Worker operating a tooling tower Tool with multiple PCD cutting edges Two workers holding a component

Turnkey – Complete solutions for manufacturing

MAPAL now offers a comprehensive range of services for the holistic planning and implementation of manufacturing processes. From project analysis and the design of tools and fixtures to commissioning and start-up support – all components are optimally coordinated and come from a single source.

The close integration of engineering, tool technology and fixture solutions results in economical, reliable and high-precision manufacturing solutions. Customers benefit from maximum planning reliability, reduced interfaces and a central point of contact – for efficient and future-proof production.

Operator setting up tools on a tooling tower

Your initial situation

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    New planned production

    Based on raw and finished part drawings and machine data, the manufacturing task is analysed in close cooperation with the customer and effective machining strategies are developed for all steps.

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    Conversion to new components

    Continuing to use existing machines saves time and money. MAPAL's expertise guarantees maximum process reliability. MAPAL provides individual support according to customer requirements and, on request, assumes complete responsibility for the conversion.

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    Efficient machining processes

    Introducing modern machining strategies and innovative tool solutions into ongoing production processes? MAPAL takes on this task for its customers. The result: longer tool life, improved component quality and increased productivity.

Complete process solutions

MAPAL assumes complete responsibility for the manufacturing process – from planning to series production. Through the precise coordination of tools, fixtures and machine parameters, MAPAL achieves stable processes, high cutting data and minimal cost per part. 

Close cooperation with machine tool builders and in-depth application expertise ensure maximum productivity and a fast return on invest (ROI). As a technology partner, MAPAL stands for technical competence and sustainable manufacturing reliability – and is the perfect partner for demanding turnkey projects.

All advantages at a glance

Drilling bar machining a component

PERFORMANCE

  • Cycle time optimisation and 99 % collisions reduction between fixture and tools

RESULT GUARANTEE – CPK

  • Analysis stability on production process

INVESTMENT OPTIMISATION

  • Focus on the best integrated fixture/tools solution: 15-20 % production cost reduction

ONE PARTNER

  • Integrated design for tools, fixture and cnc-programme development  

Overview of services

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    Project analysis & process design

    • Project analysis
    • Feasibility study
    • Cycle time analysis
    • Development of machining process
    • Definition of clamping fixture

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    Clamping fixture

    • 3D and 2D design
    • Production and assembly
    • Dimension and function testing
    • Collision analysis
    • Technical documentation

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    Tool package

    • Selection of the appropriate tool technology
    • 3D and 2D design
    • Production, assembly including presetting
    • Tool documentation
    • Delivery of the assembled tool package

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    Simulation & programming

    • Cycle time study
    • NC programme creation
    • Simulation & collision check
    • Parameter optimisation
    • Implementation of a customer-specific programme structure

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    Validation & production ramp-up

    • Verification of process capability (CPK analysis)
    • Documented customer acceptance & series release
    • Support during production ramp-up
    • Training of operating personnel
    • Maintenance & support

Reports from the turnkey sector