HellermannTyton is one of the Worlds leading manufacturers of cable ties and cable management tooling, producing a whopping 80 million components every week. To maintain its remarkable output levels, the company has over 70 production lines at its Manchester facility.
However, the main drain on the Tooling department was the service, maintenance and repair of the company's numerous mould tools. As Mr Kevin Young, Hellermann Tyton's Toolroom Manager says: "We have 15 skilled toolmakers here capable of producing complete tooling and the group globally is crying out for new tooling. When we looked to invest and reviewed our bottlenecks, one area of concern was the spark and wire erosion processes - as by design, our tools are heavily reliant on EDM."
The manufacturer of cable ties and associated products for the automotive, rail and aerospace sectors looked at a number of EDM solutions and plumped for three Sodick machines from Sodi-Tech. As Mr Young continues: "Each and every EDM supplier had an opportunity to do trials with us. However, our attention to detail, coupled with retaining definition of tool form & cavity to cavity repeatability is extremely critical. Twenty microns is the difference between a cable tie passing or failing our quality control procedures. We found that in terms of the power to wear ratio the tool form was remarkable, Sodick line ticked all the boxes for us."
"When we opted for the Sodick machines, we initially did a justification trial and realised the machines were giving us a 30% saving on component times, which massively improved the throughput of our department. In realisation, we have probably achieved more than that. So, the machines have very mush surpassed our expectation.
From a support perspective, Mr Young tells MTD: "the back-up has been superb, we had initial and expected glitches during the bedding-in period, but we've had support with us within 24 hours or we've had an engineer on the phone guiding us through the process of correcting any errors."