Do you produce taps and form taps? You know the phrase: to thwart someone? This is exactly what we at Haas Schleifmaschinen GmbH want to try together with you today, of course with the best of intentions.

For years we have noticed that production times are measured with the stopwatch - but important future factors are overlooked in the overall view. We are not only talking about the "total manufacturing time" of a tap, but also about changing framework conditions in the market, which you should also take into account. Assuming you plan to continue operating in your established - and perhaps also in new markets - equipped with all competitive advantages, from a strong position. But who doesn't want that?

Before we show where you can easily tap potential in the future, we describe a situation that is still the order of the day in the production of taps and thread formers.

So far, many taps are still manufactured in large numbers on single-purpose machines. First the round, then the groove and then the peeling groove machining. Followed by grinding the chamfer and thread profiles on 3 - 4 single-purpose machines. And when the stock is running low, large quantities are produced again.

Actually, it does not need a calculation example to realize that this production method promises little prospect for the future.

The calculation revisited

The production time for a tap has so far been calculated as follows:Production preparation, machine set-up times for the 3 - 4 single-purpose machines, production times on the respective machines, in process quality inspection, semi finish product inventory, idle times between the processes. Did we forget something? Clever computers predict the downtime of individual machines and the associated production delay already into the calculation.

But there are still important factors for an overall economic calculation missing:

The changed lot sizes and smaller quantities that are requested today. The additional waiting times due to "just in time" requirements. The extremely high quality requirements that have now become standard. The many lucrative special orders that have not yet paid off or that you cannot currently process. And last but not least, the declining trends in market prices. This not only requires high cutting performance or cutting speed, but also additional savings to keep up with the competition

How is your current production strategy reacting to these new market conditions? Because if all factors are taken into account, our hypothesis will pay off and be confirmed: Even with large as well as small quantities, the fully automated "Just in Time" production of taps in only one clamping is much more economical and precise.

The production strategy with a built-in future, 10 advantages at a glance:

Quick setup: Get started super fast with the Multigrind® Horizon grinding software. Programming directly from the 3D model, incorporating existing DXF contours and macros. Preliminary workpiece visualization and collision check with precise Multigrind® Styx visualization. Time-consuming test runs are completely eliminated.

Intelligent, fast loading: The fast processing of the workpieces requires a high cycle frequency for loading and unloading. We manage this. With a robot unit, with variable part code loading loading, even several orders can be processed automatically.

Maximum cutting performance: The extremely rigid 5-axis grinding machines from the Multigrind® series enable cutting speeds of up to 125 m/sec. Even ultra-hard materials can be machined economically.

A precision  not achieved: Complete machining in only one setup with customized clamping concepts. No loss of quality due to re-clamping. Improved quality: The taps and thread formers achieve up to 50% longer tool life. Blank in - high-precision tap out.

Precise measurement technology: Optimal production process and control through permanent measuring in the sense of a closed loop. Instead of quality problems - quality assurance, for reproducible high-precision results. The ingenious measuring system ensures that only good parts leave the machine.

Dressing in the right time: Precise dressing on the diamond form roll or diamond profile roll ensures continuous top performance in terms of dimensional accuracy and surface quality. Up to 3 dressing units are possible to hold up to 9 dressing rolls.

Automation as standard: The adapted automation unit makes even unmanned shift operation possible without problems. All requirements for Industry 4.0 are given Individual and customized automation requirements are our specialty

Flexible serial production: Production can be quickly switched from one workpiece to another. Maximum flexibility from single piece batch size through small series to large series production. This makes it possible to process orders with short delivery times of a few days as well as "just in time" provision for large orders without stocking.

Profitable new business: On a Multigrind® grinding machine you can produce anything that comes to mind and that promises success in the market in the future. Special tools, combination tools, sizes from M3 to M64, without significant material restrictions. For your core business, for which you are already specialized, but also for new industries that have a demand.

Best prospects: Within the Multigrind® cosmos you can look positively into the future. The Multigrind® high-tech grinding machines are state of the art. The Multigrind® Horizon software enables individual solutions with the highest demands of cutting tool geometries. Just take a look at the developments of Haas grinding machines in recent years and you will know where the journey together is headed: with certainty towards the future.

Have you ever done the calculation without Haas Schleifmaschinen?

You can count on Haas Schleifmaschinen.