Heller Machine Tools Ltd, based in Redditch and a wholly owned subsidiary of German manufacturer Gebr. Heller Maschinenfabrik GmbH, is celebrating its 50th anniversary this year. Established in 1974, the UK operation has evolved into a critical hub for Heller’s global production and innovation efforts.
Milestone Achievements
Heller’s UK facility, which began with a bespoke factory in 1981, relocated in 1997 to a larger site capable of assembling over 200 machines annually. The facility’s assembly capacity has since been increased to more than 300 machines per year. This site now employs over 150 staff members who deliver advanced machining solutions and exceptional service.
In recent years, Heller invested over £2 million in upgrading the Redditch plant. These enhancements included improvements to administrative and engineering departments, and the creation of a new customer area for machine demonstrations.
Advancements in Manufacturing
Heller’s Redditch facility has seen significant technological improvements. The introduction of an 11-station Strothmann flow line in 2018 has drastically reduced assembly times by over 20%, building on the productivity gains from the original flow line. This modern line allows complete manufacturing and commissioning of horizontal machining centers on-site, incorporating lean manufacturing principles to further boost efficiency.
The production process at Redditch is meticulously documented, ensuring compliance with ISO 9001 standards. The plant maintains a robust supply chain with local contractors and employs a detailed approach to assembly and testing, including laser calibration and accuracy checks.
Innovative Solutions and Automation
Heller’s approach to manufacturing emphasizes a solutions-based strategy, particularly in complex bidding scenarios for aerospace and automotive sectors. The company leverages advanced simulation tools like Siemens NX and Vericut to optimize cycle times and ensure accurate predictions, thus enhancing cost-efficiency and project outcomes.
The company offers various automation options to enhance production efficiency. Flexible manufacturing systems (FMS) are utilized for unattended operations, enabling night-time production and ensuring that components are ready for subsequent processes. Heller’s expertise extends beyond automation, encompassing entire machining systems and production planning to maximize resource use and minimize downtime.
Commitment to Sustainability
Heller in the UK places a strong emphasis on environmental sustainability, aligning with its German parent company’s practices. The facility adheres to ISO 14001 standards and promotes continuous environmental improvements. Recent initiatives include the adoption of smart LED lighting, reduced water and energy consumption, and enhanced recycling practices.
The company encourages its suppliers and customers to adopt similar sustainability measures, focusing on reducing waste and improving ecological performance. Efforts include limiting staff travel, promoting teleconferencing, and using environmentally friendly office supplies.
Looking Forward
Heller UK’s senior management reflects on the company’s growth and capabilities. “Our ability to manufacture and supply both our own and third-party automation solutions allows us to offer highly customized production cells that add significant value. Our experienced staff and skilled apprentice-trained operatives are integral to delivering innovative solutions and accelerating project realization.”
As Heller Machine Tools Ltd celebrates its 50th anniversary, it continues to drive forward with a commitment to excellence, innovation, and sustainability in the global manufacturing sector.