Facility produces intricate and complex components

As well as building very precise machining centres, Kern also operates two high precision temperature controlled subcontract units producing intricate and complex components.

Known for building its 'truly precise' machining centres Kern also operates a subcontract machine shop, which also forms a basis for employee training.

The subcontract business manufactures intricate and complex components and gives potential machine tool customers a facility for testing machining project feasibility.

* Precision machining - Kern operates two high precision temperature controlled subcontract units.

One is for volume production and the other for producing in small batches.

The volume production area has six EVO machines working at capacity until November 2008.

All EVO machining centres have 10-pallet loading systems and run one shift manned and two shifts unmanned.

Output is some 6,000 precise components/month/machine.

The EVO machines produce these components with features having a 2 micron dimensional and positional tolerance.

One feature of the component is an M0.6 thread that in volume production needs care and discipline to maintain, said Kern.

* Quality control - to control quality, Kern has a temperature controlled environment to 0.25 deg K and operates a number of CMM's including a Zeiss F25.

Uk representative, Deckel Grinders, said that the Zeiss F25 is one of the worlds' most capable measuring machines.

It uses a probe and camera to measure within an accuracy 0.25 micron or 250nm.

The subcontract service not only serves a purpose to customers with extreme accuracy needs, it is the ideal training platform for Kern apprentices.

Kern said that its UK customers, such as Micro Systems (UK), have taken note of the skill and knowledge of Kern engineers.

Production manager at Micro Systems, Gary Robinson, said: "We have recently ordered the Pyramid Nano machine and we noticed that the Kern application engineers have a remarkable level of experience, because of their intensive training and also because they are working with other customers in a very specific manufacturing industry".

Micro Systems (UK) bought the Pyramid Nano machine to machine extremely small and intricate work.

Robinson commented: "We are a specialist engineering company that wants to increase its strength in its manufacturing capability.

We currently produce intricate parts with average batches from 20- to 40-off.

The Pyramid Nano not only meets our accuracy and surface finish requirements but has the potential to integrate pallet loading and high speed spindles up to 160,000 plus high capacity tooling carousels to gear the machine up for production runs".

A close relationship with the customer is seen in the subcontract shop where customers can prove their own parts on the machines.

They also see the machines being manufactured and can also do their training on their own machine at the Kern plant.

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