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10 Manufacturers Who Transformed Their Business With UNITED GRINDING

UNITED GRINDING North America has helped thousands of manufacturers overcome some of their greatest manufacturing challenges, and many have been eager to share their success stories with the community. Beyond providing access to world-class technology, UNITED GRINDING North America employs a robust team of application engineers who bring years of experience and unmatched expertise to ensure the delivery of innovative solutions, helping many customers transform their business. As one client says, “That talent is scarce. UNITED GRINDING can add value as opposed to just selling you a machine.” 

Some transformations come through the introduction of more advanced machinery that is capable of combining manufacturing processes, such as milling and grinding, or grinding and erosion. Other transformations are through the installation of machines capable of executing previously unconventional processes with greater ease. An example of this might be through the implementation of continuous dress creep feed grinding, which allows for a more aggressive cut while eliminating the separate step of dressing the grinding wheel. 

Other transformations involve the introduction of an automated part loading system, such as flexLoad which can pay for itself in as little as 18 months by reducing costs for repetitive tasks, allowing you to leverage your human capital more efficiently. 

Some transformations enhance productivity, others improve quality. Many open up business opportunities, either with increased capacity or new types of work that serve other industries. 

In this article, you’ll learn about 10 customers who have in one way or another, transformed their business by leveraging UNITED GRINDING technology, expertise, and service offerings. 

1. Triple T Cutting Tools 

Rebuilding Machines Plus New Software Equals Great Value 

TechnologyWALTER HELITRONIC SL, HELITRONIC ToolStudio CAD/CAM software, Rebuild 

TransformationTriple T Cutting Tools chose to rebuild two CNC grinders and outfit them with new software, which made for a cost-effective upgrade in capabilities. It allowed the shop to grind extremely complex geometries in a single clamping, essentially turning machine operators into grinding professionals.  

2. Milwaukee Broach 

Clearing a Pathway For Complex Production  

TechnologyBLOHM PLANOMAT HP, Easy Profile control units 

Transformation: The company creates high-precision, tight-tolerance complex broaches that are used to create even more complex parts. Milwaukee Broach was able to greatly reduce the number of checks and inspections during production of fir tree-type broaching tools. A typical fir tree tool requires as many as 15 to 25 checks during production, including side to side, up and down, location and more, with in-process checking as well as first-piece inspection. With the BLOHM’s precision and repeatability, once that first piece passes inspection, the remainder of the job is produced before additional checks take place. 

3. Voisard Tool 

A Measured Approach to Clearing the Inspection Backlog  

TechnologyWALTER HELICHECK PLUS, Quick Assistant Software 

TransformationVoisard Tool eradicated the inspection room backlog. They have streamlined the complete measurement of cylindrical and conical milling cutters and drills to only three steps, reducing measurement setup time by more than 50 percent and the overall entire check time for a common end mill to four minutes. These have been instrumental in achieving a 10-day overall reduction in delivery times. 

4. Bridge Tool & Die 

Reducing the Number of Moves in Parts 

TechnologySTUDER CT960, StuderGRIND software 

TransformationBridge Tool & Die was able to dramatically shorten setup times by eliminating the need to move parts between as many as five separate OD machines before ID grinding. The part is now completed in a single setup. It also eliminated the need for secondary time-consuming hand polishing to achieve required surface finishes. 

5. Almar Tools 

Dual Spindles, Automation a Powerful Combination 

TechnologyWALTER HELITRONIC POWER, HELITRONIC ToolStudio CAD/CAM software, ecoLOAD  

TransformationAlmar Tools has shortened turnaround times for custom tool work for aerospace, which has allowed them to grow their business in the automobile, medical and electronics industries. The shop can set up a job for a standard end mill in as little as 10 minutes and more complex jobs in under an hour. The WALTER HELITRONIC POWER dual spindle accommodates up to six grinding wheels. Almar uses both spindles for the majority of jobs, and often up to four separate grinding wheels are required to complete one complex cutting tool. One machine has an ecoLOAD system to quickly load and unload tools, shortening overall cycle times and automating the process. 

6. J&E Precision Tool 

Eliminating Outsourcing Cleans Up Bidding Process 

TechnologySTUDER S33 

Transformation: The shop was able to close a gap in their capabilities as they previously outsourced certain types of grinding. J&E Precision Tool previously had to take into account their subcontractor’s grinding charge, which included their overhead costs and profit margin, in quoting their bids. With its own STUDER S33, J&D has eliminated those outside costs, reduced turnaround times and can offer customers more competitive pricing. The machine enhances the shop’s ability to maintain top part quality. Previously some parts were roughed and finished on turning centers. Now, many of those same parts are roughed on a turning center and finished on the grinder. The STUDER grinder also enables J&E to take on jobs it would have had to turn down in the past. 

7. Ceratizit Tools 

A Measured Approach to Increasing Connectivity 

TechnologyWALTER HELICHECK measuring technology software, flexLOAD 

Transformation: Prior to acquiring advanced tool measurement technology, Ceratizit Tools measured manually and used comparators to check its finished parts — a system that offered limited quality certification and traceability. They now have seven advanced WALTER HELICHECK optical CNC tool measuring systems, which operate autonomously. An operator loads the tool and then can work elsewhere in the shop. Ceratizit also incorporated an automatic loading machine, which allows them to run as many 45 machines overnight. They have connected five of the seven HELICHECK systems together and networked them to a central database, allowing the engineering and design departments to instantaneously access programs and reports from the HELICHECK measurement machines. This connectivity increases efficiency and provides the shop with a wealth of data to improve its production processes. 

8. Shape-Master Tool Company 

Laser Technology Helps Hone in on Complex Jobs 

TechnologyEWAG Laser Line 

Transformation: By purchasing the first two laser tool-process machines of their kind in North America, Shape-Master Tool Company was able to expand its product capability and customer base and reduce outsourcing. The laser technology enhanced their cutting tool production and also allowed them to take on more difficult work and compete against larger custom tooling suppliers. With the EWAG Laser Line’s production flexibility, Shape-Master cost-effectively processes jobs involving lot sizes that can range from 50 pieces to thousands while maintaining quality and delivery times. They now do rotary tooling and also were able to bring parts back in-house that it previously had to outsource. Both of their Laser Line machines are equipped with automation. One has an integrated 6-axis FANUC robot, a two-in-one HSK 63-tool rack and pallets — all of which provides continuous, fully automated and lights-out production of a variety of rotating-type tools. This machine also automates the shop’s high-volume production of inserted diamond tools. The other machine features a stacker that holds up to eight pallets with 300 pieces each. 

9. Precision Tool Co. 

Automation, CNC Allow for Lights Out Production 

TechnologyWALTER machines, ecoLOAD loaders 

Transformation: The shop has five WALTER grinders, four of which have automated loaders. This has resulted in far-reaching changes in Precision Tool Co.’s business approach as the specialty shop now does about 75 percent of its production on the CNC machines and has doubled its output while creating new high-tech jobs. Automation and CNC capabilities also give the company the ability to respond to customer requests for rush tooling jobs. Whereas lead time for a batch of aerospace tools might typically be four to five weeks, Precision Tool has turned them around in as little as a week. They now run lights-out for about 200 hours per month. 

10. Hammill Medical 

Introducing CDCF to Medical Implants 

TechnologyBLOHM PROFIMAT MT 

TransformationHammill Medical introduced continuous dress creep feed grinding (CDCF) to their shop as production of an implant took about an hour per part with 20 percent of material being scrapped. Hammill no longer had to stop production for dressing, instead dressing and grinding simultaneously while being more aggressive with cuts. Hammill was able to maintain the profile shape and the size of the part and reduce the cycle time to about 10 minutes. They have significantly reduced downtime and scrap while producing a higher-quality part. 

UNITED GRINDING Is the Right Partner to Get the Most From Your Grinding Technology 

Clients often cite how UNITED GRINDING North America focuses on providing solutions and customer service as reasons for their enduring partnerships. For example, a UNITED GRINDING application engineer will follow up with a client about three to six months after a purchase and installation for additional training and process optimization.  

Those relationships benefit both the client and UNITED GRINDING, which gains its grinding expertise by learning and serving clients. 

Having an experienced partner with seasoned application engineers and a reputation for stellar customer service is crucial as you plan for investments in your operation. UNITED GRINDING has all of this, plus a preventive maintenance program, remote and on-site service, and an Automation Solutions team that is close to many major manufacturing hubs. UNITED GRINDING is a one-stop shop to help you get the most out of your grinding technology, whether it’s a rebuild or a custom automation solution. 

Contact us today​​​​​​​ and give us a chance to prove how we can help you realize near-term and long-term ROI with machine tool automation. 

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