Machine tool factory enhances precision with WFL M50 MILLTURN machine

WALDRICH COBURG, a name synonymous with engineering excellence, has been a cornerstone in the manufacturing of large-scale gantry machining centres and grinding machines for over a century. Known for their ability to handle the most demanding and intricate machining tasks, these machines serve critical industries such as automotive, aerospace, and energy. However, as market demands intensified and the need for more efficient production processes grew, WALDRICH COBURG faced the challenge of optimising its operations to maintain its competitive edge. This case study explores how the company transformed its machining processes through the strategic integration of the M50 MILLTURN from WFL, setting a new benchmark in efficiency and precision.

About WALDRICH COBURG: Located in Coburg, Germany, WALDRICH COBURG employs over 520 people and draws on more than a century of success in the large machine tool construction industry. Their expertise and innovation are central to their mission, enabling them to design and manufacture large, high-precision milling, grinding, and turning machines. They specialise in creating XXL machines for clients worldwide. WALDRICH COBURG’s manufacturing and service network is exceptional, with a strong focus on innovative service concepts and modernising existing machines with cutting-edge control systems. Since 2006, they have invested over 60 million Euros into the Coburg site, enhancing renewable energy infrastructure, constructing new assembly halls, upgrading our machinery, and improving the working environment for their employees. More about WALDRICH COBURG

Challenge

For over a century, WALDRICH COBURG has been synonymous with the manufacturing of large, powerful gantry machining centres and grinding machines, servicing diverse industries such as aerospace, energy, automotive and general production. Their machines, known for their immense scale and power, handle workpieces up to 14 meters wide, 12 meters high, and 400 tonnes in weight, with machining centres delivering up to 300 kW of power. Despite their industry-leading reputation, WALDRICH COBURG faced a significant challenge in optimising its machining processes to meet the increasing demands for efficiency, shorter lead times, and high precision across various complex applications.

Solution

To address these challenges, WALDRICH COBURG invested in the M50 MILLTURN from WFL Millturn Technologies. This state-of-the-art turning-boring-milling centre was selected for its ability to combine multiple machining processes—including turning, milling, drilling, and gear cutting—into a single machine. With a centre distance of 3000 mm, the M50 MILLTURN was perfectly suited to handle the large and complex components that WALDRICH COBURG specialises in.

The decision to integrate the M50 MILLTURN into their production line was driven by the machine’s innovative technological capabilities and its potential to significantly streamline operations. The new machine allowed WALDRICH COBURG to transition from a multi-step production process to a more efficient complete machining approach. This not only reduced lead times by one-third but also increased overall production efficiency, enabling faster, cheaper, and more precise manufacturing.

The M50 MILLTURN was also equipped with iControl, an advanced process monitoring function that ensures reliable machine operation and enhances flexibility in simulations. This feature was particularly important to WALDRICH COBURG as it allowed them to maintain high-quality standards while adapting to varying production demands.

Implementation

The implementation of the M50 MILLTURN at WALDRICH COBURG marked a significant shift in their production strategy. The machine was put into production to manufacture drive components for additional units, including gear wheels, milling spindles, and swivel units. These components, which vary in size and complexity, are produced in small batches of two to four pieces, demonstrating the machine’s versatility and efficiency in handling diverse production needs.

During the initial stages of implementation, WALDRICH COBURG’s Process Engineering team took charge of programming the machine using Siemens NX, ensuring that the production process was optimised from the outset. The team also programmed the machine directly, a practice that is set to become standard to maximise production efficiency by keeping the machine free for continuous operation.

As WALDRICH COBURG navigated this new territory of complete machining, the company quickly adapted to the advanced capabilities of the M50 MILLTURN. Operators and programmers worked in shifts to fully leverage the machine’s potential, steadily climbing the learning curve and refining their processes to achieve even greater efficiency.

Looking ahead, WALDRICH COBURG is committed to further advancing its production processes through continued investment in automation, digitalisation, and sustainability, ensuring that it remains at the forefront of the machining industry for years to come.

Are you in the aerospace, automotive, and heavy equipment manufacturing industry and require large-scale, high-precision machining?

For those looking to integrate these advanced machining capabilities, we can provide tailored solutions from WFL MILLTURN machines. Our WFL experts are ready to assist with implementing these solutions and offer comprehensive service support to ensure optimal performance and efficiency in your operations.