Standardised management for high flexibility
Euler Feinmechanik machines roughly 3,500 different items for its customers – with batch sizes ranging from 1 to 5,000. To handle this level of variety, the subcontractor relies on automated HERMLE machining centres. The standardisation of the systems enables the company to respond flexibly to all enquiries.
5-axis machining, CAM programming, automation – Euler Feinmechanik clearly defines its requirements. In 2016, the company decided it was time to take action and overhauled its entire milling department. Looking back, Leonard Euler says: “It was basically a brand-new beginning on a greenfield site.” The industrial engineer has been running the company, which his grandfather Erich founded back in the 1960s, in Schöffengrund, Germany, together with his father, Hans, since 2015.
“About a decade ago, our main focus was on turning. We tended to neglect the milling side of things,” explains Leonard Euler. “Anything that couldn’t be machined on the lathes was milled using simple machines.” However, when it came to machining complex geometries in particular, this approach to production involved a lot of clamping and unclamping and, therefore, a great deal of effort. “This is something we aimed to change while at the same time automating our processes,” he says.
The milling department underwent a complete overhaul, with all the machines being replaced. “It was a massive project for us and required a certain amount of technical ability,” claims the managing director. 5-axis machining was a must from the start, and the new system needed to be designed for autonomous operation. Having developed an appreciation for HERMLE machining centres during his studies and being loosely acquainted with Ralf Schleuning, a sales representative at HERMLE AG, the company asked for a quote. “Based on the size of the components we produce, we decided in favour of the C 22 U, supplied by a RS 05 robot system,” explains the managing director. Ralf Schleuning adds: “The RS 05 was a new solution from HERMLE at that time. We supplied the very first system to Euler.”
Extensive training sessions at HERMLE’s headquarters in Gosheim and at HERMLE’s Technology and Training Centre in Kassel-Lohfelden enabled the Euler specialists to become well-versed in 5-axis machining and the TNC 640 control from Heidenhain. “This software was new territory for us, as our lathes operated with a Siemens solution,” the industrial engineer reports. “The TNC 640 is intuitive to operate and comes with a range of gimmicks – that helped make the transition much smoother.” The HERMLE Automation Control System (HACS) was also on the training agenda. The automation software controls the robot system.
It did not take long for the investment to pay off. “Thanks to the innovative solution, we became more productive and were finally able to offer 5-axis machining,” says the managing director with a smile. Something that has been recognised and appreciated by customers. “The new CAM program that we opted for has also being working diligently from the start. This has allowed us to manufacture geometrically complex components automatically and reliably ever since.” The subcontractor primarily machines aluminium, but its portfolio also includes components made of brass, stainless steel and plastic.
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Managing director Leonard Euler: “HERMLE machining centres offer benefits such as exceptional service, standardisation and outstanding process capabilities.” -
The working range of the C 32 U is designed for workpieces with a maximum diameter and height of 650 mm and 420 mm respectively. -
In the field of defence, for example, Euler manufactures lightweight housings for optical sighting systems. -
The lightweight housings and attachment parts offer space for laser guidance systems, for example.
From prototype to production
Euler now operates eight HERMLE machining centres, only one of which, the
C 400, runs without automation. “We deliberately opted for a machine on which our budding machine operators still learn to program by hand,” reveals Leonard Euler. Further, he has noticed that some applicants are somewhat intimidated when standing in front of the fully automated systems. “These systems are too complicated and complex for them at first. The C 400 allows us to gradually train new employees to meet our high quality and geometry requirements. And at some point, they are also able to reliably run in and program a system such as the RS 05,” he explains.
As a subcontractor employing 85 people, Euler Feinmechanik primarily operates in the fields of vacuum and medical technology, optics and defence. “Our batch sizes range between 1 and 5,000, and we usually produce these batches multiple times each year,” explains the managing director. Customers frequently engage the company during the design phase, with prototypes and pre-series production conducted on the HERMLE machining centres. “Whether it’s 1 or 5,000 – we always follow the same procedure, thereby ensuring efficiency and speed in production. In fact, there’s no need for lengthy prototyping or additional customization for serial production.”
Sufficient resources
The latest addition to the milling department includes two C 32 U 5-axis machining centres,
which are supplied with workpiece blanks by the RS 1 robot system. “Thanks to this solution, we have been able to create the necessary buffer to always deliver the promised quantities on time,” emphasises Leonard Euler. Yet another advantage of the robot colleague: The complexity of tasks for machine operators has been reduced, as they no longer need to clamp components manually. Leonard Euler: “Each of our qualified employees manages two machines, handling at least six different workpieces that run in parallel and may be mounted on either the left or the right.”
Automation allows for totally unmanned production at night and weekends at Euler. “For instance, we manufacture complex components that are machined for two hours at a time. To do so, the system runs throughout the weekend,” explains the managing director. The ZM 216 additional magazines, which supplement the 36 tools in the C 32 U with a further 216 tools, including replacement tools, ensure extensive machining periods.
Leonard Euler particularly appreciates the service provided by HERMLE: “Each machine is assigned a dedicated phone number that connects you directly to a competent technician and not some call centre. This has allowed us to solve many issues ourselves.” The standardisation of the machining centres also plays a key role in this respect. “The operating concept and design of the individual machines differ only slightly. This level of flexibility allows us to deploy our qualified employees where needed and to handle minor repairs by replacing spare parts ourselves.”
