During a team meeting , the MAPAL tool manager explains machining with the HPR400 reamer and the differences compared to the previous system . Standing left to right : David Castaño ( MAPAL Tool Manager ), Manuel Padilla Fernández ( DEUTZ Manufacturing Engineering Manager ) and Rafael Salinas ( DEUTZ Project Manager ). ©
MAPAL
DEUTZ uses approximately 1,300 different tools in total . Thousands of tools are available from stock and have to be managed in Zafra . To keep inventory at an optimal level ( i . e ., avoiding bottlenecks while preventing unnecessarily high tool stocks ), MAPAL uses its own warehouse management systems and digital solutions with the cloud-based software c-Com for tool management . The digital Tool Management 4.0 doesn ’ t only handle procurement processes , which are initiated semi-automatically , it also acts as a reporting tool to analyse cost drivers and stocks .
Tools just in time for the assembly line
Industrialization Manager Manuel Rodríguez López praises the good collaboration with MAPAL when it comes to tool management : “ Over the course of our cooperation , we have developed extensive technological concepts , which go far beyond mere logistics . Besides achieving cost reductions , tool setting is particularly important for us . The MAPAL employees working on-site have a lot of know-how and ensure that production has exactly the tool they need at the right time .”
MAPAL ’ s tool manager on site is David Castaño . MAPAL also employs tool setters permanently in Zafra . They make sure that a dozen different parts are produced without a hitch . “ It is very beneficial to have David here on-site with us ”, emphasises Manuel Padilla Fernández , Manufacturing Engineering Manager at DEUTZ , who works closely with the tool manager . “ We can talk about any opportunities for optimisation directly at the machine . We don ’ t consider David Castaño to be an external service provider but rather a part of our team . It ’ s a very strong cooperation .”
Developing together to solve problems
If required , new tool solutions can be developed in Aalen via the local MAPAL team . That was the case in Zafra when it became necessary to optimise the tools for machining the bore in the crankshaft and camshaft . In cooperation with DEUTZ , a new machining concept from MAPAL with the HPR400 reamer was implemented . David Castaño is convinced of its advantages : “ The tool life of the previous tool was 350 units and resetting was required every 100 units . With the HPR400 , we achieve a tool life of 1,000 parts without resetting . The resulting machining quality is exceptionally good .”
For further information , please visit https :// mapal . com / en-int /
34 PECM Issue 73