Ball Service Group Expands Operations with High-Tech Investments

Kitchener, Ontario-based Ball Service Group (BSG) is enhancing its manufacturing capabilities through significant investments in high-tech machinery and precision tools. Founded in 1987, BSG has built a reputation in the automotive industry for developing material handling systems. The company has grown substantially since relocating to Kitchener in 2000, now operating from a 44,000-square-foot facility equipped for both heavy fabrication and precise assembly projects.

In 2020, BSG was acquired by Waterloo, Ontario’s EXEL Research, which aimed to foster growth and innovation in the manufacturing sector. President Jeff Benham, who has been with the company since 1991, emphasized the importance of this transition. “They were keen to buy a company that they could grow, which was important to the original owners,” Benham stated. Under this new ownership, BSG launched a design and assembly division that incorporates cutting-edge 5-axis machining and carbon fibre 3D printing capabilities.

Investing in Precision

One of the most notable additions to BSG’s fabrication shop is the 9-kW AMADA ENSIS 3015 RIe, a hybrid fibre laser cutting machine that enhances the company’s cutting precision. This investment aligns with BSG’s commitment to delivering high-quality assemblies. “When we build carriers for automotive parts, the repeatability and tolerance between the first frame and the last frame is less than a millimeter,” Benham explained.

Another key investment is the acquisition of Siegmund welding tables through BTH Sales, which have been instrumental in refining the company’s fabrication processes. Benham first encountered these tables during a tour of a customer’s operations in March 2024 and was impressed by the positive feedback from fitters. This prompted the purchase of several tables, starting with two 1,500 by 3,000 mm tables in April 2024, followed by additional tables and tooling carts in subsequent months.

Immediate Benefits

The introduction of Siegmund tables has yielded immediate benefits, particularly in accuracy and efficiency. “The increased accuracy due to the precision of the tables allows us to build more accurate, repeatable fabrications,” Benham remarked. The streamlined process has reduced the need for custom fixtures, minimizing labor intensity and freeing up valuable shop space.

Previously, BSG had to build and store numerous fixtures for various jobs, which often resulted in waste when designs changed. Now, the company can replicate setups more efficiently, enhancing both the quality of their work and the overall workflow. “Sometimes we’ll take a picture of the setup and place that in our files for future reference,” Benham added, highlighting the practicality of their new approach.

This newfound accuracy also translates into cost savings. With the ability to achieve high tolerances directly with welding fixtures, BSG can avoid the additional step of machining locator holes on larger machines. “If you can achieve that same tolerance on a welding fixture, you can save a lot of time and money,” Benham stated.

Training and Team Dynamics

The Siegmund tables have also improved the training process for new employees. BSG has found that less-experienced workers achieve better fitting results when using these tables. “Giving them good tools to work with increases their chances for success and helps them improve,” Benham noted, especially as the industry faces challenges in finding skilled labor.

Additionally, the standardized tools foster knowledge-sharing among team members, creating a cohesive work environment. “Customers come for site visits to see prototypes and check products. When they see the precise fit-ups we’re building, they feel more confident in their investment with us,” Benham remarked.

Innovation with Cobots

BSG has also integrated a collaborative robot (cobot) into its processes, further enhancing operational efficiency. Benham chose to use a Siegmund table to maintain standardization instead of opting for a table provided by the cobot vendor. “The cobot is ideal for those monotonous jobs. We want to hire people to do the more complex fit-ups,” he explained.

Even in a custom environment, Benham is optimistic about the opportunities the cobot presents. “There is so much innovation you can add to a cobot,” he said, indicating that the future holds promise for further integration of automation in their operations.

The Human Element

While technology plays a crucial role in BSG’s success, Benham emphasizes that the company’s people are its greatest asset. “You can buy all the technology you want, but you must have the people to run it,” he stated. He believes in promoting a collaborative culture where all employees, regardless of experience, can contribute ideas and feel invested in the company’s vision.

This approach not only retains existing talent but also attracts new employees, ensuring that BSG remains competitive in a challenging market. As the company continues to innovate and expand its capabilities, the commitment to its workforce and their development remains at the forefront of its strategy.

For further information, visit Ball Service Group at www.bsginc.ca and BTH Sales at www.bthsales.ca.