Surgical instruments are high-precision products that are manufactured with great care,usually in small quantities. The structures and equipment of manufacturers specializing in these products are designed, above all, for a high level of flexibility in retooling.
In the realm of precision manufacturing, where each surgical instrument is a masterpiece in its own right, enter the heartwarming story of SW Schwäbische Werkzeugmaschinen and their incredible journey in revolutionizing the production of medical wonders.
Surgical instruments, known for their delicate precision, have traditionally been crafted with great care, often in small batches, blending the artistry of human touch with the advancements of modern technology. Enter Frank Pasuchert, the regional sales manager of SW, who shares the challenges and triumphs of manufacturing these intricate tools. He emphasizes the high requirements and fierce competition in the precision mechanical surgical instruments industry.
Among SW's clientele is a company that has blossomed from humble beginnings in the 1980s to a medium-sized enterprise with 130 dedicated employees. Together, they manufacture around 1000 diverse utensils for surgical applications, with each part made from premium biocompatible materials like stainless steel.
Despite the use of cutting-edge NC-controlled machine tools, the magic lies in the hands of skilled artisans. Up to 40 different components are delicately refined, surface-treated, and assembled by hand, showcasing the commitment to quality that sets these instruments apart. The need for small batch sizes and the constant demand for various product variants make flexible retooling a prime requirement.
The hero of this tale is the automated dual-spindle BA 321 machining center from SW. Picture it as the sports car of machining centers, with a working area of 300 x 500 x 375 mm per spindle, reaching speeds of up to 17,500 rpm. This magnificent machine, adorned with an HSK A63 interface, became the key player in carving forceps halves made of aluminum. Its custom-made automation unit ensured a continuous supply of materials and the efficient removal of milled parts.
What makes this story even more heartening is the partnership between SW and their clients. They joined hands in the summer of 2017, and what followed was a collaborative journey in automating machining processes. Together, they designed and developed a special machine based on the BA 321 model, using press-drawn sections as raw material.
The forceps halves are delicately carved out of these sections, avoiding clamping problems with the slender and delicate pieces. The final touch involves a precise saw cut, ensuring minimal burr to protect the delicate tips of the forceps. Special adapters loaded into the spindles, combined with a conveyor belt system, gracefully handle the forceps parts, breaking off any remaining burrs. This choreography, crafted through the efficient collaboration of both teams, ensures the delicate instruments are handled with care.
After months of joint development, project planning, setup, and trials, the system was commissioned in June/July 2018, with production ramping up in November 2018. Since then, the machining center has been operating 24/6, sometimes going a week without any human interaction beyond supplying materials and removing finished milled parts.
SW's commitment doesn't stop at production; it extends to quality, support, and service. Through "life startUp" production monitoring and "life data" online service, they maintain constant connectivity to the machine. Quick responses to issues through remote diagnostics and "Life help" consultations showcase the caring touch that sets SW apart.
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