The largest part of the product range at Agilent Technologies in Waldbronn has been designed for maximum precision, as numerous mechanical components are installed in the pump systems and optical units of e.g. liquid chromatographs. High pressures build up due to the small diameters of the capillaries - often smaller than 0,1 mm. At the same time, the extremely small valves are subject to high loads and stress. In addition, holes in stainless steel with 0,2 mm diameter or tolerances of 3 µm are not uncommon at Agilent Technologies. Therefore, it quickly became clear to the people responsible for making the investment decisions about a machining center that high precision was to be given topmost priority. This is why the benchmark was narrowed down to three premium brands. The decision was ultimately made in favor of the Fehlmann PICOMAX 60. Thomas Wenz, precision engineer at Agilent Technologies, explains the decision: „While Fehlmann offers the PICOMAX 60 with a stationary table, other suppliers use a swiveling table. However, when machining the holes, we have to bring the tool very close to the component. This means that the interfering edges in case of small tools would simply be too large if we used a swiveling bridge. High precision was at the top of the list, it is true. However, what finally convinced us was the overall package, as we also wanted to produce in a flexible and economical manner. What spoke in favor of Fehlmann was the automation, as numerous projects are running in parallel in our plant. Thanks to the automation, we are now significantly more efficient." In the department of Thomas Wenz, mainly prototypes are manufactured, that much is true. However, due to the automation, they also started producing higher number of pieces.  This means that for 12 hours during the day, the machine is used for prototype production, while for more than 8.5 hours overnight, lot sizes between 50 and 100 pieces are machined. Thanks to the increased machine hours and turnover, components that were critical in regards to precision and technology and had to, therefore, be outsourced in the past, can now be produced in-house again. In this connection, it is another positive aspect for Thomas Wenz and Production Manager, Heiko Breckwoldt that Agilent is often awarded the order in external tenders based on the results of feasibility studies and cost comparisons for later production.. 

Flexibility protects from production downtime
In the course of modernizing the machine pool, as well as in view of a planned investment in apprenticeship positions for precision mechanics, management at Agilent decided to invest in an additional machining center.  The requirements for apprentice training demanded a certain level of machine. A further requirement was that the new machine should have the same standards as the PICOMAX 60 as regards control and tool holders. We were particularly impressed by the high-precision milling and drilling machine PICOMAX 56 as it allows for both manual operation, using handwheel, and for CNC operation, as well as offering an L version with long table. We also invested in a fourth axis and clamping systems. Since October 2015, tools for production and components for the automation department are being manufactured on this flexible machine. These components had been outsourced until then, but can now be machined inhouse again. However, Heiko Breckwoldt sees more in the PICOMAX 56 than just a milling and drilling machine: The decision in favor of this machine was a relatively easy one, as it is perfectly suited for every production plant given the corresponding lot sizes and part range.  For instance, we also accept reworking jobs. For instance, we may have to correct wrong hole positions in components or missing threads if such parts were produced by external suppliers. We must execute such corrections very quickly, as production would otherwise come to a standstill. With the PICOMAX 56, this is possible without any problem and with absolute precision.“
This enormous flexibility may also be achieved as the 800 mm machining table allows for machining 600 x 700 mm plates and permits the installation of the 4th axis plus two vices. Using a special clamping system by Lang, this even permits 4-face machining. What is more -  thanks to the identical tool holders (SK 30), clamping systems and the control unit, we may easily switch from the PICOMAX 60 to the 56 in case of bottlenecks.
So far, this department has officially been called the prototype shop, with approx. 25% being considered production site. With the automated PICOMAX 60 plus the complementary PICOMAX 56, however, we have now developed into a serious supplier compared to external companies.

Agilent Technologies Company
The globally operating company based in Santa Clara develops, produces and markets leading products and solutions for the entire workflow in analytical laboratories. With their high-tech systems from sectors like liquid and gas chromatography, mass spectrometry, vacuum technology, as well as atomic spectroscopy, Agilent covers a comprehensive range of analytic measurement technologies. The plant in Waldbronn with its 800 employees is one of the largest locations of Agilent; including additional branch offices, a total of approximately 1,000 employees work for Agilent in Germany.

Interesting side note
Agilent uses an example to demonstrate the extreme sensitivity of high-performance liquid chromatography (HPLC): According to this, the type of red wine (0.25 ltrs) could be determined in pure waters having the volume of Lake Constance (48 billion liters).

back