Issue 6 October 2008
Meeting of the Giants Page 3
WALDRICH COBURG Gantry-Type-Milling Machines are
used to machine the large components of the world’s
most powerful diesel engines.
PowerTec HB in Operation Page 4
During an in-house exhibition at company G.M.W. Prä-
zisions GmbH & Co. KG, the new horizontal boring ma-
chine system PowerTec HB was presented to a large and
by WALDRICH COBURG expert public.
Successful family enterprise entrusts WALDRICH COBURG
Leipert Maschinenbau is investing
L eipert Maschinenbau GmbH is in-
vesting in another WALDRICH
COBURG machine. This is a good
Why did you decide on a WALD-
RICH COBURG machine in 1994,
although you were maintaining
occasion to ask them for the reasons business relationships with other
and the experiences they have had. suppliers?
Mrs. Scheidel: In 2006, your com- In 1991, when we purchased the
pany celebrated its 50th anniver- first gantry milling machine, we
sary. Can you tell us something made our first experiences. Being
about the beginnings? satisfied with the results, we or-
dered a sister machine.
In 1956, my father, Albert Leipert,
founded a turning shop in some The former supplier, who went
empty rooms on a farm. His first bankrupt, was not able to com-
employees were my mother and I, plete the machine, so I contacted
who was only 11 years old at that WALDRICH COBURG again. By
time. In 1962, my husband, Ro- chance, they had a gantry milling
land Scheidel, joined the company machine PowerTec 5000 for sale - Third manager generation of Leipert Maschinenbau: Mr. & Mrs. van de Ven
where we both have been manag- all components ready, packed and
ing directors since 1973. stored. It was great fortune that the
machine fitted closely on the exist- the first PowerTec 5000 AG Gan- our customers’ new requirements Mr. van de Ven, in 2006 there
Mr. Scheidel, how did it continue? ing foundation and that the first try we reached new dimensions. - we did not ignore them, but we was one of the biggest investment
WALDRICH COBURG gantry For the first time, roughing of met them. projects at Leipert. The PowerTec
With the first CNC boring ma- could start up production after 5 large and heavy workpieces with 7000 AG with floorplate and in-
chine (in 1975) a new era started. months only. big stock allowances and then fin- Consequently, a bigger WALD- tegrated turntable of diameter
Further CNC machines followed as ishing with the highest geometri- RICH COBURG machine had 6000 mm, prepared for adding
well as larger workshops. We slowly With the PowerTec 5000, also cal accuracies was possible on the to be purchased. The PowerTec a second portal to the bedways
closed down our turning and mill- your customer profile has sub- same machine. This was an abso- 6500 having an X-axis travel 20 later. What was the reason to de-
ing shop as we did good business stantially changed. lutely new experience. m, equipped with an S2 boring cide on this configuration?
with the machining of large and and milling head (drive power 105
complex workpieces. I guess, our Yes, that’s right. Before that time, We very soon identified the market kW, Z-axis travel 2500 mm). Fur- The ongoing boom in the energy
first contact with WALDRICH our customers were companies lo- trend towards more complex work- ther WALDRICH COBURG ma- sector, in the machine tool indus-
COBURG was in 1990 and since cated close to us, coming from pieces like press columns, press chines followed: in 2000, another try, as well as in the plant engi-
that time ‘complete machining the general machine-tool indus- head ends, machine beds for re- gantry milling machine PowerTec neering industry is driving us to
with portal milling machines’ has try, printing industry and equip- volving transfer machines or gear- 5000 AG, and in 2003 a turning new investments. Leipert has to
been our only business. ment-engineering industry. With box housings. We were open to machine PowerTurn AS. Revert- keep pace with the dynamics of
ing to your question regarding our the global markets. An increas-
customer profile: these investments ing customer demand can only
have changed it indeed, from re- be met by further investments.
gional companies to worldwide- For the time being it is not pos-
operating companies. Larger orders sible to extend the existing work-
require a change of internal proc- shop, therefore we have planned
esses as well as an efficient project to extend the capacities of the
management, along with produc- machine which is presently be-
tion documentation. ing assembled by a second portal:
There will be one portal working
Mrs. van de Ven, you have been in the area of the turntable while
a member of the board since the other portal is working in the
2003. With you and your hus- area of the floorplate. This opti-
band, Jeroen van de Ven, a gen- mum configuration permits dou-
eration change has taken place ble use of the ocupied area. Fur-
at Leipert. ther considerable savings can be
achieved by the common use of
In fact, one can say that I grew up the chip conveyors, coolant sys-
in the company, so it was obvious tem, tool changer and spindle-
to chose a profession in the field of unit serving system.
economics, always with the ambi-
tion to work in the family business. By the way, we have already re-
The change of generations - planned ceived the first order for our new
by my parents - went smoothly. We gantry. The workpiece to be ma-
have managed the transition period chined has a weight of 200 tons and
very well and have made some re- a length of 38 m. It is apparent that
organizations. We are continuously we made the right decision.
The new WALDRICH COBURG machine will start up production in October. improving our processes and are op-
timistic about our future. continued on page 2>>>
NEWS by Page 2
keeps on growing New Shop Building
At nearly 180 million EUROS our
2006 target order income was ex-
ceeded by 2.5 times - We achieved
W ALDRICH COBURG extend
their assembly and storage ca-
a further increase in 2007 to 250
million Euros and, this year to- On August 14, after 3 ½ months con-
date, has already exceeded the struction time, a new shop building
record high of 2007. There is no was officially inaugurated in the pres-
change in sight and the energy sectors in Europe, Asia and ence of representatives of the local pol-
America show high investment requirements. This sensa- itics, the construction companies as
tional order inf low will generate an order backlog, ensuring well as the management and staff of
full employment for more than 3 years. WALDRICH COBURG. The high
order volume and consequently the
In order to deal with the increasing delivery times, we will need for more capacity made this ex-
realize a turnover of twice the figures of 2006. Three se- tension necessary. WALDRICH COBURG management, representatives of Coburg and
quential years with growth rates of more than 30% are a big construction companies, Otto Waldrich (former owner, 2nd from right)
challenge and we are proud to have people achieving these The new shop building has the fol-
high goals. lowing dimensions:
• Area 1550 m²
The number of employees has increased by 65 to 688 and • Length 50 m
we are glad to welcome 20 new apprentices who have started • Width 31 m
their career at WALDR ICH COBURG in different fields of • Height approx. 15.5 m
This building project, representing
We took advantage of the good business situation and have an investment of 1.75 Mio. Euros,
significantly increased our investment volume in 2008. The was exclusively carried out by local
extension of our assembly area by 1550 m² has been com- companies. Further substantial in-
pleted and the procurement of a jig boring machine as well vestments will follow and show that
as further machine tools will help to increase our produc- WALDRICH COBURG is strength-
tion capacity. Additional new projects are running in the in- ening their Coburg facility.
frastructure area. The new building was inaugurated on August 14.
by Sven Grosch
We have a strong market position and are a competent part-
ner developing new technologies for all kinds of applications.
The orders for retrofits and modernizations on a high-qual-
ity level has increased, despite the high order volume of new
20 New Apprentices
machines. The next project on our list will be the strategic
development of our service activities.
The future of WALDR ICH COBURG is optimistic and we
are looking forward to continued successful cooperation with
our customers. O n September 1, 2008, twenty
young people started their
apprenticeship at WALDRICH
10 industrial mechanics, 3 elec-
tronic technicians, 3 cutting
mechanics, 2 draughtsmen as
tices have started their career at
Enjoy reading this newsletter! COBURG. well as 2 administrative appren- by Klaus Damaschke
Since the last issue, we expanded our personnel by 65 employees to Trainers and management welcome the new apprentices.
At present, we have a total of 54 apprentices. This corresponds to rate
of 8 % of the whole staff and exceeds the average rate in Germany.
Leipert Maschinenbau is investing
>>> continued from page 1 At the time of order, we take care as a 24-hour service guarantee.
IMPRESSUM This investment in our Kraich-
that the new machine is designed
with identical motors and drives
Regular maintenance reduces
the stress in production and
tal location will secure the jobs of - or even better - having milling avoids conf licts with the cus-
News by WALDRICH COBURG our longstanding employees and and boring units with identical tomer. Annual geometrical in-
shows that Leipert is well positi- interfaces. spections reduce the rework, re-
Issue: No. 06, 10/2008 oned for the future. sulting in higher efficiency. Due
Publisher: Werkzeugmaschinenfabrik WALDRICH COBURG GmbH The fast error analysis through to our highly qualified personnel
Telephone +49 9561 65-0 · Fax +49 9561 60500 · www.waldrich-coburg.de Mr. Ott (production manager), INDIS (INteractive DIagnos- and sufficient spare parts avail-
Editor: Hubert Becker (firstname.lastname@example.org) you have played an important tics System) enables an exact er- ability of important electrical
Coordination: Sven Grosch (email@example.com) role in this story of success. ror detection by the operator. components and drive motors,
Production: WALDRICH COBURG Quality and availability are WALDRICH COBURG‘s tel- our machines have an average
Print run: 3500 german and 2000 english copies the pre-condition for a smooth eservice provides immediate availability of approx. 98%.
Info: The current issue of „News“ can also be downloaded from the internet at: production. How do you man- access to the control system.
www.waldrich-coburg.de age to achieve a constantly high WALDRICH COBURG offers Interview dated 21.08.08
availability? excellent stand-by times as well by Willi Grolmus
NEWS by Page 3
Gantry-Type Milling Machines in the Diesel Engine Industry
Meeting of the Giants
H uge WALDRICH COBURG gantry-type milling machines are
used to machine the large components of the world’s most
powerful diesel engines driving the giants of the oceans.
Globalisation sets new stand- Equipment And Machine Re-
ards in the design of super-con- quirements
tainer ships and super-tankers
(length 415 m, width 65 m, The machine is designed for
draught 15.5 m to 35 m - pic- the complete machining of the
ture 1). These giant ships are workpieces.
being equipped with new pow-
erful main engines (80.000 kW The milling power is 105 kW,
= 110.000 hp) in order to ensure with a torque of 10.000 Nm.
the transport of enormous car- For machining a wide range of
gos in a faster, more economical engine types, the machine is
and more environment-friendly equipped with 10 to 12 attach- Picture 1: Super-Container-Ship of class A1 Photo: Hero Lang/ddp
way over the oceans. Even big- ments which can be automati-
ger tankers and engines are al- cally changed and can have an
ready being designed. automatic tool changer hav- Currently 25 gantry-type mill-
ing a capacity of 200 to 400 ing machine of the PowerTec
In general, a slower-running tools with max. weight up to series are on order. 11 of them
two-cylinder engine consists of 150 kg. will be used for the two-cylin-
three main components: base der heavy engine production.
plate (picture 2), column (pic- The high level of automation
ture 3) and cylinder block (pic- ensures that one operator can When purchasing a
ture 4), which are machined operate the machine alone in WALDR ICH COBURG ma-
seperately. automatic mode. Observation chine, our customers trust in
cameras, controlled via moni- our innovative products, tech-
The biggest component is tor in the operating panel, show nological competence and long-
the column; for a 14-cylinder the machining area. term reliability of their invest-
block, it is 24 m long, 5.5 m ment.
wide and 5 m high. The com- All linear guideways are hydro- Picture 2: Base plate Picture 3: Column
pletely assembled engine weighs static, which guarantees high- by Peter Schneyer
approximately 2300 tons, has est cutting performance and ul-
the height of a five-story apart- tra-smooth surfaces (Ra < 0.4,
ment house (15 m) and a quar- roughness 3 microns) during
ter of the length of a soccer finish machining.
field (25 m).
The machining of such large
workpieces requires huge ma- Base plate and column of the
chines having the following ca- motor block are welded parts.
pacities. High rigidity of machine, ram
and attachments is required to
Machine Specification machine the guiding surfaces
of the cross head. These guid-
Overall dimensions 42 m x 20 ing surfaces have a width of
m x 15 m (L x W x H - pic- 270 mm and are finish-milled
ture 5). The portal of a gantry- in one cut by means of a mill-
type machine moves in longitu- ing cutter of dia. 400 mm, the
dinal direction over the work- stock allowance being 0.05
piece clamped on the f loorplate. mm. The vertical stroke of the Picture 4: Cylinder block Photo: MAN Diesel SE
This longitudinal travel length WALDRICH COBURG ram of
is variable and can be extended, type S20 is 3500 m and the ad-
if necessary. The machining ditional special attachment has
range is 30 m x 7.5 m x 8 m (L a length of 1850 mm.
x W x H), the total weight of
the machine is 800 tons. In order to ensure machin-
ing over the entire height of
Foundation And Workpiece 5200mm, ram and crossrail
Weight move simultaneously in verti-
cal direction (Z- and W-axis -
To ensure the accuracy of all picture 5).
axes and the proper function of
the guideway systems, the foun- On the crossrail - 14.5 m long,
dation has an essential impor- weight 80 tons -, the milling
tance for the machine. The per- head of type S20 (weight 30
missible def lection of the mov- tons) travels in transverse direc-
ing load in longitudinal and tion (Y-axis). The guideways on
cross direction must not exceed the crossrail are provided with a
0,005 mm/m for a machine por- compensation curve ensuring a
tal with 330 tons. The biggest straightness of < 0.055 mm over
workpieces weigh 600 tons and 7 m milling head motion in re-
more. The foundation thick- lation to the f loorplate.
ness ranges between 5 and 7
m, depending on the local soil WALDRICH COBURG Gan-
conditions. As a general guide- try-type milling machines are
line, the weight of reinforced an outstanding product of the
concrete used for the founda- German machine-tool industry
tion is 8 to 10 times the ma- and are the result know-how Picture 5: Gantry-Type Milling Machine with engine part.
chine weight. and experience over decades.
NEWS by Page 4
EMO, METAV & Co. In-House Exhibition at G.M.W.
Trade Fairs PowerTec HB in Operation
T rade fairs at home and abroad
are an important platform for
WALDRICH COBURG to present
Chicago and will participate in
the BIMU in Milan. D uring an in-house exhibition
at company G.M.W. Präzi-
sions GmbH & Co. KG, the new
tion in the facilities of Burg. The
machine system consists of two
floor-boring machines and was
Nearly 250 visitors got the chance
to see this powerful machining sys-
tem. In the party pavilion the audi-
their innovative products to ex- In 2009, we will exhibit at the horizontal boring machine system put into operation by Norbert and ence was also informed of the next
pert public. CIMT in Beijing and at the PowerTec HB was presented to a Erich Brinkmann (Managing Di- investment of company G.M.W. .
EMO in Milan. For further in- large and expert audience.(>> is- rectors of G.M.W.) and Hubert Peter Schneyer, Applications Man-
A lively year of trade fairs has formation about our trade fair sue 2/06). Becker (CEO of WALDRICH ager of WALDRICH COBURG,
started in 2008 with the METAV schedule, please refer to our in- COBURG). The main character- presented the portal milling ma-
in Düsseldorf, followed by the ternet site: On June 11, 2008, WALDRICH istics of the PowerTec HB are the chine PowerTec 6500 AT-M2 re-
Metalloobrabotka in Moscow. www.waldrich-coburg.de COBURG‘s latest development hydrostatic bearings of the mill- cently ordered by G.M.W.
In September resp. October we was presented under production ing and boring spindle and linear
were represented at the IMTS in by Sven Grosch conditions at the in-house exhibi- guideways. by Sven Grosch
Exhibition booth at the METAV.
Impressing machine system: 2 PowerTec 180 HB horizontal boring machines.
Dr. Kapp Award
Award for Volun-
tary Social Work
T he Dr. Kapp Award supports voluntary social work, and two
WALDRICH COBURG apprentices were among the honourees.
The Dr. Kapp Award honours the Hubert Becker and their train-
social work of apprentices. The ers, Mr. Damaschke and Mr.
award is endowed with 10.000 € Henze, attended the ceremony
and is split among 41 honourees. and showed by their presence
Wolfgang Reß and Tobias Siegel that the social involvement of
were honoured for their work WALDRICH COBURG appren-
with the Boy Scout Confedera- tices is greatly appreciated.
tion ‘Weltenbummler’ and with
the volunteer fire brigade. by Klaus Damaschke Almost 250 visitors attending the in-house exhibition at G.M.W.
Change of Legal Status
New Company Name
T he change of the legal sta-
tus facilitates the inter-
nal processes of WALDRICH
Coburg GmbH & Co. KG has been
changed to Werkzeugmaschinen-
fabrik WALDRICH COBURG
are no changes in the existing con-
tracts. Our VAT ID number will
remain the same. Regarding our
COBURG. GmbH. new tax and commercial-register
numbers, please refer to our web-
With registration in the Commer- The company with the new legal site. Our customers are kindly re-
cial Register of Coburg as per July form assumes all rights and duties quested to use the new company
Congratulating the honourees (from left): 2, 2008, the legal status of our of the contractual relationships of name from now on.
H. Becker, K. Damaschke, T. Siegel, W. Reß, M. Henze former company name Werkzeug- the company with the former le-
maschinenfabrik Adolf Waldrich gal form, which means that there by Uwe Herold