Reloaction

An in-house hardening shop, including its peripherals, is to be relocated to another facility.

Challenge

Turnkey relocation of furnace systems and peripheral equipment, including disassembly, transport, and recommissioning, to a new location with a different power supply.

Solution by IVA Schmetz

Recording of the current status and preparation of a quote for the professional transport of the systems to their new location. Due to the different power supply, frequency converters had to be installed in some of the aging systems. An additional optional quote for recommended wear parts and training for employees at the new location ensured that the recommissioning of the systems could proceed as smoothly as possible.

Result

Relocation of the systems within the shortest possible time and handover to the new location together with the customer's project manager. The final training of the employees by IVA Schmetz commissioning technicians at the new location ensured a quick introduction to furnace technology.

Increased efficiency through targeted training on vacuum furnaces

A medium-sized company in precision manufacturing operates several IVA Schmetz vacuum furnaces for the heat treatment of high-performance components. Despite modern system technology, process deviations and increased maintenance requirements repeatedly occurred. An internal analysis revealed that operating errors and insufficient technical understanding of the complex furnace systems among employees were a key cause.

Solution approach: A customized training program was developed that covered the following topics:

Fundamentals of vacuum technology and furnace components

Safety in handling high-temperature systems
Fault diagnosis and preventive maintenance
Practical exercises directly on the company's own furnaces

The training was conducted in two modules: a basic course for machine operators and an in-depth technician course for the maintenance team.

The investment in targeted training on vacuum furnaces paid off just a few months after the training. In addition to technical optimization, safety awareness was also strengthened and employee self-responsibility was promoted.

Performance-Analyse eines Vakuumofens 

Zielsetzung:

• Identifikation von Ursachen für Prozessinstabilitäten

• Ableitung konkreter Maßnahmen zur Effizienzsteigerung

Vorgehen: Datenerfassung & Analyse

• Auslesen und Auswertung von Temperatur- und Vakuumdaten

• Vergleich mehrerer Chargen zur Erkennung von Mustern

Technische Prüfung vor Ort

• Sichtprüfung außen: Wasserleckagen, Pneumatiksystem, Pumpenstand

• Sichtprüfung innen: Zustand der Heizelemente, Isolierung, Türdichtung

• Durchführung einer Lecksuche (z. B. Helium-Lecktest)

• Mapping der Temperaturverteilung mit Dummy-Chargen

Dokumentation & Beratung

• Protokollierung aller Auffälligkeiten

• Beratung mit dem Kunden zu Reparatur- und Wartungsumfang

• Erstellung eines Abschlussberichts mit Handlungsempfehlungen

Ergebnisse: Gleichmäßigere Temperaturverteilung (±5 °C) Zykluszeitverkürzung um 18 % Reduktion der Ausschussquote um 40 % Höhere Prozessstabilität und Kundenzufriedenheit