Positive outcome of the project
The thoroughly positive results of the SMED project were successfully integrated into the set-up process at weba Werkzeugbau with the support of the automotive cluster. The advantages of this method are numerous: throughput times were reduced, plant downtimes were minimized thanks to optimized retooling processes, and a valuable exchange of experience took place between the cooperating companies. These improvements led to additional capacity, reduced manufacturing costs and faster identification of quality defects.
Increased safety and employee qualification
Another significant benefit was the reduced risk of injury and increased employee qualifications. These factors contribute to continuous improvements, which are of great importance for the company's future competitiveness.
Implementation in the milling machining center
To implement the project, weba opted for a milling machining center (Mazak 60/120), which enables both 2D and 3D machining and where the set-up processes were previously very time-consuming. By manufacturing a second set-up plate, which can simply be placed on the machine table and removed for each set-up process, the set-up time was reduced from 120 to 30 minutes. The free accessibility and comfortable working height of the plate make set-up processes much easier.
Extended applicability and increased productivity
The possibility of using the SMED method on other machines can significantly increase the company's productivity. On completion of the project, it became clear that increased productivity and increased capacity can also be combined with reduced workload and employee motivation.
Positive feedback from employees
The project was well received by the participants and consistently implemented. “Although I was skeptical at the beginning, the involvement in the various project phases quickly convinced me of the project benefits. I think it's good that the project team received all the support it needed for successful implementation,” says a machining technician at weba.
Another machining technician adds: “The set-up situation before the SMED introduction was unsatisfactory. The findings from the project have shortened and simplified the set-up processes. Thanks to the cooperation with other companies, many views and ideas were brought in, enabling good and efficient optimization processes to be developed. The working method has become much more ergonomic thanks to the second set-up plate. This is accessible from all sides and thus facilitates the set-up process. By outsourcing the set-up and alignment work, set-up is less stressful for the staff and machine downtimes have been significantly reduced.”
The SMED project at weba Werkzeugbau has impressively demonstrated that considerable improvements in production processes can be achieved through a methodical approach and cross-company cooperation. The successful results make a lasting contribution to the company's competitiveness and efficiency.
About weba Werkzeugbau
Since its foundation in 1982, weba Werkzeugbau has established itself as a leading specialist in the manufacture of tools for cold and hot forming in the automotive industry. With over 300 qualified employees at two locations, weba combines state-of-the-art technology with in-depth expertise to provide its customers with customized and innovative solutions. The headquarters and development center in Dietach, Austria, is the creative heart of the company, while the site in Olomouc, Czech Republic, focuses on hot forming. With an innovative and quality-oriented corporate philosophy, weba focuses both on the needs of its customers and the well-being of its employees.
