Precision for success: WFL technology at Plasser & Theurer
Plasser & Theurer is the global technology leader for track maintenance machines. As a globally active, family-owned company, they are committed to supplying suitable track and maintenance systems to all regions of the world. It is clear that, although the basic operating principles are similar, the specific requirements vary considerably from country to country. The Linz-based company will achieve this goal with reliable and precise machines, including an M30-G MILLTURN with automation cell.
Plasser & Theurer and WFL are two full-service providers that are united in their commitment to producing durable machines. The decision to invest in a MILLTURN with automation was undoubtedly influenced by these and other reasons.
"We drew up a specification beforehand and invited tenders from five companies. WFL was the only company that met our requirements for accuracy and cycle time. We also expected very good support, as we are only a few minutes' drive from each other," says Clemens Huber, Plant Planning and Procurement. He continues: "Achieving surface accuracy and concentricity of two different axes in relation to each other was vital. We guarantee a maximum concentricity deviation of the cylinder to the central axis over both centers of less than or equal to 0.015 mm. The accuracy value is of the utmost importance here. Apart from WFL, no one could give us a 100% guarantee.
Plasser & Theurer was determined to avoid interface problems. As a full-service provider, WFL supplied the in-house automation, integrated an external measuring machine and a cleaning station. "The fact that everything is supplied from a single source was another decisive factor for us. WFL's complete acceptance accelerated the ramp-up," Huber asserts.
Lead time drastically reduced
The M30-G MILLTURN replaced four other machines. Before the investment, the production process was fragmented. Separate machines for sawing, milling, turning and grinding were available at the main plant in Linz. All processing steps are now combined on one machine. Huber confirms that the processing time has remained the same, as the machines can run in parallel. The throughput time has been drastically reduced. Raw parts can now be produced in less than 30 minutes. Before the MILLTURN was purchased, it took a whole day. This is a major advantage in terms of spare parts availability. The throughput time is minimized, and the set-up time is reduced. The M30-G MILLTURN is the tool for producing a family of products where all the tools are always in the WFL machine.
MILLTURN in operation
"The WFL machine was the first to be designed for a lightly manned shift. It is possible for one operator to work on two or three machines at the same time because the WFL is so well automated," says Huber, adding: It is clear that the more you automate these days, the better! He also makes this statement regarding ergonomics at the workplace. The jointed-arm robot makes handling much more comfortable. The 15 to 25 kg raw parts no longer have to be transported by hand. The operator's sole responsibility is now process and quality monitoring at the machine. "The operator's workload has been reduced, as has our quality assurance, because every part is measured in the measuring station and declared as good or scrap," says Huber.
EuProGigant as a flagship project
The EuProGigant project was launched at the same time as the final negotiations with Plasser & Theurer. WFL invested heavily in time, energy and measurement data. This was and still is an important topic for the track construction company in terms of green footprint and sustainability. This quickly led to cooperation between WFL, Plasser & Theurer and the Vienna University of Technology.
The WFL machine from Plasser & Theurer works in shifts, so it can provide meaningful measurement data. To summarise: WFL provides the technology and support, and Plasser & Theurer carries out the field test. The resulting energy data are findings that represent a win-win situation for everyone and generate considerable added value.
Service support is guaranteed.
WFL is a service partner of Plasser & Theurer. It is quickly available due to its proximity. "We have had a very positive experience with WFL's service. The response time is very short and even WFL employees who are not actually in the field come to us when things have to be done quickly," says Huber. He also praises the smooth communication between the various departments at Plasser & Theurer and WFL. The short distances for data exchange and support are very attractive.
Second-hand machine
The second WFL machine in the main plant in Linz is a completely overhauled M65 MILLTURN. "It's a great sustainable alternative, and it's also cost-effective," Clemens Huber emphasizes. It is clear that a new machine would not have been economical for Plasser & Theurer, as the machine is used in 2-shift operation at most.
"Buying used machines that look like new and come with a warranty is a great opportunity. We are very satisfied with our purchase and are currently considering buying a second used machine from WFL," says Huber.
Sustainable into the future
Plasser & Theurer's approach is clear: ecology and economy go hand in hand. A few years ago, hybrid drive technology for machines was still the exception.
Today, the E³ generation of track-laying machines uses electrical energy from the catenary and battery power for the working drive. This reduces local emissions – pollutants and noise – on the construction site to virtually zero.
The demand for these machines is growing massively. Sustainability is now essential.
"Our product lifetime of 30 years on average and a 'lifetime' spare parts guarantee make an important contribution to sustainable use. Key issues for a production company like ours are resource recovery, energy consumption during processes and transport, and the emission of air pollutants," says Huber. Plasser & Theurer is committed to minimizing these impacts through targeted measures. It is certified according to ISO 14001 Environmental Management and ISO 50001 Energy Management. This certification underlines its efforts in the areas of energy efficiency, environmental management and recycling management.
A brief portrait of Plasser & Theurer:
- Founded in 1953
- Approx. 2,000 employees in Austria
- Approx. 6,000 employees in Austria and the 22 international partner companies
- Product range: Machines and systems for new construction, conversion and maintenance of tracks and overhead lines
- Delivery of more than 17,800 large machines to 110 countries
- Export quota 93 %
- Main plant in Linz, company headquarters in Vienna
- Service, repair and spare parts bases worldwide
- Largest sales countries overall: Germany, USA, Great Britain, India, Japan, France, Austria, Brazil, Spain, Australia
- Customers: Railroad operators, construction companies, municipal transport companies, industrial and mining railroads