HELLER solutions at ZF
New 8-speed automatic gearbox produced on the HELLER ModuleLine
The wide variety of parts was to be machined randomly. With ModuleLine, HELLER delivered powerful machining modules for cubic components. Ever since, 750 units per day are machined with cycle times below 100 seconds. Moreover, several variants can be machined at the same time with minimal effort.
Task
- flexible manufacturing system for high part diversity
- "chaotic" production of all variants on one system for just-in-time delivery for assembly
- production with adapters for the highest possible accuracy
- loading and unloading of raw and finished parts in the same place
Project scope & solution
- ModuleLine from HELLER: Powerful machining modules for cubic components, series production
- flexible loading concept: manual and fully automatic
- machining modules arranged on two sides with central, floor-supported loading system
- three handling systems that move independently of one another
- development of a standardized workpiece carrier for a standard clamping concept
Result
- production time of less than 100 seconds
- 750 units per day
- simultaneous machining of several variants without equipment modifications
- due to the high demand for 8-speed gearboxes, the pilot system has been expanded by a second identical, mirror-inverted system
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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