Hedelius Acura CNC machines and BMO handling robot cell provide substantial capacity expansion at Abbink Metaal – a first in the Netherlands!
Abbink Metaal recently acquired two Acura CNC machines from Hedelius with a BMO robot cell between them. This arrangement means a single handling robot can operate two machining centers. The company has significantly increased capacity and speed with this BMO/Acura combination, the first in the Netherlands. New plans are already in the pipeline.
A year and a half ago, the Almelo-based company became part of DG Holding, owned by entrepreneur Dennis Grolleman. DG Holding also acquired sheet metal fabricator Keizers Metaal in 2016. DGS also falls under a branch of the holding. DGS is a developer and manufacturer of production lines for the food industry, especially the meat processing industry. In time, the company plans to transfer its own products to the subsidiaries, which means sheet metal processing to Keizers and turning and milling of machine parts to Abbink Metaal. But Abbink is currently so busy that regular customers from various industrial sectors take precedence.
Abbink Metaal designs and manufactures machine parts, machines and machine lines. This involves conventional turning and CNC turning and milling of materials such as aluminium, stainless steel and plastic. Demand at the company has never been this high before. ‘We’re swamped for the next few weeks,’ says manager Joy Fiechter. ‘The semicon, food, and defence sectors are operating at full capacity, and we’re seeing that reflected in our own operations. Milling is really under pressure, but demand for turning is high too. So further expansion with machines, as well as people, is much needed.’
One option: Expanding
‘After the takeover, we really only had one option: expand substantially,’ he says. “With the current order book and the ambitions of both companies, more capacity is essential. That added capacity is sorely needed for the future anyway. Besides, we wanted to replace a CNC machine anyway, so we might as well buy two. Dennis Grolleman is an all-or-nothing guy and hates half-measures. He switches gears quickly when something else comes his way that he believes in.’
The pre-acquisition Abbink Metaal was nothing like the current company, Fiechter points out. ‘We’ve invested heavily in expanding with skilled workers (from 15 to 21), machines and automation. That makes a completely different impression and projects professionalism.’
The brief for the new machines at Promas and BMO was clear. Fiechter explains, ‘We presented a pile of drawings and said, “This is what we make. We work according to the 80-20 rule: that the combination we purchase should be capable of producing 80% of the products. What machines do we need for that?”’
Abbink Metaal already has many Promas machines. This includes four CMZs with automation, five Hedeliuses, including the two new Acuras, as well as a Hartford with automation. ‘Our experience with CMZ and Hedelius has been good, so the choice was quickly made,’ says Fiechter. ‘We have loyal suppliers and customers,’ said Grolleman. ‘We make a choice, and if it proves a good one, we stick with it. Promas has a knowledgeable team, with good, fast service. And we have 20 years of experience with Hedelius; there’s a click, and the machines and service are good.’
‘I see lots of other companies installing BMO cells, and they can’t all be crazy.’
– Dennis Grolleman, Abbink Metaal
Complete combination
The choice came down to a Hedelius Acura 50 and an Acura 65, both with rotary swivel table and liquid-cooled, torque-driven direct drive for fast, backlash-free positioning. The Acura 50 has a mirrored configuration compared to the 65, so it loads on the right side rather than the left. Each of the 5-axle machining centers has its own standby tool magazine with a total of 486 tools.
Abbink bought over 120 holders with tooling straight away. ‘Even with so many, it’s not even half full,’ Fiechter says. And all the tools we have in it will stay in it.’ Between the two 5-axis machines, the BMO automation solution was chosen for the workpiece loading. ‘I see lots of other companies installing BMO cells, and they can’t all be crazy,’ laughs Grolleman. Based on the provided drawings and what the cell needed to be capable of, the company started calculating and ultimately recommended the Titanium 180. Now, with the Acura 50 to the left of the BMO and the Acura 65 to its right, we have a complete combination that can handle anything, explains Fiechter. It makes 24/7 possible. ‘Or I should say 24/8, because the machines keep right on working during the breaks too,’ says Grolleman.
All in one go
Fiechter is convinced that speed is important and even necessary. ‘All in one go. That’s my motto. By that I mean, whenever possible, everything you start should be finished in one go, including all the necessary operations. That’s the operating model we present to customers, too, because it gets things done quicker.
We want to double the amount of work we handle in the next five years, mainly through automation but also with additional skilled workers, so surely you need 50% more capacity. A combination robot cell with two 5-axis machines is the perfect solution.’ The robot picks material to be machined from one of the drawers and places it through the side door into one of the two Acuras. Then the machined part is removed from the CNC machine and placed back on one of the drawers. The BMO has seven drawers that can be flexibly arranged according to the size of the components. Between operations, the robot can also change grippers or continue with a different drawer. Moreover, the robot can pick up the part from the bottom, turn it and then place it in the other CNC machine.
First in the Netherlands
The combination was ordered in May last year and delivered in February. BMO delivered exactly the same week as Promas. The installation was already running at full capacity the same week. Establishing the interface between BMO and the two Acuras went without a hitch. Hedelius machines run with BMO automation elsewhere, including in Germany, so it is a proven match.
BMO even has a BMO Acura combination of its own. However, Abbink Metaal did become the first machining contractor in the Netherlands to link the complete set of two Acura CNC machines to one Titanium robot cell. With that combination, capacity has skyrocketed, according to Fiechter. It works for both larger series (around 400 pieces at Abbink Metaal) and smaller series. For repeat jobs, it is also a good combo. ‘For example, when we get a new order for something we made two months ago, the job can be up and running within 10 minutes.’ However, the interplay between the Acuras and the BMO could be further optimized, he has noted. ‘When the CNC machines are still working, the robot sometimes stands still, while it could be performing some additional preparatory tasks in the meantime. But that is streamlining and fine-tuning. I’m already overjoyed that we have the machines.’
‘Although the BMO Acura trio may have been purchased to produce for DGS, Abbink Metaal’s regular customers are our top priority,’ stresses the manager. Because of the heavy schedule, the machines must be quick and easy to operate. And that has been invested in too. A day after the course, the Acura 50, Acura 65 and BMO Titanium combination was already producing. ‘We have three people who can work with it,’ says Fiechter. ‘They were trained internally, including with EdgeCam. That ensures stability within the organisation.’
Own digital portal
Abbink Metaal is also working on a digital portal. ‘With everything in it,’ says Grolleman, ‘including welded parts and assembly parts made of sheet metal from Keizers. Then we will be subcontracting within our own company. Turning and milling, as well as assembly, will be added within the next six months. This portal will be so smart that it will automatically correct based on manufacturability. Then it is production-ready at the touch of a button. This will enable us to handle every aspect of the process for our customers.’
Dedicated
Abbink Metaal, like DGS, believes in dedicated partnerships. Fiechter explains, ‘This means that all parties involved can ask a fair price and use good components. We strongly believe in speed. Delivering the right product, at the right time, as agreed. Achieving that is a real differentiating factor these days. In recent years, I’ve been genuinely surprised on more than one occasion by how subcontractors can mishandle projects and then have the audacity to deliver subpar quality.’ Competing on price alone, he says, is not the way. ‘Nowadays, everyone spends a lot of time answering quotation requests, while that benefits no one. With dedicated partnerships and good agreements with buyers, you can spend your precious time producing the best quality turning and milling work. That approach means everyone works on the basis of trust and for a fair price for the parts. That kind of partnership is exactly what is necessary to truly provide added value. The overall operating model just has to be right.’ And since the company wants to double its business in five years, in his view, apart from additional machines, the premises will also have to be expanded. ‘We already have plans for a 30-40 square meter addition. But then we will also need more machinists.’
This article was produced by MTL Metaalmagazine in collaboration with Promas.
