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19/06/2009 In the field of mould and die construction JRG counts on a CERATIZIT tooling concept MaxiMill 211 ensures economic applications and compact organization

When CERATIZIT engineers use their persuasive power, this is normally not without consequences. In Switzerland at JRG, a leading producer of fittings for water and heating, this is the case. The tool and die construction department switched to milling tools from carbide specialist CERATIZIT – their favourite being the CERATIZIT product of the year 2008, MaxiMill 211.

The production of fittings at JRG requires numerous special tools; in addition, tailor-made workholding is necessary to fix the work piece optimally in the correct position for further processing, and dies for the in-house foundry.

At JRG a team of 40 experts is responsible for the rapid production and optimization of tools. These tools are perfectly tailored to the clamping systems, products and product lines. JRG has a total of 400 employees where tool and die construction play a central role.

The CERATIZIT analysis showed optimization potential with regard to both the application and variety of tools
In order to be able to face the internal challenges which are continuously increasing, the tool and die construction department of JRG is constantly looking for optimization possibilities. “We have reached a certain position, so the pressure is rising. We have to act in such a way that we keep in shape,” says Ochsner. “This is why we have looked into the machining processes together with the CERATIZIT cutting tool specialists.”

Robert Denny works as a sales manager at Utilis, CERATIZIT’s Swiss distribution partner, who has already been working with JRG since 1979. Denny knows: “The orders in the field of mould and die making are characterized by small batch sizes and short flow times. Saving when it comes to the tools is minimal, but cutting data and tool life are nevertheless an important factor. The greatest potential for optimization was in the economy of applications as well as in the variety of tools." Ochsner adds: "In the past we had a rather extensive tooling range which caused a lot of time loss. We often had to change the tools which led to machine downtimes. Due to the numerous milling cutters and inserts we were not even able to keep consistent data sheets. In addition, processing small orders from all the different suppliers became rather complex and enervating.”

The CERATIZIT product of the year has been successfully introduced at JRG
After analyzing the situation at JRG, CERATIZIT elaborated a new tooling concept, the MaxiMill 211 solution. Ochsner: “The MaxiMill 211 milling concept fulfils all our wishes. It is exactly what we need: a tool with a smooth cut which is suitable for multiple applications.” At JRG the CERATIZIT milling cutters are mostly used for roughing and peripheral milling. Even on older machine tools and on conventional machines MaxiMill 211 achieves a high chip volume. Ochsner continues: “The highly precise manufacture of these milling cutters and inserts ensures that the cutting edges can be quickly replaced without having to readjust the tool, which means additional time saving. Now we also keep data sheets and can share our experiences within the team. So ’trial and error’ are things of the past. This was an essential optimization and to me it proved that a good tool is not sufficient - you also have to be able to use it. This is why the technical advice must be appropriate.“

Quick response to customer requests – quality and cleanness are decisive
The company JRG was founded in 1887 and has ever since specialized in the demanding production of fittings made of corrosion-resistant materials (mainly gunmetal). JRG develops fittings and installation systems for drinking water and heating for detached family homes as well as for larger projects.

Ochsner: “We are able to react quickly to the increasing demands in terms of quality and cleanness. In some countries the quality criteria are stricter and only certain alloys may be used.“ Reduction of furring is always an issue, but currently bacteria elimination is the main focus. JRG offers an extensive programme without dead space which guarantees that there are no spots in the fittings where bacteria can settle and multiply, but the components can even be completely disinfected. This is done through the LegioTherm system which can be integrated into the cycle as a circulation regulator for thermal disinfection.