HELLER solutions at Siemens
HELLER convinces with absolute precision
This presented a special challenge: First of all, we had to find suitable machines with the right processes in order to meet the accuracy specifications. The original solution was based on various machine concepts and, for the automation system, a simple pallet magazine. Then, however, the project evolved into an integrated network with three HELLER CP 2000 5-axis milling-turning machining centers and the Multi Level System (MLS) from Fastems.
Task
- The requirements of the standards can be fulfilled only with absolutely precise and extremely accurate production.
- Economic production must be guaranteed, even with diameter tolerances of 9 μm and qualities in the range of IT 6 and higher, which have to be reliably produced with a corresponding machine capability of Cmk 1.67.
- production of a diverse range of parts (over 500 types) in small batch sizes (up to 30 items)
- shorter setting time and increased efficiency overall
- just-in-time production for assembly
Project scope & solution
- three CP 2000 5-axis milling-turning machining centers plus a a MLS (Multi Level System) from Fastems
- MLS-LD (Low Duty) from Fastems offers, with a load capacity of 700 kg per pallet, space for a total of 72 machine pallets and integrates two high-precision setting stations
Result
- overall system availability of 95 percent
- 20,000 spindle hours per year by reducing setting times and increasing machining times
Customer testimonial
Rolf Gritl
Head of Industrial Engineering at Siemens
"Our biggest challenge is accuracy. [...] We knew that this would be difficult to achieve. However, we produce a diverse range of parts (over 500 types) in small batch sizes (up to 30 items). Reliably achieving the tolerances we require is difficult. By investing in new machines, however, we also wanted to reduce setting times and efficiently increase the machining times."
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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