a machine to tap, drill, and saw.
“He said, ‘We don't have that, but I can tell you - 100 percent we can do it,'” Whitmire says. “About 8 months later, two showed up at the shop, and we got started.”

PAT MOONEY SAWS MACHINES

For years, Boltswitch regularly attended IMTS and FABTECH searching for a machine capable of meeting their unique copper-cutting requirements.

Nothing they encountered delivered the combination of speed, cleanliness, and precision they needed — until they visited Pat Mooney Saws for a live demonstration of the PMI-NC24 LS-Type High-Speed Circular Saw.

What they saw changed everything.

“There, Patrick Thornton demoed a PMI-NC24 LS-Type High-Speed Circular Saw that cut copper in 10 seconds. Our mouths dropped open,” Kingston said.

The Solution: PMI-NC24 LS-Type High-Speed Circular Saws

Boltswitch purchased two PMI-NC24 LS-Type High-Speed Circular Saws last year, replacing three of their bandsaws.

The impact was immediate.

Faster Throughput

The PMI-NC24 LS-Type machines transformed copper processing productivity throughout the operation.
• One bar that previously required all day now takes roughly one hour
• 12-foot copper bars are processed in approximately 10 minutes
• Copper tube drop-offs that were impractical to cut with bandsaws are now completed in less than an hour
• Cuts that previously took several minutes on a bandsaw were completed in seconds.
“The PMI-NC24 LS-Type machines were a blessing,” said Kingston, “The same volume of work that used to take us over two weeks with four band saws now takes four days with two PMI-NC24 LS-Type machines.”

The contrast to their existing process was dramatic.

Most importantly, the saws completely eliminated a longstanding production bottleneck.

Cleaner Cuts, Better Accuracy, and Improved
Working Conditions

Beyond speed, the PMI-NC24 LS-Type machines delivered significant improvements in cut quality and shop conditions.

Boltswitch immediately noticed:
• Cleaner cuts
• Greater cutting accuracy
• Reduced airborne dust and mist
• Quieter operation compared to older cold saw technology
Initially, Boltswitch had concerns about the machine’s large air filtration system.

“Part of my concern when we were purchasing was the air filter. It’s nine feet tall, and I was a little apprehensive about that. But it does a great job - no mist coming out of the saws,” Kingston noted.

The minimal coolant usage also created unexpected advantages for operators.

“Because the coolant is used so sparingly, there’s no need to wipe down the parts after cutting; they come out clean and dry,” Kingston explained, “Even after cutting thick copper materials, the parts remain cool to the touch. You’d expect them to be warm, but that’s not the case at all. The operators really appreciate this feature.”

Operator-Friendly Design Improves Daily Workflow

Boltswitch also praised the machine’s ease of use and thoughtful engineering.

Intuitive Controls

The HMI control system made it easy for operators to program and repeat jobs efficiently.
• Programs can be stored for repeat work
• Operators can quickly adapt to different material sizes and cut lists
• External software optimizes material usage and cut sequencing
“We move the copper material to the drop stop, hit start, make an end cut, and keep going until it’s done.”

Service and Support That Continued After Installation

Boltswitch emphasized that the support from Pat Mooney Saws extended well beyond the installation process.

After setup, Pat Mooney Saws provided advanced operator training and followed up later to answer adjustment questions and ensure optimal machine performance.
The machines have proven highly reliable.

“We haven’t had to order parts.”

Boltswitch now sends all blades, including those from other brands in the facility, to Pat Mooney Saws for sharpening.

Looking Ahead

The success of the PMI-NC24 LS-Type machines has already influenced Boltswitch’s future equipment plans.

The company is currently looking to purchase a PMI-20 24 upcutting machine in the next fiscal year.

“We’ve been tickled pink by the PMI-NC24 LS-Type machines.”
-Mark Kingston, Boltswitch

Results at a Glance

Before PMI-NC24 LS-Type

• Multiple bandsaws required to maintain throughput
• One copper bar could take an entire day
• Excessive cutting time on trim operations
• Dusty, noisy cutting environment
• Major production bottleneck

After PMI-NC24 LS-Type

• Copper cutting dramatically accelerated
• Cleaner, more accurate cuts
• Reduced labor and handling
• Cool, dry parts directly off the saw
• Bottleneck eliminated
• Two weeks of work reduced to four days
• Planning future machine purchases

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