HELLER solutions at MAN
Successful product and process development of an ultra-modern 6-cylinder diesel engine
The manufacturing task concerned 6-cylinder diesel engines with common-rail technology. HELLER contributed the entire know-how for the required modifications resulting from ongoing product and process development. The result are four transfer systems comprising four to six machining stations and 18 MCH 400 machining centers.
Task
- production of a 6-cylinder diesel engine with common rail technology
- product and process development (simultaneous engineering)
- high flexibility and comprehensive engineering know-how
Project scope & solution
- four "FST" transfer systems, each with four to six machining stations and 18 MCH 400 machining centers
- material transport with "lift-and-carry" system or linear loader
- in-process gauging for comprehensive quality assurance
Result
- 25% fewer components
- weight saving of 100 kg per engine
- compliance with all existing and future emission standards
- extension of maintenance intervals to 120,000 km
- 5% less fuel consumption
More references
Peter Arnold
Head of Mechanical Manufacturing at Komax
"If you have to deal with 30 pallets containing, at times, up to 50 different clamping points per clamping cube, you need the right tools in the magazine to avoid having to constantly change the tool sets. Our tool count currently stands at 409. Comparable or smaller machines simply do not achieve capacities such as these."
Günter Muhr
Managing Director at Franz Haas Waffelmaschinen
"HELLER has exceeded our expectations. Everything went well, the machines run extremely reliably and our throughput times have also measurably reduced."
Thomas Kaysser
Managing Director at H.P. Kaysser
"Our experience with HELLER, including Service, has been nothing but positive. We speak the same language, so there was simply no reason to change supplier. The entire team has now identified with the HELLER machining centers – because they deliver what HELLER promises!"
Frank Brunner
Head of Manufacturing and Production Engineering at Bitzer
"For me, it was much more important to have found, in HELLER, a manufacturer whose machines are able to meet our high standards without extensive options."
Gerhard Aigner
Head of Production at Engel Austria
"We consider quality to be fundamental. The tolerances for our core components are between two and three hundredths of a millimeter. That's why we made the conscious decision to go for HELLER machines, which are renowned for their stability."
Nicholas Warnken
Nicholas Warnken, Project Manager
"Key contributors to these massive savings are fewer setups thanks to the 5th axis and higher achievable cutting parameters. On the other hand, however, it was the overall package, including the automation system and new tool technologies, that was able to optimize the processes in this way."
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