Product category:
Machining centres - all types
News Release from: Heller Machine Tools
Edited by the Manufacturingtalk Editorial
Team on 17 January 2001
Heller plans to double its output
Heller Machine Tools, Redditch, aims to double its output of horizontal machining centers (HMCs) by the end of 2001. UK users are buying higher quality machine tools.
Heller Machine Tools, Redditch, aims to double its output of horizontal machining centers (HMCs) by the end of 2001 Managing director Geoff Lloyd said that the current output of 170 units/year will be increased to 305 units/year
This article was originally published on Manufacturingtalk on 27 Feb 2002 at 8.00am (UK)
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There is capacity at Redditch to raise production to 350 units/year.
It would represent an 80% advance in machine output and an increase in annual turnover from GBP27m in 1999 to GBP45m in 2001.
Lloyd sees the 350 units/year level as being the 'turnkey' at which further site expansion would occur.
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A further factor is the launch by the Heller group of new designs of machining centers at EMO 2001.
"Expansion is not just 'hopeful'," said Lloyd.
"We already have more than two-thirds of production for next year sold." Plant growth would see Redditch progress from that of assembly only into the machining of key components - columns, beds and so on.
These are at present machined in Germany.
"We would do the machining here as buying in heavy duty machining quality is difficult." Redditch is building the Heller MC16, MC25 and MC26 series of HMCs.
Its success is based on a steady reduction in build time - from 360h/machine in 1997 to 270h/machine in 2000.
Factory lead time is under 7 weeks.
"What we have done is very simple and not market-driven," said Lloyd.
"We needed a productive plant, purpose-built with a proper floor, cranage, tools and fixtures and can easily double our plant size." He laid emphasis on building a core of skilled people, running a serious engineering apprentice training programme and providing them with the right incentives and technical challenges to keep them at the plant.
"Therefore it is easier to double plant size.
We allocate two men to each machine, who follow it through from start to finish, we do not tie them to dedicated tasks.
They are responsible for quality and build time, which generates 'local' competition between the teams." Other important points to cut factory lead times: waiting time for parts has been decimated - for example, guarding is delivered complete and logoed, realising a 90% reduction compared with previous piecemeal supply - while completed machines do not stand around on the floor - they are shipped out as quickly as possible.
To increase output, 32 skilled men will be added to the existing 106 machine fitters.
Some of the existing teams will be split, a new man joining an existing operative to make a new team.
"After one month there is only, on average, a 5% time penalty as the new man gains experience.
So by 2001 we will be back in line with double our output," said Lloyd.
"It is the result of investment and training." The original productivity target of 20% above what was possible with building the same HMCs in Nurtingen has been exceeded: productivity at Redditch is running at 40% according to Lloyd.
In Nurtingen, Germany, the Gebr.
Heller group, with plants in the US and Brazil, also continues to grow.
Heller group turnover in 1999 was DM560m (GBP175m) and the forecast is DM750m (GBP234m) in 2001.
Heller builds transfer lines, turn-broaching centers and specials in its factories in Nurtingen.
The demand for quality HMCs has grown since Heller took on board Siemens Sinumerik and GE Fanuc CNCs as alternatives to its home-spun Unipro CNC.
This is not a negative reflection on the Unipro CNCs which still have strong following in Germany, commented Lloyd, but the market demanded Siemens and Fanuc.
In the UK, Heller1s HMC market is growing.
Lloyd said that during 2000, 22 UK companies bought Heller machines of which 17 were new customers.
Of the total, 40% were in the automotive supplier industries.
Also, the new customers are replacing cheaper MCs with the higher quality and more expensive Heller product.
"In Germany, Italy and Spain, companies can find funds from local governments and banks," said Lloyd.
He said that in the UK, sourcing funds to buy machine tools is still very difficult.
But the message is getting through that one has to buy quality machine tools to compete as a quality, cost-competitive supplier. Request free introductory details about products from Heller Machine Tools ...
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