HELLER solutions at Hansgrohe
High availability and flexibility
Hansgrohe SE ranks among the world's leading manufacturers of taps and showers worldwide. The company manufactures products characterized by quality, functionality, and design. Diversity in product design therefore calls for a high degree of flexibility. In 1995, the company made just 60 different versions at its factory in Schiltach. Today, there are 250 designs. To handle this variety, the company relies on 13 machining centres, 11 of which are from HELLER. The six H-series 4-axis machining centres are particularly impressive.
Task
- small batch sizes have to be realised at short notice through fast response times and high flexibility
- 250 versions of mixers with batch sizes of between 100 and 1,500 units
- design-oriented products present new challenges for machining complexity, contours change, components require contour cutting
- due to the broad product diversity, short setting times are also key
- process reliability is much more important than chip-to-chip times
Project scope & solution
- eleven machining centres, six of which are type H 2000
- 80 tool pockets in the standard version
- pallet changer for setting during the production process
Result
- compact 4-axis machining centres boast extremely stable and reliable axes
- over 90 percent availability
Customer testimonial
Christian Lang
Head of the Mechanical Machining Department at Hansgrohe
"The pallet changer allows us to set up a large variety of models even while production is running. In other words, the setting process occurs at the same time as production. These machining centres achieve an availability of over 90 percent, so we supply all of our customers on time."
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 centres – because they deliver what HELLER promises!"
Frank Brunner
Head of Manufacturing and Production Engineering at Bitzer
"For batch sizes of up to 3 components, the machining centres have to perform reliably as soon as they are switched on, even after scheduled shutdowns. But neither availability nor the required precision presented a major challenge to the H 6000."
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 millimetre. That's why we made the conscious decision to go for HELLER machines, which are renowned for their stability."
Nicholas Warnken
Project Manager at Fette Compacting
"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 optimise the processes in this way".
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