The Polish branch of a family-owned German company that manufactures lightweight structures and key components for the world's leading car manufacturers faced a critical challenge of keeping up with increased customer demand. After assessing manufacturing processes, the company determined that reducing cycle times while grinding spring ends was the most significant improvement opportunity. The company was looking for a solution capable of precisely grinding spring ends made from wires with a diameter of 4,25 mm.

Using the Weiler Process Solutions (WPS) program, an on-site testing process was carried out with the customer to achieve the set goal of reducing cycle times. Besides testing various compositions and specifications of the grinding wheel, adjustments were made to key parameters such as grinding speed, infeed interval, machine power, change infeed interval, and table RPMs to optimize performance and results.  

To ensure optimal performance in the spring end grinding process, Weiler Abrasives experts closely monitored the dimensions of finished springs to maintain strict tolerances and manage wheel consumption at an efficient rate of 0,11 mm per loading plate. Improving dressing frequency and wheel lifetime were also keys to maximizing productivity and ensuring quality.

Through continuous collaboration, comprehensive testing, repeated evaluation, and readjustments of various parameters, Weiler Abrasives experts developed a customized ICE Spring grinding wheel that met the customer's requirements.

The outcome exceeded expectations, achieving:

• Grinding Time Reduction: From 4 minutes to 2,5 minutes. 
• Extended Wheel Life: The ICE Spring ground 443.898 springs per wheel compared to 174.600 by the competitor, showcasing superior durability and a 154,24 % boost in efficiency. 
• Reduced Wheel Consumption: Per loading plate, Weiler Abrasives' wheel exhibited a consumption of just 0,026 mm, against 0,06 mm by the competitor, underscoring exceptional cost-effectiveness. 
• Labor Cost Savings: a 41% reduction in labor cost per cycle, from 3,83 € to 2,25 €, translating to substantial savings for our customers. 

Weiler Abrasives experts supplied the optimal spring-end grinding solution and went even further by contributing to the customer’s grinding process optimization by providing in-depth industry knowledge and expertise.

The ICE Spring grinding wheel delivered a significant boost of efficiency and cost-effectiveness. By closely aligning with our customer's unique needs, rigorously testing and adjusting our approach, we have not only met but exceeded expectations. This success story underscores our commitment to pushing the boundaries of technology and service in the spring manufacturing industry, proving that with the right partner, the potential for improvement is limitless.