Waltz Brothers reaches new heights with TNC7 and 5-axis machining

Waltz Brothers, Inc. has been in business since 1939. Started by three brothers as a grinding house, it has evolved and expanded with every new Waltz generation. Today, both brothers and sisters run the facility and have solidified it as a go-to source for high-quality, close-tolerance parts used by some of the most renowned Aerospace companies in the world.

Their full-service manufacturing capabilities span everything from “print to perfection,” as the team says. That includes engineering, CNC turning, CNC machining and abrasive processing services.

One thing that has remained constant over the decades is a never-ending commitment to stay constantly moving and make the best parts for their customers. And Waltz knows the key to quality parts is quality machines and talent.

THE SITUATION: Navigating complex parts and a skills gap

Waltz Brothers has manufactured parts for various industries and leading brands like Caterpillar and Hewlett-Packard. Over the last few years, aerospace has been the primary focus. The shop averages about a few hundred parts a month with consistent repeatability.

However, some challenges come with working in such a demanding industry, starting with the complexity of the parts themselves. That complexity is only increasing, while at the same time, the margin for error is getting smaller and smaller.

In the past, machinists may have gotten by with little blemishes. However, clients today want perfect parts every time—and they want them fast. When you’re making 50 parts, that can take up to seven months to make, and those little blemishes can equal a hefty fee even to ask if they’re acceptable.

At the same time as mounting pressures to perform, Waltz is also navigating labor challenges like the rest of the industry. “The parts are getting tougher. The people aren’t going through the trades anymore,” says James Waltz, Shop Manager at Waltz Brothers.

Waltz is finding the opportunities to push forward amidst the challenges, though. With new talent and a new job to manufacture highly complex impellers, he knew it was time to invest in 5-axis technology, finally.

THE SOLUTION: Harnessing 5-axis control

The jump to 5-axis machining was something Waltz had been considering for a while, especially as he looked to standardize equipment on the shop floor. A requirement was that any new additions must be versatile and perform at the highest level to ensure top-quality parts.

In January, Waltz Brothers added the HERMLE C 250 machining center with the HEIDENHAIN TNC7 control. Jake Schnitzler, manufacturing engineer at Waltz, immediately went to work learning the ins and outs of the new control system. That included a new programming language unique to HEIDENHAIN.

After getting past the initial learning curve, Schnitzler was astounded by how intuitive the HEIDENHAIN control was to set up. Another feature he found exciting was the collision monitoring and 3D machining simulation, which provides a perfect visualization of the machined part and work envelope. This simulation helps the team pinpoint any issues early to avoid those little yet costly blemishes — or worse a machine collision.

“For the complex parts that we do, the TNC7 just makes it easier to do it in ways that I haven’t really seen on other controls — or anything close,” says Schnitzler.

Defining the tool is vital to a proper simulation — something the Waltz team was unfamiliar with before the TNC7. Essentially, the team inputs all the tool definitions, saves them to a file and stores all the tools externally from the machine. Then, they can return to that job later, import the file and be ready to go.

“What seemed like a burden at first turned into a blessing. We’re basically able to plug and play with an automatic setup. We’ve never really been able to do that before,” Schnitzler adds.

One of the biggest concerns was whether the next person could pick up using the TNC7 as quickly as Schnitzler. After just a month and a half, Schnitzler’s young apprentice – who had never run a machine before – is on her third setup. Something that could have taken engineers years to master in the past, which speaks volumes to the ear and intuitive nature of the control.

One of the biggest concerns was whether the next person could pick up using the TNC7 as quickly as Schnitzler. However, after a month and a half, they had trained another teammate, Adela. While she had never run a machine before training, Adela is now on her third setup. Something that could have taken engineers years to master in the past took Adela just months. This speaks volumes to her aptitude and the ease and intuitive nature of the control.

THE IMPACT: Unlocking efficiency and confidence

Not only has Waltz Brothers seamlessly onboarded to the TNC7 software, but they are already seeing results. In fact, after just seven months with the 5-axis technology, Waltz has been so impressed with the performance that he already ordered a second machine with the TNC7.

They are seeing faster parts and cycle times. With the TNC7, they can put a part on in the morning and run it with confidence, knowing it’ll be good when they return at the end of the day. No more scrapping parts, chasing sizes and needing to make constant adjustments.

“Let’s say every operation was 10 minutes. Before, we did a part every 40 minutes, and now it’s 30 minutes. I’m saving 10 minutes a part, which is great. But the bigger thing is that the machine is running for 30 instead of 10 minutes – and now people have more time to do more things,” says Waltz.

The ability to hand off or run jobs and step away confidently has also freed employees to do more. The team can now run eight machines versus two or three. This not only leads to speed and saving but also allows for more experience and training.

“We’re trying to take a lot of headaches out of the shop. That was one of the main reasons for getting the HERMLE with the TNC7. It just makes our operators’ lives a lot easier and our quality guys happier. It’s all those things,” Waltz adds.

Regarding the complexity of the parts, Waltz Brothers also has complete confidence in the precision and reliable processes of the TNC7. It’s making the complex and the difficult easier, and that makes all the difference when it comes to achieving their goal of being one of the top manufacturing companies in the world.

To continue paving their way forward, Waltz Brothers is also working closely with the HEIDENHAIN team in Schaumburg to ensure they are fully utilizing all aspects of the TNC7 on their HERMLE machine — and soon to be machines. From additional training to insights and learnings, the Waltz Bros are reaching new levels of precision, performance and efficiency.