HELLER solutions at ZF

ZF
Automotive
4-/5-axis machining centres MC
Transfer line systems TRS

New 8-speed automatic gearbox produced on the HELLER ModuleLine

The wide variety of parts was to be machined randomly. With ModuleLine, HELLER delivered powerful machining modules for cubic components. Ever since, 750 units per day are machined with cycle times below 100 seconds. Moreover, several variants can be machined at the same time with minimal effort.

Task

  • flexible manufacturing system for high part diversity
  • "chaotic" production of all variants on one system for just-in-time delivery for assembly
  • production with adapters for the highest possible accuracy
  • loading and unloading of raw and finished parts in the same place

Project scope & solution

  • ModuleLine from HELLER: powerful machining modules for cubic components, series production
  • flexible loading concept: manual and fully automatic
  • machining modules arranged on two sides with central, floor-supported loading system
  • three handling systems that move independently of one another
  • development of a standardised workpiece carrier for a standard clamping concept

Result

  • production time of less than 100 seconds
  • 750 units per day
  • simultaneous machining of several variants without equipment modifications
  • due to the high demand for 8-speed gearboxes, the pilot system has been expanded by a second identical, mirror-inverted system

More references

HELLER solutions at Komax: Customer testimonial

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."

HELLER solutions at Franz Haas Waffelmaschinen: Customer testimonial

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."

HELLER solutions at H.P. Kaysser: Customer testimonial

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!"

HELLER solutions at Bitzer: Customer testimonial

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."

HELLER solutions at Engel Austria: Customer testimonial

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."

HELLER solutions at Fette Compacting: Customer testimonial

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".

Komax
Franz Haas Waffelmaschinen
H.P. Kaysser
Bitzer
ENGEL
Fette Compacting

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