Latest tool and cutter grinders do not let down

Kevin Taylor's innate fear of letting customers down is, he says, one of the main reasons why he continually invests in CNC tool regrinders from Walter GB - machines he describes as 'the world's best'. As managing director of Peterborough-based tool regrinding specialist Marlor Tooling, he regards his high-tech portfolio of six multi-axis Helitronic grinders and the Walter Helicheck tool inspection machine as critical in enabling his company to consistently meet the quality and accuracy now demanded by modern tooling and manufacturing methods. 'Okay, there will always be somebody in a shed with a cheap machine offering some level of tool regrinding,' he admits.

'We don't compete with that - we sell on service and quality.

'However, as tooling (high-speed and coated types, in particular) and tool regrinding equipment technology (software as well as machine capability) improves, the 'little people' simply can't provide the required quality and accuracies, and more and more customers recognise that cheap regrinds are a false economy.

'All our serious customers now look at cost per item rather than just the 'buy' function; if a drill costs twice as much to buy/regrind but does three times the work, then it obviously makes good economic sense.

On that basis, we continually attract more work.' Coupled with a 'can-do' work ethic that, says Taylor, 'ignores what everybody else is doing - or not doing - and means getting on with the job', Marlor Tooling's continuous investment in CNC tool grinding has springboarded the company into 'big league' status as one of the UK's leading tooling regrinders with the capability and mindset to meet all requirements.

The philosophy - established by Taylor's father, George Taylor - is being increasingly appreciated by blue chip OEMs and major tooling manufacturers and distributors.

Marlor Tooling offers a one-stop nationwide tool regrinding service, and especially for customers with multiple sites, this is proving beneficial in terms of both quality of service and cost-effectiveness.

'While we've always tried to make it easy for customers to deal with us, we have always been a little 'gung ho' in terms of machine investment,' he continues.

'We've tried to ensure we have extra capacity to be in a position to respond to anything - our business can change on a 'phone call.

We are always looking to buy a machine when we don't necessarily have work for it!' It was that policy that led to the introduction of the first Walter CNC tool grinder, the Helitronic CNC 45.

At the time, the machine purchase price equated to 20 per cent of the company's turnover 'and we could justify only up to 40 per cent of its capacity'.

Since then, a succession of Walter CNC tool grinders - Helitronic Minipower, Helitronic Classic Power and a trio of Helitronic Power Regrinders (one equipped with a 40-tool Disc Loader, for unmanned/lights-out machining) plus the Walter Helicheck NC4 tool inspection machine - have been installed, giving Marlor Tooling the largest collection of Walter machines in the UK dedicated to sub-contract regrinding.

Offering a full spectrum regrinding service covering the whole range of drills, reamers, cutters and other tooling up to 370mm long and 320mm diameter, the company also regrinds gears hobs, mostly in solid carbide.

Requirements for accuracy in gear cutting increase as users demand improved fuel efficiency and reduced heat and noise generation - seen at the most extreme in Formula 1 gearboxes designed for dry running.

Each hob may be worth GBP 4,000 - 5,000, and flatness on the teeth of better than two microns is required.

Importantly, the company also ensures its software capability matches the hardware.

'Every time we buy a new machine, we buy all the available programs and we do our best to stay on top of the updates.

We push the software to the limit, stretching and testing it.' Despite its heavy dependence on CNC, Marlor Tooling says the Walter machines are the ideal complement to operator expertise, with Taylor stressing that: 'the Helitronics are the perfect tools for allowing our guys to optimise their skills for the consistent production of tool regrinds of the highest quality'.

Another strategic plank in the company's quality ethos was the investment in the Helicheck inspection machine, which boasts repeat accuracy on diameter measurements of +0.002mm and +0.003mm on length, and performs all routines in accordance with DIN ISO EN 9000.

Helicheck optically gauges the accuracy of all the critical features of a tool, and performs inspection routines independent of operator control.

The fact that it can produce a printed record of every tool measured - detailing required sizes, admissible tolerances, actual sizes measured while showing a comparison between required and actual geometries - is also described by Taylor as 'a fantastic marketing aid'.

The company's shopfloor is another example of how Marlor Tooling is keen to present the right image.

It is clean, and light and airy, creating an environment in which both operators and visitors feel confident and comfortable, as Taylor concludes: 'I say to everyone who comes through the door, 'Let me show you the machines and the shopfloor - you'll be impressed'.