A desire to automate the manufacture of high precision components, whilst getting the best utilisation out of their skilled engineers, was the key element which prompted WLR Precision Engineering Limited to purchase the Kern Micro Vario complete with Erowa Compact 80 automated pallet loading system. Recognising the limitations of traditional workflows and the opportunities presented by automation, WLR sought a solution that could deliver unmatched accuracy, streamline operations, and support their vision for long-term growth.
What follows is a closer look at how this investment has transformed WLR’s approach to manufacturing, delivering remarkable precision, consistency, and efficiency across their operations.
As an existing Kern user WLR were fully aware of the benefits a Kern machine delivers having first installed their Pyramid Nano Machining Centre in 2013. Discussing why WLR invested in its second Kern machine, the automated Kern Micro Vario, Kevin Callon, Managing Director at WLR, said: “One of my regrets was not having some form of automation on the Pyramid Nano when we first bought it, despite having the option. There was no way we would have bought another Kern without some form of automated loading to maximise the running hours of the machine.”
The introduction of the automated Micro Vario now enables WLR to run production continuously ‘lights-out’ whilst utilising the existing Pyramid Nano for smaller batch runs and one-offs during daytime working hours.
Kevin explained: “The consistency of the components the Kern machine produces is amazing and repeatable to the micron. The precision is so impeccable that we now channel as much work as possible through the Kern Micro Vario. It’s not only the really demanding and high-accuracy work that the Kern was initially intended for, but also the less demanding work that would normally be done on less precise machining centres.”
The reward for this incredible accuracy and repeatability means less demand on the engineering team to constantly check workpieces produced with far less demand on the inspection team. An example of one component, which was previously being machined on one of WLR’s other machining centers, was a part which required the alignment of an internal angled hole of 2.0mm diameter inside a bore to a 4.0mm wide keyway which was being milled into the OD of the component. These two features had to align within a tolerance of +/- 0.0125mm, a tolerance which was having to be constantly checked on the other machine due to scrap rates, and which the Kern achieved easily requiring no monitoring at all.
"The Kern is on another level"
Kevin added that what sets the Kern apart from the rest of the CNC machines at the Nottinghamshire business is: “It's definitely the accuracy and repeatability as well as a big improvement in surface finishes. The Kern is just on another level, especially on harder materials. This isn’t just down to the spindle concentricity but the whole package. It is a very robust machine designed to deliver incredible repeatability.”
Kevin continued: “Previously, we didn’t have enough of the right sort of work for the Kern to keep it fully occupied. We started putting other work on the machine to fill its capacity. We now realise the benefits of this strategy because of its repeatability. The tolerances we struggle to maintain on other machines are easily achieved on the Kern.”
“The cost benefits are great because we never scrap anything”
With machine utilisation down to a ‘fine art’ and the variation in size and complexity of components in the workpiece loader honed to perfection, the company is maximising the capabilities of the Kern. Kevin stated: “The cost benefits are great because we never scrap anything. When we run the machine unmanned through the night, we know that everything will be spot on when we come in the next day.”
Even amongst the extremely impressive array of CNC machine tools at WLR, the Kern Micro Vario was clearly a complete game changer regarding repeatability and consistent part quality. In these demanding times, the ability to produce consistently high quality is key to ensuring complete customer satisfaction, and it certainly looks as if WLR has found the right solution.
“Overall, it is a great asset to our business.”
Alluding to the Kern machine's cost per part, Kevin commented: “Based on cost per part, the machine more than pays for itself. It makes the job easier, and because we have such a robust process in place, it has generally reduced the burden on the inspection department and the workforce. It has also improved planning and lead times because parts come off the machine correctly the first time. Overall, it is a great asset to our business.”
If you would like further information on the Kern Micro Vario and Erowa Compact 80 Robot Loading System or any of the Kern machine tool ranges, please contact Rainford Precision today. Our team pride themselves on helping businesses overcome manufacturing challenges with bespoke solutions tailored for their unique requirements. We'd be happy to assist with any of your queries and can provide our expert guidance to solve any problems you may have.
Let us show you how the right technology can redefine what’s possible in precision engineering and elevate your business to the next level. For more information or to discuss your requirements please contact our national machine tool sales manager, Jaison Toon, on 07774 924757 or email him at jaison.toon@rainfordprecision.com.
You can also get in touch with our offices either via our website or by giving us a call on 01744 903757.