Going into Production Constantly faced with new challenges

Anyone that manufactures complex hybrid metal and plastic parts has to master more than just working with these two materials. It is also vital for the several-million-euro production system to quickly enter service. German manufacturer of punched and hybrid parts KRAMSKI uses multisensor measuring machines from ZEISS for this.

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Success Story
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How Kramski succeeds with ZEISS Solutions:
Success:
  • Optical and contact measurements on one machine
  • Time savings through offline programming
  • Quickly from prototyping to serial measuring program

Multisensor Measuring Machines Accelerate Initial Sample Inspection at KRAMSKI

The challenge: quickly from prototype to volume product

It is not uncommon to measure more than 100 initial samples at KRAMSKI before the tools are adjusted sufficiently to enable volume production to start. For each part, the objective is to ensure the quality of up to 500 characteristics. And once the first samples are available, the clock starts ticking on the measuring technicians. According to Mathias Schlegel, Measuring Technology Team Leader, "Reliable results then have to be delivered very quickly." After all, time is money. The sooner the results are available, the sooner the toolmakers learn if or what they have to correct, and the sooner production can start up the several million dollar production systems.

Up to 500 characteristics must be checked on each workpiece during initial sample inspection
Up to 500 characteristics must be checked on each workpiece during initial sample inspection
Schlegel and his team measure numerous characteristics optically using distance sensors. Others can only be measured by contact
Schlegel and his team measure numerous characteristics optically using distance sensors. Others can only be measured by contact

The solution: ZEISS O-INSPECT 442 multisensor measuring machine

To complete these measurements in such a short time, Schlegel and his team rely on two ZEISS O-INSPECT 442 multisensor measuring machines. They enable contact and optical measurements on one and the same machine very quickly. "We save an enormous amount of time today because we can create the measuring programs offline. This was not possible with our previous measuring machines," explains the team leader.

"It is not without reason that our company founder proudly states that 'You can negotiate with us about everything – everything but quality'."

Matthias Schlegel, Measuring Technician Team Supervisor

The benefit: valuable time saved

Offline programming is beneficial for multiple reasons. First, because the measuring machine is not blocked during programming and can be used for other tasks. Thanks to ZEISS CALYPSO measuring software, it is also possible to program directly in the CAD program. This means that the measuring programs are generated before the workpiece is available. Another benefit of the measuring machine: on the basis of a prototype program with several hundred characteristics, measuring technicians can subsequently generate a serial measuring program with 100 or 150 characteristics for random sampling relatively easily. They simply select the required characteristics, the machine then automatically calculates the travel paths and saves KRAMSKI additional time. As Schlegel says, "None of the other machines we looked at could do this."

Work in a measuring lab must be fast and precise. Team supervisor Mathias Schlegel (left) and his colleague Waldemar Fust are supported by multiple ZEISS measuring machines
Work in a measuring lab must be fast and precise. Team supervisor Mathias Schlegel (left) and his colleague Waldemar Fust are supported by multiple ZEISS measuring machines
About KRAMSKI

The core competency of the KRAMSKI Group is the development and manufacture of technologically advanced punched and hybrid parts. The family-run company produces 2.5 billion parts annually at its headquarters in Pforzheim, Germany, and its subsidiaries in Sri Lanka, the USA and India. Most of them, as with a large number of the tools, are developed in house by the company's approximately 700 employees. The company's customers can be found in a wide variety of industries, including automotive, electronics and telecommunications, as well as medical technology and the solar and consumer goods industries.