12/02/2009
High pressure, high speed and precision
CERATIZIT is the technological leader worldwide in the field of the die industry |
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Every day we deal with stamped parts. No matter whether it is furniture metal fittings or motor saws, small plug-in contacts in computers, mobile phones or electric household appliances – we can find stamped parts practically everywhere. At the Reutte site CERATIZIT produces carbide erosion blocks and formed parts for the die industry according to customer drawings. One of the CERATIZIT customers who has been trusting the carbide expert for many years already is the Leicht + Müller Stanztechnik company.
Stamping is the manufacture of flat or bent parts made of sheet metal or foil strips using a stamping press and a stamping tool. CERATIZIT produces carbide erosion blocks and formed parts from which the customer makes die inserts and punches through spark erosion (EDM and wire erosion) or grinding. In fact the business segment ‘tool and die industry’ has gained the world leadership in the past few years.
The Leicht + Müller success story
The Leicht + Müller Stanztechnik company produces stamped parts and tools for automotive electrics, telecommunication, household appliances and many other industry sectors. The company was founded in November 1984 by Heinz Leicht, expert toolmaker, and Klaus Müller, tool constructor, in Remchingen near Pforzheim (Germany). Their priority was to enter the international vanguard of tooling manufacturers.
As far back as 1985 Leicht + Müller also started their production of stamped parts. This second string to their bow not only provided synergy effects but also decisive growth impulses for the company. Today Leicht + Müller has 60 employees, who on a surface of 5,500 sq.m. produce approx. 1.3 billion stamped parts (20-80 tons) per year on 10 Bruderer stamping machines.
Up-to-date stamping machines for razor blades
The company is particularly proud of the project for Gillette (Procter & Gamble Group): together with other companies Leicht + Müller developed a complex, fully automatic stamping line for the further processing of razor blades which are applied in the latest product ‘FUSION’. The Americans requested a higher output from Leicht + Müller as compared to the previous technology applied.
In the meantime three complete stamping lines have been built at L+M which are suitable for batch production and have been delivered to Gillette (two of them in Boston/USA and one in Berlin/Germany). The most important parameters of the currently most modern stamping machines worldwide is the notably higher output, 500 strokes per minute, two blades with 13 laser points per stroke respectively, a cleaning module, laser measuring device and a camera in the stamping tool. Furthermore robotics and conveyor belts to guarantee full automation of the process are also utilized.
Vision Control for one hundred per cent process security
Leicht + Müller offers an extensive service range. The company’s designers work on 2-D (Cadda) and 3-D (Solid Works) CAD work places from Daveg. The Pforzheim based company is also able to offer prototyping and pilot production. Last but not least it is involved in batch production of stamped parts with Vision Control for guaranteed product quality and ‘laser marking on the fly’ for 100 per cent traceability (every single part is provided with a marking without slowing down the process).
Combinations of metal and plastic
Leicht + Müller SYSCOTEC (Systems, Components, Technologies) was founded in 2004 and specializes in the development and production of complete assemblies, i.e. combinations of metal stamping products and plastic parts. The new products from Leicht + Müller SYSCOTEC have brought customers such as Mercedes, BMW, TRW and Continental Teves onto the scene. The first batch production for level sensors in automotive windscreen washing fluid started in 2005.
Interview with the leading management quartet of Leicht + Müller
At Leicht + Müller the young generation is already straining at the leash. The sons Timo Leicht and Marco Müller have both completed a profound education. Currently they are working in Sales, Marketing, project management and in the company management, and later on they will entirely take on the responsibilities of their fathers, Heinz Leicht and Klaus Müller.
What is important in stamping technology and what does that mean with reference to the carbide?
Marco Müller: “High precision, long tool life and profitability. Carbide applied in high-performance stamping technology has to be adapted continuously to the high demands regarding tool life and will always be under scrutiny when compared to ceramics.”
Is there a ceramic solution which can keep the pace?
Marco Müller: : “This discussion has been going on for a while. Of course we have already tested special ceramic grades and the results in terms of wear and tool life were sometimes even better than with carbide. However, the application of ceramic is not worthwhile considering the high acquisition costs and the extraordinary complexity of machining operations compared to carbide. Up to now ceramic has not caught on in our sector for economic reasons, and this is also not to be expected in the near future.“
What are the trends in the stamping sector?
Timo Leicht: “Target prices on a globally minimum level, but products of the customary best German quality. The market is becoming more and more difficult and one has to orient oneself based on low-wage countries. For cost reasons one should actually buy components for stamping tools there in order to remain competitive. The quality however up to now does not meet the standards of Leicht + Müller. So we have to concentrate on cost reduction in our company, e.g. automation of the processes. Another tendency is towards hybrid components (plastic-metal composite material). An ever increasing number of customers requests complete assemblies from one source, that means stamped parts are covered with plastic and provided with additional components such as e.g. Reed sensors or resistances. Since 2004 we have been able to offer this through Leicht + Müller SYSCOTEC.“
How did the partnership with CERATIZIT start?
Heinz Leicht: “That was at the beginning of the 80’s. At that time Josef Lämmle was the segment manager. He visited us frequently and asked if we were ready to test his products, and he was successful.”
How do you assess the relationship with CERATIZIT?
Klaus Müller: “We are delighted with the carbide from CERATIZIT! We appreciate speed, the large assortment and above all consistent quality. In a business where time pressure is enormous the business partners have to be absolutely reliable. And we fully trust the CERATIZIT team which has been serving us professionally for many years. Carbide is really a matter of confidence!”
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