by Blaser Swisslube | May 27, 2021 | Customer Cases
Holistic approach optimizes processes and tool life Tools and instruments of the highest precision and durability are manufactured at the headquarters in Wasen andSumiswald (Copyright PB Swiss Tools). Swiss tool and instrument manufacturer, PB Swiss Tools, and Blaser Swisslube agreed on a collaboration with ambitious goals in early 2019. By taking a holistic approach under the “Liquid Tool” banner and promoting a change of coolant, the aim was to optimize processes, increase tool life and reduce production costs. A test phase proved very successful, achieving the ambitious goals that had been set. Since then, the collaboration has been expanded to include further production processes. What started with the production of nose rings for taming oxen in the village blacksmith’s shop in Wasen in Switzerland’s Emmental region, evolved over the years into a global and innovative company synonymous with tools and medical instruments that are unrivalled for their precision and durability: PB Swiss Tools. The tool manufacturer’s history can be traced all the way back to 1878. It has been manufacturing tools since 1940, and medical products since 2013. Today, specialists in more than 80 countries choose PB Swiss Tools when their work needs to meet the highest quality standards. 180 employees in Wasen and Sumiswald manufacture 12 million tools and instruments each year. More than two thirds of these are exported all over the world. These tools and medical instruments from the Swiss Emmental are distributed to over 80 countriesworldwide, equipping production lines in a wide variety of areas, and provide valuable service in operatingtheaters (Copyright PB Swiss Tool) Blaser brand ambassador, Titan Gilroy, and coolant Synergy 735 caught the attention of PB Swiss Tools representatives at the Prodex exhibition in Basel in 2019. PB Swiss Tools Production Manager, Patrick Gehrig, was particularly interested in the holistic approach taken by Blaser Swisslube, increasing productivity and optimizing costs through the use of the Liquid Tool. “A visit to PB Swiss Tools’ shop floor was arranged to discuss potential collaboration,” explains Hans-Peter Dubach, application engineer at Blaser Swisslube. This visit was entirely consistent with the overall approach adopted by Blaser Swisslube: In addition to talks and discussions, all the production details were closely examined. Hans-Peter Dubach explains: “This includes an analysis of the water quality, the tools and machines used,...
by Blaser Swisslube | May 27, 2021 | Customer Cases
High-performance grinding oil improves quality and economic efficiency Left to right: Roland Brouczek (Berner + Straller), Hugo Limmer, Linus Erlacher (Werkzeugschleiferei Hugo Limmer) and Martin Reichhart (Blaser Swisslube GmbH Germany) at the Rollomatic 620XS (Photography: Sonja Sindlhauser) In 2017, Werkzeugschleiferei Hugo Limmer, which specializes in the production of high-precision cutting and machining tools, started an initial test phase using Blaser’s Blasogrind GTC 7 grinding oil. The goals were ambitious: faster grinding processes, fewer dressing intervals and machine idle times, better process security, fewer rejects, better surfaces and optimum human compatibility. Blasogrind passed the test with flying colors, and all goals were achieved. Machine efficiency was increased by 15 percent. Werkzeugschleiferei Hugo Limmer was established in 2000 and is based in the quiet town of Waakirchen in Bavaria, not far from the shores of Lake Tegernsee. The company focuses on the production of high-precision cutting, drilling, milling and special tools, and on sharpening services for the mechanical engineering, aerospace and medical technology industries. Staff at the tool grinding shop have many years of experience and manufacture within very tight tolerances. Implementing such high-precision grinding processes reliably and efficiently calls for a suitable high-performance grinding oil. Looking for a coolant solution tailored to its production processes, company founder Hugo Limmer and the responsible industrial engineer Linus Erlacher contacted the specialists at Berner + Straller GmbH in Munich, the official business partner of Blaser Swisslube in Bavaria, Saxony and Thuringia. The experts from Berner + Straller and Blaser examined the grinding processes, looking for ways to optimize operations. The first machine was filled with Blaser GTC 7 in March 2017, and further machines were gradually switched over in the following years. Linus Erlacher inspects a cutting edge on the Zoller measuring machine (Photography: Sonja Sindlhauser) Ambitious targets At the start of the cooperation, a comprehensive analysis of the current situation was carried out and goals were defined. The new metalworking fluid needed to be almost odorless, as well as offering optimum human compatibility and low misting. “At the same time, we wanted to continuously improve productivity and quality, to get the most out of the available resources and in this way to add economic value,”...
by Blaser Swisslube | May 27, 2021 | Customer Cases
Tool cost savings by up to 40 percent and rust-free parts with Blasocut Imtiyaj Mujawar and Blaser Swisslube staff (Amol Malichkar) discussing about improved tool life Technocube in India experienced the leverage effect of the optimal coolant on the productivity: They were able to reduce tool costs by almost 40 percent with the Blaser Blasocut coolant solution Technocube, located in Kolhapur, is a young organization and ventured by M/s Siddhi Technozen. They supply and support sectors like Aerospace, Hydraulic, Medical Implants and Oil and Gas with various steel components. In their turnmill centers they’ve experienced issues with the previous coolant. They fighted with unpredictable tool wear and observed rust on the produced components after 24 hours. “We’ve reached out to our Machine Tool Builder DMG Mori and they recommended Blaser Swisslube to us”, explains Imtiyaj Mujawar Partner at Technocube. Imtiyaj Mujawar from Technocube in front of DMG Mori machine The Blaser experience Taking a holistic view on the production process at the customer’s production site was the first step towards getting to the bottom of the issues described. With the gained knowledge, the Blaser coolant specialist Amol Malichkar was able to recommend the right solution to meet with the customers’ requirements. “Our focus was on resolving the two main issues of Technocube”, says Amol Malichkar. Firstly, we wanted to improve the unstable processes and to avoid the rust occurences on the parts. From my experience Blasocut is well suited for the manifold applications at Technocube” explains Amol Malichkar from Blaser Swisslube India. Imtiyaj Mujawar agreed to run a test with the recommended Blaser coolant solution on a DMG Mori NLX 2500 for two months. The produced part was for the oil and gas segment and included applications like running, grooving, milling and drilling. Tool cost savings which convince The Blasocut solution made the convincing difference.The tool life improved by up to 40 percent on six DMG machines. The increased and consistent tool life resulted in overall ROI of 244 percent per year. An investment that pays off. Even though the coolant costs of Blasocut are higher than the previous product. The expected leverage effect has been proofed at its best. New developed coolant solutions in the future Imtiyaj Mujawar is convinced that the right coolant solution has a positive effect on the entire production process and the overall costs. “I am happy to be a...
by Blaser Swisslube | May 4, 2021 | Customer Cases
Vascomill CSF 35 – optimizing a hobbing process at its best View of the Production site JinMyeong PowerTech in Korea JinMyeong PowerTech experienced the leverage effect of the optimal cutting oil. They were able to reduce tool costs by 25 percent with the Vascomill CSF 35. Produced powertrain part at JinMyeong Power-Tech JinMyeong PowerTech is a start-up company that produces powertrains – a core component for the agricultural machinery. They offer a variety of products in low volume and did not pay much attention to the importance of coolant and cost savings. Yoon Dong-seop, Director of the facility at JinMyeong PowerTech knows Lee Won-Ho, Managing Director of Blaser Swisslube Korea for quite some time. After hearing about the leverage effect of the Blaser coolant during a sales visit, Yoon Dong-seop, showed great interest. He gave his agreement to conduct a test to check if cost reductions are achievable also for JinMyeong PowerTech. Cost savings and environmental improvements Because JinMyeong PowerTech produces multi-variety products in a small batch, it was difficult to disclose the improvement of tool life. For the test, the cost of a hobbing cutter was analyzed in detail. Taking a holistic view on the hobbing process, the Blaser coolant specialist recommended to perform the test with the Vascomill 35 CSF. From his experience he knew, that this ester oil-based cutting oil is well suited for this application. Vascomill CSF 35 is low in emissions and ensures a clean working environment. The test was conducted step by step on a hobbing machine KASHIFUJI KA220a. By replacing a convenient cutting oil with Vascomill CSF 35, Yoon Dong-seop from JinMyeong PowerTech explains: “We were able to achieve cost savings by increasing the tool life of the cutter. We use now 1’500 instead of 2’000 cutters for the same period. Plus the workers are no longer experiencing discomfort due to strong smell of the oil and inconvenience of the burr removal. We are so happy with the Blaser coolant solution.” Collaboration moving forward An investment that pays off. The increased tool life resulted in overall cost savings of ₩ 392,000 and in addition saved time of tool regrinding. Even though the coolant costs of Vascomill CSF 35 are higher than for the previous product. The expected leverage effect has been confirmed. Yoon Dong-seop is now convinced that the right coolant solution has a positive effect on the entire process and the overall costs. Yoon Dong-seop said,...
by Blaser Swisslube | May 4, 2021 | Customer Cases
Achieve tool cost savings and stable processes in the medical industry Shop floor at Sigma Surgical Sigma Surgical in India experienced the leverage effect of the optimal coolant on the productivity: They were able to reduce tool costs by almost 50 percent and achieve a stable process with Synergy 735 and Vascomill CSF 35. Sigma Surgical, located in Ahmedabad, is an upcoming leader in the Indian medical implant and surgery instrument sector. They produce bone screws, bone plates, hip and knee joints and more out of Titanium and Stainless Steel (316 LVM) as well as surgical instruments. Known for high quality implants, Sigma surgical was founded by Mr J J Gothi in 1998 with just 3 employees. From there the company has grown by leaps and bounds. Now under the leadership of Mr Mehul Gothi and his vision of providing international quality implants at affordable price to Indian customers, Sigma Surgical is set for the future with their state-of-the-art facility.To provide more high-quality products, the decision makers at Yuhuan Jingrun wanted to focus on improving the product quality while at the same time optimizing the overall cost. Mr. Dasheng Zeng, the responsible production supervisor, explains: “We had the issue of high tool costs because of a too low tool life. The production efficiency and machine utilization did not meet our expectations. We set the goal to create a reliable and highly efficient process, increase the tool life and improve the production efficiency.” At the same time, Yuhuan Jingrun aimed to reduce the cost of the metalworking fluids. Yet they’ve experienced issues with their previous coolant. They did not have a stable process and fighted with unpredictable tool wear. “The unpredictable wear of inserts at Sigma Surgical was varying to an extend which did not allow them to plan and work properly. There was also a gap as some tools showed a higher tool wear than others. This resulted in component rejection and affected the productivity negatively” explains Amol Pawar, responsible Sales representative from Blaser Swisslube the issues. “Amol Pawar explained to us how to analyze the production situation and what we can expect further down the road in regards to optimization and cost savings”, explains Mehul Gothi, Director at Sigma Surgical. He trusted in the comprehensive Blaser approach as he was looking for a long-term relationship and a technology leading partner. So he gave his agreement to run a test...
by Avery1Media | May 4, 2021 | Customer Cases
Vasco 3000 maximizes tool life and productivity of automotive manufacturer Company building of Yuhuan Jingrun Machinery Co. Ltd. In early 2020, the Chinese automotive parts manufacturer Yuhuan Jingrun Machinery Co. Ltd. contacted the metalworking fluid experts of Blaser Swisslube China to discuss pressing challenges: The tool costs were too high, and the machine utilization as well as production efficiency could not meet expectations. After an in-depth analysis of the processes, materials, and tools, Blaser Swisslube proposed the use of the mineral oil free cutting fluid Vasco 3000. With outstanding results: The tool life was increased between 30% and 55%, the process reliability was maintained, and the coolant costs were reduced. produced brake calipers for trucks Yuhuan Jingrun Machinery Co. Ltd., established in 2018 and located in Yuhuan City near Taizhou in the province of Zhejiang in China’s East, is a young but ambitious and quickly growing manufacturer of automotive parts. The company mainly produces automobile parts, motorcycle parts as well as engine parts. The manufacturing processes include casting and forging blanks as well as precision machining. The materials include cast iron, carbon steel, alloy steel, stainless steel and others. To provide more high-quality products, the decision makers at Yuhuan Jingrun wanted to focus on improving the product quality while at the same time optimizing the overall cost. Mr. Dasheng Zeng, the responsible production supervisor, explains: “We had the issue of high tool costs because of a too low tool life. The production efficiency and machine utilization did not meet our expectations. We set the goal to create a reliable and highly efficient process, increase the tool life and improve the production efficiency.” At the same time, Yuhuan Jingrun aimed to reduce the cost of the metalworking fluids. Coolant becomes a Liquid Tool In early 2020, decision makers of Yuhuan Jingrun and Blaser Swisslube China discussed the situation. Jack Wang, Blaser Sales Representative, looks back: “Blaser stands for an all-encompassing approach: It is crucial to evaluate all parameters, such as water quality, tools, machines, and materials, in order to identify the optimization potential of the whole process.” If the metalworking fluid matches perfectly to all the circumstances, it becomes a Liquid Tool and influences all other factors – productivity, tool life, surface quality, machine cleanliness – in a very positive way. Mr....
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