Keeping old machines and systems in operation not only conserves resources, but also usually makes economic sense. Sometimes, however, spare parts are no longer available and the operator is faced with the dilemma of obtaining suitable replacement parts. From the design of the components, to the procurement of raw parts, mechanical processing, the application of hard coatings, dynamic balancing and various coatings, tests and transport, a component can go through many stages.
Finding the individual partners and coordinating them so that a suitable spare part is in the company on time requires a lot of time and coordination effort. This challenge requires not only technical know-how, an excellent network, but also creativity and a sustainable mindset.
The following article is about the production of industrial parts (even without existing design drawings) and about how I managed to establish myself in this market with my network of specialists.
The challenge: Old machines, no spare parts
In many industrial companies I come across the same problem: old machines from the 60s, 70s and 80s are still in operation, but there are no longer any spare parts. These machines were built robustly back then, but wear parts still need to be replaced regularly. Instead of replacing the entire machine, some companies opt for revitalization. This is where my expertise and the know-how of my network partners come together.
The solution: technical know-how and creativity
Thanks to my background as a mechanical engineer and toolmaker, I have the expertise to trace or redesign parts even when no original drawings are available. I used the expertise of a selection of designers and manufacturing partners to ensure that the reproduced parts meet the highest technical standards and, of course, fit perfectly.
The process: From analysis to delivery
The process we go through in a project like this is extremely structured. First, we analyse the worn component, the operating environment and the area of application of the part in order to make the optimal material selection and determine the necessary materials and surface treatments. If original drawings are available, they will be used and optimized if necessary. If there are no original drawings, I design the components from scratch, and CAD draftsmen who work for me then convert this into production drawings and CAM files. The drawings are coordinated with the customer, optimized and approved.
I then select the right experts from my partner companies to produce the required component. Since I manage the interface coordination between the individual companies, the customer can continue to concentrate on their day-to-day business.
The production of the parts is accompanied by strict quality controls. Material selection is based on the specific structural requirements, including mechanical and chemical properties. During manufacturing, we use state-of-the-art CNC machines and specialized tools to produce the parts with the highest precision. Quality controls include dimensional testing, surface testing and non-destructive testing methods such as ultrasonic testing, dye penetrant testing, etc. to ensure that the parts meet the defined standard.
Quality assurance: ensuring the agreed quality
Quality assurance is crucial. We create test reports for all of our components, which are filled out and confirmed by our producers. These test protocols are crucial as they ensure that only flawless parts are delivered to the customer. For particularly critical parts, an additional external inspection is carried out by a specialized surveying service provider.
Conclusion: Repair instead of investing
A central aspect of my approach is sustainability. Instead of scrapping machines and replacing them with new ones, I focus on repairs and revitalization. This not only in terms of environmental protection, but also in terms of economic efficiency. By using tailor-made solutions and optimizing tolerances, significant costs can be saved without compromising product quality. In this context, my credo is: “Repair instead of investing”. It is a philosophy that not only conserves resources, but also makes economic sense in the long term.
