Euler Feinmechanik Relies on Automated Machining Centers from Hermle Manage High Flexibility in a Standardized Way

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Euler Feinmechanik machines approximately 3,500 different items for its customers—from batch size 1 to 5,000. To manage this variety, the contract manufacturer relies on automated machining centers from Hermle. Through standardization of the systems, the company can respond flexibly to all inquiries.

5-axis machining, CAM programming, automation—Euler Feinmechanik precisely defined its requirements. In 2016, the company took decisive action and restructured its entire milling department. "It was practically a restart from scratch," recalls Leonard Euler. The industrial engineer has been running the company since 2015 together with his father Hans, which was founded by his grandfather Erich in the 1960s in Schöffengrund (Germany).

"Nearly ten years ago, we were primarily a turning operation. Milling was rather neglected," recalls Leonard Euler. "Everything we couldn't machine with the lathes, we milled with simple equipment." However, this production method involved many setups and thus a high level of effort, especially with complex geometries. "We wanted to change that and simultaneously automate our processes," he emphasizes.

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In the milling department, not a single stone was left unturned; the entire machine park had to be replaced. "This was a very large project for us and also involved technical work," explains the managing director. 5-axis machining was set from the beginning, and the new system was to run autonomously. Since Leonard Euler had appreciated Hermle's machining centers during his studies and had a loose contact with Ralf Schleuning, a field representative of Hermle AG, the company requested an offer. "We decided on the C 22 U based on our component sizes, which is supplied by the RS 05 robotic system," explains Managing Director Euler. Ralf Schleuning adds: "The RS 05 was a new solution from Hermle at that time. We delivered the first system to Euler."

Extensive training at Hermle's headquarters in Gosheim and furthermore at Hermle's own demonstration center in Kassel-Lohfelden familiarized Euler's specialists with 5-axis machining and the TNC 640 control from Heidenhain. "This software was new to us since our lathes operate with a Siemens solution," reports the industrial engineer. "The TNC 640 is intuitively operable and also has small gimmicks – this facilitated the transition." Additionally, the Hermle Automation Control System (HACS) was part of the curriculum. The automation software controls the robotic system.

The investment paid off shortly afterward. "Thanks to the innovative solution, we are now more productive and can finally offer 5-axis machining," the managing director is pleased to say. This was noticed and appreciated by the clients. "The new CAM program we decided on also worked very well from the beginning. We have been producing geometrically demanding components automatically and with process reliability since then." The contract manufacturer primarily machines aluminum, but also includes brass, stainless steel, and plastic components in its portfolio.

From Prototype to Series

Meanwhile, Euler manufactures on eight machining centers from Hermle, only one of which, the C 400, lacks automation. "We deliberately chose a machine where our upcoming machinists can still program manually," reveals Leonard Euler. He also noticed that some applicants are a bit intimidated when facing the automated systems. "It's initially too complicated and complex for them. Thanks to the C 400, we can gradually introduce new employees to the high quality and geometry requirements. Eventually, they are able to safely operate and program a system like the RS 05," he explains.

As a pure contract manufacturer with 85 employees, Euler Feinmechanik mainly operates in the vacuum and medical technology, optics, and defense industries. "Our batch sizes range from 1 to 5000, and we usually produce these batches several times a year," the managing director clarifies. Customers often involve the company during the design phase, with prototypes and pre-series running on Hermle's machining centers. "Whether it's 1 or 5000 units, we always have the same approach and quickly transition to series production. Labor-intensive prototype construction and subsequent adaptations to series production are completely eliminated."

Sufficient Reserve

The latest addition to the milling department consists of two 5-axis machining centers C 32 U, which the RS 1 robotic system supplies with workpiece blanks. "With this solution, we have created the necessary buffer to always deliver the promised quantities on time," emphasizes Leonard Euler. Another advantage of the robotic colleague is that the complexity for the machine operator decreases, as they no longer have to clamp parts manually. Leonard Euler states, "Each of our specialists oversees two systems and thus at least six different workpieces, which run in parallel and are sometimes machined on the left and sometimes on the right."

Thanks to automation, Euler manufactures without personnel during the night shift or on weekends. "For example, we machine complex components that are each processed for two hours. The system runs throughout the entire weekend for this purpose," the managing director explains. The additional ZM 216 magazines, which supplement the 36 tools in the C 32 U with an additional 216, including sister tools, ensure long machining times.

Leonard Euler particularly appreciates the service from Hermle: "Each machine displays a phone number that connects me to an experienced technician, not a call center. This has allowed us to resolve many issues on our own." The standardization of the machining centers also contributes to this. "The operating concept and the design of the individual machines differ little. This allows us to deploy our specialists flexibly and replace parts ourselves during minor repairs."

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