It is machine spindle hours that generate income. Thanks to automation solutions from System 3R, Trimatec is now achieving 70 percent more hours than one and a half years ago – even though short series and one-offs make up the company’s output.
“In our industry, everyone is seeking increased productivity,” explains owner Alfons Hillebrand. “The constant question is, ‘How do I get more spindle hours out of my machines?’ We considered automation as early as 2006. At that time, not many in our industry were thinking along those lines. Since last year, we have had automated pallet changing for two of our milling machines. This enables us to produce at night and over the weekends. With the same workforce, spindle hours have increased 70 percent!”
The “Nordwalde ship” is now one of the area’s landmarks.
Trimatec’s operations are devoted entirely to stock removal. Short series of complex components are delivered to customers primarily in tool production, medical technology and machine manufacture. “In this niche, when it comes to quality and flexibility, we have, practically speaking, no competitors. However, we also have no room for machines to be idle for long periods,” emphasises Hillebrand.
Eleven years ago, backed by his thorough experience in machine manufacture and business administration, Hillebrand decided it was time to start his own operations. He set up Trimatec Mechanische Systemtechnik GmbH in Münsterland, between Osnabrück and Münster. “I started in old factory premises with one coworker and two CNC controlled machining centres,” relates Hillebrand. The firm has grown steadily to 20 coworkers and a modern fleet of machines – three lathes and eight milling machines.
The company’s uniqueness and go-ahead spirit have set their stamp on its new premises. Ready in 2004, these are shaped like a ship. In the beginning, they were regarded with a certain degree of scepticism, but have now become a local attraction. Everyone in the area knows the “Nordwalde ship”.
Alfons Hillebrand: “With the automated production cells, we are also more flexible than ever.”
Hillebrand: “The building’s shape and the surrounding artificial pond exemplify the company’s philosophy – we are all in the same boat and we must always have a hand’s breadth of water under the keel! Each employee is an important part of the company’s development and success.”
Correct navigation is, however, vital. Hillebrand is convinced that short-series production and one-offs are the future. “Components are becoming ever more complex and it isn’t everyone who dares take them on,” reveals Hillebrand. “We are often presented with things where standard solutions are insufficient. We have to be innovative and react quickly to customer wishes.”
Hillebrand pondered how dead time could be reduced. “Shifts were one solution, but skilled personnel are in short supply. In addition, information transfer and control can be problematic with shifts. We chose continued single-shift operation complemented by automated production. There were several options for this, but we liked System 3R’s comprehensive automation solutions best. Furthermore, they’re particularly good for short series and one-offs.”
The proposed pallet system was first tested manually. Shortly thereafter, it was decided to upgrade a DMU 50eVolution with System 3R’s simplest pallet changer, WorkPal Compact Servo. “This cell has now been in operation one year and the machine’s spindle hours have increased 60 percent. During the day, we run components that have short machining times. We also prepare the night runs – components that have long machining times. Series size is normally 2 to 3 pieces.”
The operators are also enthusiastic. “After only a few days, an operator came to me and said, ‘This is fantastic,’” states Hillebrand. “Any fears that robots would take their jobs have been transformed into increased job satisfaction. Operators still take care of the creative part of the work, but the tiresome loading and unloading of workpieces has been transferred to robots. Even when the operators have gone home for the day, the cell steams on.”
The positive results from this automated production cell led rapidly to a second cell being taken into use. At installation, a brand new DMG machine was equipped with a WorkPartner with 25 magazine places. “In this cell, which has considerably greater capacity, we run, for the most part, short series,” says Hillebrand. “The increase in spindle hours has already reached 70 percent.”
“The be all and end all for increased productivity are, nonetheless, good planning and preparation. Rather than tackling operations in chronological order, it’s a question of combining them to maximise use of the available resources. For example, if we have a series of 20 components, we divide them up into several batches. This is partly to ensure that the machine has work throughout the night and partly to avoid the need for 20 identical fixtures. Furthermore, we can then modify job priorities whenever we wish.”
Work allocation that gives greater job satisfaction – operators take care of the creative, robots the tiresome.
Trimatec’s increased productivity is to the benefit of its customer base. “Good quality and high delivery dependability create good relationships, not to say partnerships, with customers. We’ve never actually had a ‘one-job’ customer. We are what we are – we manufacture complicated components and are receptive to customer wishes. Now, with the automated production cells, we are also more flexible than ever,” concludes Alfons Hillebrand.
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