Ceaseless development of still more complex and automated machining continues at KP Components A/S in Spjald, Denmark. The company has started its next era with the purchase of a manufacturing system with four HELLER H 4000 4-axis machining centres and additional robot automation from QRS. The installed machines from HELLER replace an older robot cell which produces complex parts in the same product family for mobile hydraulics. The manufacturing system comprising four CNC machines and robotic loading is one out of six systems. It is about 15 years ago that the first cell was taken into operation and seriously boosted KP’s robot automation of the machining process.

Even though a lot has happened since the first cell was taken into operation, the same product family still produces to the same customer as back then. However, it is important for CEO Søren Husted that the company does not stagnate. The parts require more of the machine park and at the same time, there is a continuous need to increase the competitive position: “In order to maintain our high level of technology and the position of being the leading subcontractor for complex machining processes, we chose to analyse the possibilities within technology. First, we conducted a thorough scan of the possibilities within the market. Afterwards, we invited a range of contractors to submit an offer on the whole machining task. It was a close run; however, we chose the HELLER solution, which is represented by Masentia A/S in Denmark,” states Søren Husted.

In addition to purchasing the manufacturing system for the factory in Spjald, the company also ordered three equivalent HELLER machines for the sister factory in the USA, where KP Components has been based in the state of South Carolina for the last ten years. The factory, which was doubled in size in 2020, is supported by the headquarters in Spjald, which has been responsible for the machine purchase. Therefore, the experience with HELLER was transferred to the factory in the USA from day one, where also a wide range of parts for mobile hydraulics are produced.

Mature solutions are implemented quickly

Preparations for the machine investment were started in mid-2020 in the middle of the Covid-19 pandemic. As the first negotiations were to be completed in early 2021, Covid-19 lockdowns made visits to HELLER’s headquarters in Nürtingen impossible. Instead, the ongoing dialogue was conducted via online meetings and visits from Masentia’s Sales Director Karsten Bechmann to the factory in Denmark.

“In many ways, this investment round differs from previous ones. The digital meetings clarified our partnership, even though we would have preferred to meet with the people from HELLER face to face,” states Søren Husted. KP Components has maintained the longstanding partnership with QRS A/S in terms of robot automation, which has been a natural part of the online meetings with HELLER. “All in all, this has meant that the pandemic did not become an obstacle in the negotiation process, which is very important in such a huge and complicated investment. One could say that Covid-19 was just a bump in the road,” states Søren Husted and continues: “We have chosen a path and are continuously developing our setup for this. A high degree of automation is important, even with smaller sizes of series. As something new, we have integrated a 3D-coordinate measuring machine into our cell. Thereby, we are doing our maximum to ensure that only good parts come out of the cell. Together with our internal expertise in design and construction of fixtures, we have a production setup that we expect to be competitive for many years.”

However, the HELLER machines presented one challenge: the Siemens controls, which the company’s technicians are not used to. Søren Husted: “My fears have proven unfounded, I must say. The course programme from HELLER meant that our experienced technicians were quickly introduced to the new programming world, and that went faster than I had ever hoped.”

The company is agile and has factories in Denmark, the USA and Sweden, which primarily approach global manufacturers that want high-end products. “We strive for stable and long-term partnerships, where we can support our global customers where they need us, and this is often in connection with their assembly plants. The customer portfolio includes the five biggest manufacturers in the world of mobile hydraulics, as well as several other international manufacturers. We supply parts for both valve and control systems as well as pumps and engine parts,” states Søren Husted.

The partners up close

The high degree of automation requires a lot from the supplier QRS and the same applies to the CNC machines. In addition to the current machining centres from HELLER at KP Components, the large machining park comprises Mazak CNC machines with a fair share of Japanese machines from Brother for drilling and milling.

”Uptime is very important for us. If there is a breakdown, we risk that the entire lines might stand still, so service and repair must be started quickly. We have good experience with the existing CNC machines, as Masentia has a partnership with Brother. Naturally we expect this to be the same when it comes to the machines from HELLER”, emphasises Søren Husted.

When KP Components initiates a process with a potential customer, it usually takes at least three to five years before serial production of a new product begins. Therefore, the company attaches great importance to choosing the right solution for a project from the start.

“We must make our money from the machining, as the customers often purchase the raw materials themselves. Therefore, it is the margins that decide whether we will deliver on the set business case and to earn money on delivering the parts at the agreed price,” tells Søren Husted.

In practice, challenges must be solved at the company in Spjald. And here, QRS and Masentia should not point the finger at each other – they should assist in solving a challenge if it arises. “We are dependent on our suppliers delivering as agreed upon and the cell running as it should. Ultimately, our end customers depend on the entire value chain working, and when this is the case, it has a positive effect on everyone,” says Søren Husted.