A BETTER WAY TO SERVICE WAY COVERS

At the Robert Bosch LLC Chassis Systems Brakes Division facility in Johnson City, TN, and the Diesel Systems facility in Charleston, SC, they build a series of brake components and complete braking systems, using assorted machine tools and machining centers. The parts produced at these plants include brake rotors, brake drums, disc brakes and parking brakes, as well as master cylinders, brake boosters, fuel injectors, unit injectors, ABS materials and related brake assist assemblies.

On the 44 machining centers at the Charleston facility, as parts planner Warren Yeo explains, there are occasional breakdowns of the way covers protecting the mechanical motion components on these large work centers. Usually, these are caused by either the metal dust produced from the machining process, normal corrosion of the cover from the coolant and lubricants used, or a mechanical break in the cover, particularly fatigue on the scissors mechanism. A seemingly minor problem on a huge machining center, these breakdowns can cause substantial downtime on the factory floor, as the way covers can require considerable labor to remove, repair and replace them. ?We can?t let that happen, if at all possible,? Yeo states bluntly.

One strategy used here is to keep a supply of way covers to replace broken ones. As it happens, the original equipment manufacturer of the covers on the Charleston facility?s Grob machining centers, Hennig (Machesney Park, IL), has one of its service centers in nearby Charlotte, NC, a facility that also serves the Bosch plant in Johnson City, TN. Larry Carver is the service center manager in Charlotte.

Hennig designs and manufactures custom machine protection and chip/coolant management products for state-of-the-art machine tools that are designed to protect against corrosion, debris and common workplace contaminants. Its manufacturing facilities are located in the U.S., Germany, Brazil, India, Japan, China and South Korea. At its Charlotte service center, technicians perform a variety of services on the way covers for original equipment made by its parent company in Machesney Park, plus it repairs and/or replaces covers made by other manufacturers. Under a performance contract, Hennig engages customers such as Bosch for a full package of maintenance, repair and replacement services on way covers.

The repair services include replacement of wipers, straightening of box covers, replacement of rollers and V-guides, polishing and reassembly of cover boxes, replacement of side brass guides, complete refurbishing of both many cover brands for the end user, as well as onsite service at the customer facility when needed. All types of covers are serviced at this facility, including telescoping, roll-up apron and others, as are chip conveyors and other machine tool enclosures.

In a light moment, Yeo recalled a situation where a cover was repaired and replaced in a timely fashion, but was reassembled in reverse. ?Larry and his guys came right over and fixed it immediately. They are always going the extra mile for us by frequently performing extra services, such as modifying a cover with cut holes in the X-axis. We appreciate that because it means we run more efficiently and with less downtime in our department. No one can ask for more than that.?

David Cloyd from Bosch in Johnson City echoes that thought. ?They?ve been completely professional and courteous in every aspect of the business relationship. I?ve recommended their products and services to other companies in the area.? The Charlotte service center is one of eight such facilities being operated in the U.S., Canada and Mexico to serve a growing customer base for way cover repair and maintenance. The other facilities are currently located in Machesney Park; Cincinnati, OH; Detroit, MI; Chandler, OK; Kitchener, Ontario; and Mexico City and Saltillo (Mexico).

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Hennig, Inc., 9900 Alpine Road, Machesney Park, IL 61115, 815-636-9900, Fax: 815-636-9737, www.hennigworldwide.com, info@ame.com.