The Power of Equipment Modernisation:

25-year-old shot peening machine at ThyssenKrupp as good as new.

Chassis technology experts ThyssenKrupp Federn und Stabilisatoren GmbH (ThyssenKrupp Springs and Stabilizers) supply the automotive industry with high-performance chassis springs manufactured in-house. Their unconventional route to a new shot peening machine shows the power of equipment modernisation.

Shot peening is a crucial step in the manufacturing of springs. At ThyssenKrupp this used to be carried out by a 25-year-old Gutmann shot peening machine, which still met the high quality standards required, but was no longer up to date when it came to ease of use, machine availability, maintenance cost and energy efficiency. It was also limited in the product range it was able to handle.

To optimise production processes, the ThyssenKrupp team decided to buy a new shot peening machine and let the old one make a pit stop at the Wheelabrator Plus Technology Centre, for an equipment upgrade as part of a comprehensive Equipment Modernisation Programme (EMP).

The result: ThyssenKrupp now have two machines at their disposal, both equipped with the latest shot peening technology. One is new, the other as good as new − at less than half the cost.

The “new” old machine, designed for three-shift operation, now runs with significantly reduced idle times, mostly due to improvements on blast wheel wear parts. It’s also equipped with a range of blast programmes that can achieve a precision surface treatment for a range of product geometries and materials. This means the machine is not only up to date, but future-proof.

The example from Germany shows a growing trend for equipment upgrades to meet the demands of tight global supply chains, as upgrades usually come with shorter turn-around times, lower cost and alternative financing options (i.e. through maintenance budgets). Machines also have to be more flexible to allow production to respond quickly to ever faster product model cycles.

Markus Bremer, Senior Vice President & Sales Director at Wheelabrator Plus, commented: “In fast-paced, highly sophisticated industries such as medical technology or automotive manufacturing, time is often the most important factor − here EMPs are the faster route to a “new” machine. Three weeks can make the difference between being able to deliver a contract and losing it.

An often overlooked aspect of the equipment upgrade versus new machine debate is the financing. Depending on the organisation, upgrades and modifications can be covered by maintenance budgets, rather than being classed as a capital investment. Our customers tend to find it easier to get cost for an EMP signed off quickly.”

Upgrading and modernising machines is not a new idea. What’s new is the possibility of getting a machine that is tailored to latest requirements, equipped with the newest technology and engineered by experts. All using existing equipment − resulting in a much lower price, a shorter turn-around time and less disruption to operations than purchasing a new machine.

Markus adds: “With an EMP we’re not just making the most of an old piece of kit, we optimise the process end to end, achieving the performance of a new machine. Our experience and our knowledge of the science of blasting allow us to get under the skin of a customer’s machine and design the process they need on top of what they’ve got. Blast efficiency, blast cycle time, blast pattern and blast media flow are all variables that can affect a production line’s performance and cost efficiency − and a customer’s ability to deliver.”

Back at ThyssenKrupp in Germany, the Wheelabrator Plus team around EMP Manager Ulrich Goos carried out a detailed analysis of the blast process and systematically improved the old machine - to reduce maintenance and operational costs.

But the shot peening experts also ensured that the machine would fit seamlessly into the upgraded production environment. This included a range of practical adjustments, such as converting the machine from 500V connection voltage to a standard 400V.

To improve and simplify part and maintenance management, both the new and old machine were fitted with the same wear parts. They now feature the latest blast wheels with variable speeds and higher volumes of media flow. All blast wheels fitted are of identical construction, minimizing training requirements for maintenance staff.

Markus concludes: “With an EMP, it pays to be open-minded about the changes that can be done and not to rule out things that feel too complex or too simple. It’s important to analyse the process holistically and in a structured way. That’s the key to seeing a trusted old trooper perform like never before!”