MAPAL Logo Logo MAPAL Dr. Kress KG Tailored services Gaining technological lead with engineering services by MAPAL As an engineering partner, MAPAL accompanies its customers from the planning to the optimisation of the production. They can select from service modules as required, or make use of service packages specially tailored to their needs. In both cases, MAPAL experts with many years of experience place their high level of innovation and their holistic perspective of processes at the customers' disposal. The technology centre with its state-of-the-art equipment is able to exactly simulate every production process, allowing the specialists to find new, even better solutions for the customers. Advantages: Solutions for complete workpieces from experienced specialists Complete process design and implementation from a single source Latest manufacturing methods Efficient, cost-optimised tool technology Optimal harmonisation of tool, workpiece, fixture and machine Highest product quality, process reliability and cost-effectiveness from the start Quick transition from planning to implementation with completely dependable planning Services tailored to different initial situations Desiging a new manufacturing line MAPAL takes over the project planning for your complete workpieces and plans and realises a reliable process – quickly, flexibly, on-site, with transparent costs and complete documentation. Customers can concentrate on their core competence. Re-tooling the manufacturing for new parts Continuing to use existing machines saves time and costs. With many years of experience and know-how MAPAL guarantees the highest process reliability. The specialists support individually according to customer needs and, upon request, take over the complete responsibility for the re-tooling. Optimising tools and processes during on-going production Introducing modern machining strategies and innovative tool solutions during on-going production also represents a considerable potential for increases in productivity. The result: longer tool lives, improved part quality and increased productivity. Engineering service modules E1 - Project analysis Based on raw part and finished part drawings as well as machine data, MAPAL analyses the manufacturing task in close collaboration with the customer and develops effective machining strategies for all steps. The project analysis includes: Machining proposals for all machining steps Tool list Tool sketches Feasibility study Harmonisation with the machine situation Preparation of bore and surface plans E2 - Process design Irrespective of whether the focus is on flexibility or productivity: with a sound design of the machining process, MAPAL supports its customers on the way to stable, economic manufacturing. Elements of process design: Cycle time studies Definition of technology data Division of process over individual machines Clamping principle sketches E3 - Tool solutions Outstanding performance, simple handling, cost-effective reconditioning: MAPAL specifically selects or develops the best, latest, cost-effective tools for the application. Elements of the tool solutions module: Tool design Tool engineering Combination tools for reducing process steps Design of clamping technology Tool drawings Assembly, setting and balancing (at MAPAL) Delivery to the place of use Professional support during breaking-in E4 -Documentation Upon request, the documentation prepared as part of the engineering services is specifically adapted to customers' requirements. This ensures the rapid implementation of the new processes and makes future changes easier. Documentation services: Setting plans Tool plans Setting and installation instructions Work instructions Inspection and measurement logs/reports Trials logs Process capability reports E5 - Fixture solutions With individual solutions MAPAL ensures that as many workpieces and as many machining steps as possible can be reliably machined with μ-precision in one clamping system. Options within the module fixture solutions: Preparation of drafts Engineering Manufacture/buying-in Assembly and commissioning Technical support Pre-acceptance with clamping trial E6 - Tool restriction study To prevent collisions and to identify optimisation potential, MAPAL simulates the planned machining process in advance and based on 3D models in a virtual environment. Tool restriction studies comprise: Collision analyses 3D study Optimal harmonisation of tools to fixture, workpiece and machine compartment Prerequisite: virtual models of tools, workpiece, clamping fixture and machine E7 - NC Programming To design the process as productive as possible, MAPAL optimises the machining parameters during NC programming. In this way secondary activities such as loading/unloading and tool change can be accelerated. Elements in the module NC programming: Preparation of NC program taking into account manufacturer-specific machine functions Preparation of special milling cycles (e.g. interpolation turning, trochoidal milling) Computer-based generation of machining contours (2D/3D) Customer-specific program structure E8 - Breaking-in and commissioning To help customers produce reliably and without scrap, MAPAL offers to take over the commissioning and the breaking-in of the process on-site. If the schedule is tight, breaking-in can also be undertaken in the MAPAL technology centre. Services for breaking-in and commissioning: Checking and logging the machine geometry Installation of NC technology Breaking-in the complete machining process Preparation and implementation of process capability study Transfer of process to the customer E9 - Start-up support On-site support is also available as the production starts up. To guarantee a manufacture as productively and economically as possible, the machining specialists continuously check the tool lives and cutting data for the tools. Options of start-up support: Support for production start-up Troubleshooting Technical support Training on operation, programming and process sequence Solutions for complete workpieces The Technology Expert Team TET service package usually comprises the engineering modules 1-4. The TET experts take over the complete planning for the workpiece; customers and profit from MAPAL's engineering experience. Contact Data protection Imprint © 2021 MAPAL Dr. Kress KG