A turned parts contractor from Berlin is boldly setting out on a new path: With the purchase of a Bumotec s181 machining centre from Swiss Starrag, Heinrich GmbH from Berlin entered into the field of high-precision complete processing of components for respiratory protective devices.
"Welcome to the Swiss corner," says Christian Pooch, managing partner of Heinrich GmbH from Berlin, and takes us to his latest investment: a Bumotec s181 5-axis CNC turn-mill centre with a total of nine CNC axes, which now stands next to five automatic lathes that are also from the Swiss manufacturer.
The large machine park allows for "order diversity"
More machines than people work at Heinrich, because the sheer variety of different orders – from batch size one to large series with several million parts – requires a very large machine park with more than 30 systems. Pooch: "Whenever the process and the product allow it, we also let some of the machines run overnight without operators in a ghost shift.
The Berliners want to use the new machines, the company's largest investment to date, to break new ground. A regular customer asked the Berliners, after a competitor had already decided not to bid, if they would be willing to produce a distributor for a respiratory protective device. "It is a component that has extremely high demands with regard to tolerances and the absence of burrs," Pooch explains. "Because it is not acceptable for a fireman to inhale small pieces of burrs during use."
Although much lower-priced machine tools are available, precision was not the only reason Pooch chose the Bumotec s181, a 5-axis simultaneous turn-mill centre with a CNC FANUC 31i panel and retaking unit, for the complete machining of complex and high-precision workpieces.
"I think the main spindle is very smart," Pooch explains. "It makes it easier for our operators to transit from a standalone lathe to the machining centre." With its HSK-40 tool spindle (30,000 rpm), very small components can be machined precisely to 1.5 µm either bespoke or off the shelf (maximum diameter: 32 mm). Pooch has two sons who work alongside him, one of whom speaks very enthusiastically about the new possibilities. "On its own, our former core business of lathing nuts and screws has not been enough to sustain us for a long time," says production engineer and general manager Tobias Pooch. "But now, with the Bumotec, we can position ourselves even better than before with high-precision components, and also establish ourselves internationally." There is great resonance with the customer base, because the Bumotec has allowed Heinrich to open the gateway to completely new worlds, meaning growth.
Bumotec s181: Use in a traditional turned parts contractor
"A gateway to more growth"
The Pooches have put particular emphasis on a high degree of automation so that they can use the s181 around the clock if necessary. For this purpose, it has been equipped with an automatic tool and workpiece change system: the tool changer has 60 places, which can be freely equipped with lathe or milling tools. The workpiece changer is a palletizing system for five pallets, each of which offers space for 30 blanks. Both systems can be expanded in case of increased demand to a maximum of 90 tools and 300 workpieces. The workpieces, which are completely processed on all sides, are unloaded on a conveyor belt and collected in a container filled with oil (capacity: 300 workpieces). Another factor in favour of this system is that handling occurs without adversely affecting the primary processing time. The user can operate, equip and handle all of the automation components without stopping production.
Together with a Starrag expert, the Berliners adjusted the process for the new component in the late autumn of 2017. "It's unbelievable but true," says Tobias Pooch happily. "We have been producing since the commissioning and we have not had to make any corrections since then." "We also deliberately purchased the machine with set-up included, because we are entering new territory here," his father adds.
Ready for the ghost shift
Turned parts contractor Heinrich has put particular emphasis on a high degree of automation so that it can use the Bumotec s181 around the clock if necessary. For this purpose, the machine has been equipped with an automatic tool and workpiece change system.
