October 10, 2024 - Exhausted capacities are a thing of the past at Amandus Kahl. The company has made strategic investments in the double-digit million range to modernise its die and pan grinder roller production, thus ensuring continued growth and success in the future.
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| Following the modernisation of the Amandus Kahl production line, two high-performance 8-spindle machines now speed up the drilling of dies. |
Amandus Kahl is known for the high quality and efficiency of its customised plants. To ensure continued market competitiveness, the mechanical engineering company based in Reinbek has implemented a comprehensive reorganisation of its production of spare and wear parts. "Our machines for the production of dies and pan grinder rollers had become outdated and reached their capacity limits", says Jörn Meyer, Production Manager at Amandus Kahl. The objective of laying the foundations for future growth has been met: the company has almost doubled its output. At the same time, the lead time for die production was reduced from 28 weeks to eight in ten weeks.
Fast lane and deep-hole drilling: new plants enhance efficiency
A central element of the reorganisation was the creation of two specialised production lines: standard flow production for day-to-day business and a fast lane for urgent orders. Thanks to the introduction of one-piece flow production in this fast lane, tools can now be efficiently produced in 'batch size one'. The fast lane consists of three additional machines that are on standby for emergencies.
In the course of the modernisation, more than half of the machines were replaced by faster and more powerful models. For example, two high-performance eight-spindle drilling machines now speed up drilling of the dies. In the new automated roller production line, four new machines and a high-performance robot ensure a smooth workflow from the blank to the finished pan grinder roller. Other new processes not only increase the capacity, but also improve the quality. Amandus Kahl has switched to deep-hole drilling with oil cooling in place of the previous helical drilling with water cooling. This process provides a smoother surface of the boreholes, which means that the die reaches its full capacity much faster during the start-up process. As the oil, unlike the cooling water, is not changed but is circulated, we have taken a major step towards more sustainable production and an ecologically sound use of consumables. We have made further important investments in quality improvement, including a chemical analyser that tests the composition of raw materials before processing.
Smart logistics and redundant machines guarantee on-time delivery
The implementation of a new logistics concept is an integral part of the modernisation process. An AI-based system now ensures that all orders are processed in the optimal sequence so that the customers' delivery dates can be reliably met. This has significantly increased transparency and efficiency in the production process.
Amandus Kahl also guarantees shorter delivery times by reducing the risk of downtime. This is ensured, firstly, by a farsighted stock-keeping policy. The company can respond quickly to orders because it always has the raw material for all dies and the most common pan grinder rollers in stock. Furthermore, we purchased two of each production machine so that an identical replacement machine is available in the event of a defect, tis flexibility is also provided by their staff. The staff have been trained in the operation of the different machines and can easily step in to cover for absent colleagues.
These extensive measures are already proving effective and Jörn Meyer is convinced that they will pay off in the long run. "We have already received positive feedback from our customers. They confirm that Amandus Kahl dies start up faster and more efficiently. If you want to stay competitive, you have to invest in modernising your company - especially in this fast-paced world."
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The Global MillerThis blog is maintained by The Global Miller staff and is supported by the magazine Milling and Grain
which is published by Perendale Publishers Limited.
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