Bulgaria
Alcomet AD
Seat:
Shumen
Year established:
1981
Number of employees:
1500
Industry segment:
E-automotive
Final products:
Various components for e-automotive
Final customers:
Automotive
Machinery:
Machining centres H 2000
Initial situation
Starting position of the customer: new investment, no know-how in the field of CNC series production available yet
Requirements: machines for processing aluminium for series production
Why HELLER
Known quantity in the automotive world, reliability
Order
Scope of delivery: H 2000 with Siemens control
Workpiece and clamping situation: terminal strip, aluminium; hydraulic multiple clamping (by Paatz)
Production volume: high volume production (over 100,000/year)
Specialty: high production
Evaluation
Challenge: achieve series production readiness
Result: almost all components on series status
Great Britain
Meritor HVBS (UK) Ltd.
Seat:
Cwmbran, Wales
Year established:
1937 (1999 acquisition by Meritor from Lucas Varity)
Number of employees:
400 in the UK, over 8000 globally
Industry segment:
Automotive
Final products:
Pneumatic disc and drum brakes
Final customers:
Volvo, MAN
Initial situation
Starting position of the customer: new investment, replacement investment
Requirements: productivity increase, complete solutions, first-class service, HSK100A spindle, 50% reduction in cycle time
Why HELLER
Local machine tool manufacturer, complete solutions, local engineering team, first-class service
Order
Scope of delivery: nine H 4500, two H 4000 planned for 2022
Workpiece and clamping situation: cast iron axle beams in single clamping
Production volume: high production (1 m/year)
Evaluation
Challenges: non-stable workpieces, cycle time, quality restrictions
Result: Reduction of cycle time through the combination of working processes, a stiffer clamping device and the use of the latest cutting tools
Germany
Manfred Martin GmbH
Seat:
Rot an der Rot
Year established:
1958
Industry segment:
General mechanical engineering
Final products:
Contract manufacturing
Final customers:
Various
Machinery:
Mill-turn machining centres
Initial situation
Starting position of the customer: new investment
Requirements: flexibility, accuracy, expansion possibilities
Why HELLER
Reference, trust
Order
Scope of delivery: HF 5500, pallet automation will possibly be retrofitted, maintenance contract
Workpiece and clamping situation: predominantly aluminium enclosures in various sizes; multiple clamping
Production volume: one-off and small batch production
Specialty: 5-axis machining with angular head
Evaluation
Challenges: detailed advice on workpiece machining, feasibility study
Result: time, cost and quality benefits
Poland
Gebrueder Peitz Polska Sp. Z o.o.
Seat:
Żory
Year established:
1997
Number of employees:
210
Industry segment:
Process engineering, contract manufacturing of complex components
Final products:
Ready-to-assemble powertrain components for e-engines, various housings for combustion engines, cylinder heads, cylinder crankcases, suspension components, component assembly
Final customers:
Automotive industry and Tier1 suppliers
Machinery:
Fully automated 4- and 5-axis machining lines, rotary transfer machines, assembly machines
Initial situation
Starting position of the customer: expansion of activities in the field of electromobility for electric drive systems and electric vehicle components
Requirements: increasing demand for degree of completion, extreme competition with continuous optimisation processes and rapidly changing component quantities
Why HELLER
Long-term and honest partnership, easily accessible and quickly available service, positive further development of proven 4- and 5-axis series, guarantee of highest reliability and availability, high flexibility
Order
Scope of delivery: over 80 machines; MC 16, MCi 16.2, MCi 25, MCi 25.2, MC 200, MCH 250, MCH 280, MCH 280C, H 2000, H 3000, H 4000, H 5000, HF 3500
Workpiece and clamping situation: aluminium and steel castings and forgings; single and multiple clamping
Production volume: medium and large batch production
Specialties: 5-axis machining, high-precision machining, high production etc.
Evaluation
Challenges: highest reliability and availability absolutely necessary, drives and chip removal must fit 100%, 24/7 usability of the solution is indispensable
Result: time, cost and quality benefits
Italy
Marzocchi Pompe S.p.A.
Seat:
Zola Predosa (Bologna)
Year established:
1949
Number of employees:
271
Industry segment:
Hydraulics for industrial, mobile and automotive applications
Final products:
External gear pumps and motors
Final customers:
Industrial, mobile and automotive OEMs, distributors and resellers of hydraulic equipment
Initial situation
Starting position of the customer: new investment
Why HELLER
Historical partnership, system competence, experience, technology, consulting, machine programme and much more
Order
Scope of delivery: four H 2000 wir SPEED package, SC63 Speed Cutting spindle, tool chain magazine with 160 places
Workpiece and clamping situation: aluminium housing gear pump; single clamping
Production volume: small, medium and large batch production
Evaluation
Challenge: management of the manufacturing processes
Result: more flexibility, efficiency and quality
USA
Cummins Rocky Mount Engine Plant
Seat:
Whitakers, North Carolina
Year established:
1979
Number of employees:
1800
Industry segment:
Engines business unit of Cummins Inc.
Final products:
On-highway and off-highway diesel engines (60-600 hp)
Final customers:
Over 530 customers, including Daimler, Freightliner, Navistar, Blue Bird, Komatsu, Kenworth, Peterbilt, New Flyer and International
Machinery:
CNC machines and special transfer machines
Initial situation
Starting position of the customer: planned new investment in a 9-litre cylinder head production line to replace the existing 35-year-old transfer line
Requirements: flexible 9-litre cylinder head production line suitable for both existing and new cylinder head generations
Why HELLER
New partnership, customer recommendation, system competence, experience, technology, consulting, machine programming, integration experience
Order
Scope of delivery: nine H 8000 DL, three F 8000 DL, one H 8000, one FP 8000, Liebherr gantry automation, Reinhart robot rail system (from customer)
Workpiece and clamping situation: cast-iron 9l diesel cylinder head with several part types; single part clamping
Production volume: one-off production of 40,500 units/year
Specialties: flexible CNC machining line that can completely machine 9l cylinder heads in moderately high quantities
Evaluation
Challenge: integration of multiple suppliers that were not part of HELLER’s original scope of work, which required close coordination with the Cummins project team
Results: production rates, cost reductions, quality advantages and reduced missing parts
Brazil
Pontual Tecnologia Em Manufatura Ltda.
Seat:
Erechim (Rio Grande do Sul)
Year established:
1999
Number of employees:
110
Industry segment:
General mechanical engineering
Final products:
Cast and machined parts as well as machined and assembled subassemblies
Final customers:
Commercial vehicle industry (heavy automotive), agriculture and general mechanical engineering
Machinery:
(4-axis) CNC machines
Initial situation
Starting position of the customer: new investment to increase production
Requirements: better quality and higher machine performance
Why HELLER
Known for special quality machines with low downtime as well as good technical support and spare parts; robust machines suitable for machining cast iron and with a good cost-benefit ratio
Order
Scope of delivery: two MCi 28, one MCH 350, two H 4500, training in operation, programming and maintenance
Workpiece and clamping situation: cast iron; hydraulic
Production volume: around 30,000 parts/month in two-shift operation
Evaluation
Challenge: expectation of increased quality and shorter processing time
Result: better conditions in terms of productivity, repeatability and performance
China
Bosch Rexroth Co., Ltd.
Seat:
Changzhou
Year established:
1996
Number of employees:
500–1000
Industry segment:
Hydraulic components
Final products:
Standard and special applications of hydraulic cylinders
Final customers:
Haitian Group, Estun Automation Group
Machinery:
CNC machines
Initial situation
Starting position of the customer: high accuracy, short delivery times, high cost performance
Requirement: improving production efficiency and reliability
Why HELLER
The quality and service of HELLER machines have proven themselves time and again over the years of cooperation. The stable performance, excellent accuracy, fast response and proximity to the site make HELLER competitive.
Order
Scope of delivery: H 6000
Workpiece and clamping situation: hydraulic block; tower clamping device with high pressure, three OPs combined in one device
Production volume: continuous production of large batches
Specialties: efficiency and high accuracy
Evaluation
Challenge: short delivery times, high precision and good quality required
Results: higher productivity and time savings
