The Company Aalen, Mapal

8/14/2019 The Company Aalen, Mapal

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The Company.


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MAPAL Przisionswerkzeuge Dr. Kress KG a medium-sized family company has been for decades one of the leading suppliers of precision tools for the metalmachining industry. As a supplier MAPAL provides support for its customers fromproject planning for individual processes to Tool Management.


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The MAPAL Group headquarters

With the establishment of MAPAL byDr. Georg Kress in 1950 in Aalen, thefoundation stone was laid for the com-pany which now operates worldwide.The meteoric success of the companybegan with the successful introductionof single blade reamers with guidepads (the MAPAL principle).Based on this tradition the headquar-ters in Aalen is now the main produc-tion site for reamers and fine boringtools with guide pads. With morethan 1.100 employees, multi-bladedreamers, clamping systems and settingdevices are also produced in Aalen.

In addition to the general manage-ment, the central functions are alsolocated in the headquarters as coor-

dination points for the whole MAPALGroup. Along with the developmentand marketing centre, the new cus-tomer services centre is also part of theMAPAL Group central functions. In theproduction area MAPAL Aalen suppliesthe manufacturing daughter com-panies with tool bodies and numerousadditional parts. The headquartersis also the venue for the wide varietyof MAPALs general and advanced trai-ning events. This includes technicalseminars and technical orientation aswell as offer training sessions, both forcustomers and for employees from all

MAPALs daughter companies andagents.

MAPAL Dr. Kress KG in Aalen


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MAPAL Przisionswerkzeuge

Dr. Kress KG

P.O. Box 1520D-73405 AalenTelephone +49 (73 61) 5 85-0Fax +49 (73 61) 5 85-1 [email protected]

www.mapal.com


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MAPAL ISOTOOL GmbH in Sinsheim

MAPAL WWS GmbH in Pforzheim

MILLER GmbH in Alt enstadt

Rudolf Strom GmbH in Vaihingen/Enz

MAPAL Sites in Germany

The MAPAL Group in Germany

In addition to i ts headquarters inAalen, there are four other productionsites within t he MAPAL Group inGermany:

The WWS company was set up inPforzheim in 1980 and has been partof the MAPAL Group since 1994. To-day MAPAL WWS GmbH is the leadingmanufacturer of t ools wit h PCD blades.Combination t ools for gun boring andcircular interpolation mill ing are oneof t heir highlights.

With the foundation of MAPAL

ISOTOOL GmbH in Sinsheim in 1997MAPAL extended its range of productswith generating slide tools and slidetools, together wi th special tools withISO elements.

MILLER GmbH, founded in 1991 hasbeen part of the MAPAL Group since2003. MILLER produces precision t oolsfor boring, mil ling, counterboring andreaming in solid carbide and in Cermet.

Rudolf Strom GmbH in Vaihingen/Enzhas been part of the MAPAL Groupsince 1999 and produces special toolswi th ISO elements for a wide variety ofoperations.


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M APAL Group sites

In EuropeGermanyMAPAL Dr. Kress KG in AalenMAPAL WWS GmbH in Pforzheim

MAPAL ISOTOOL GmbH in SinsheimMILLER GmbH in AltenstadtRudolf Strom GmbH in Vaihingen/EnzFranceMAPAL France in Le Chambon FeugerollesGreat BritainMAPAL Ltd. in RugbyItalyMAPAL Italia S.R.L. in Gessate/MIPoland

MAPAL Narzdzia Precyzyjne Spka z o.o.in PoznaCzech RepublicMAPAL CZ s.r.o. in Dlouh Lhota

In AsiaChinaMAPAL China Ltd. in ShanghaiJapan

MAPAL KK in TokyoKoreaMAPAL HTT Co. Ltd. in Kyunggi-DoMAPAL TET Office Asia in UlsanIndiaMAPAL INDIA Private Ltd. in BangaloreSingaporeMAPAL Asia TET Office in SingaporeTaiwanMAPAL Precision Tool System Co. Ltd. in Tainan

In AmericaUSAMAPAL Inc. in Port Huron MIM i

The MAPAL Group in f igures:

more than 2.500 employees20 subsidiaries17 product ion sit es30 offices providing service andadvice in very continent

Quality, close customer contact and early ident if ication of t hedevelopments and demands of the market are MAPAL's primaryobjectives. More than 2.500 people employed by the MAPALGroup work out perfect solut ions every day for customers' ma-chining tasks. Because of the ongoing general and advancedtraining of personnel and the constant exchange of experience,MAPAL ensures high technical standards worldwide and guar-antees MAPAL's legendary quality.

MAPAL worldwide


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M APAL wherever the customer is, we are there.


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M APAL

Reliably innovative


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How can one define a company, an extremely lively organism, which has developed furt her and furt herfor more than 50 years and with which so many people customers throughout the world, employeesand suppliers are so closely l inked, in a brochure with just a few pages?We have dared to do so because we know that in our Company it comes down to just a few importantprinciples.We want to be close to our customers, be and remain in dialogue with t hem, think and act for them. Find

and form a team which wi ll f eel permanently committed to this idea at all levels of the company.Qualit y, reliabili ty and innovative strength are also factors which play a decisive role in the company day aft er day.Using brief comments throughout I hope to i lluminate the various aspects of our Company and clarif ywhat is important to us now and in the future.

Dr Dieter KressChairman &Managing Director


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Perfect dialogueBranches and products


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Whether you are travelling in a high performance car with good fuel economy,safely lifting heavy loads wit h hydraulics or reading your freshly print ed news-

paper, MAPAL will always have been involved.MAPAL's knowledge and experience of tools is found in almost all areas ofmetalworking. Absolute precision and efficiency with maximum productionreliabili ty are required in increasing measure in modern production technolo-gy. The customers' demands are met by high quality specifications and theconstant development of M APAL precision tools.

The customers expect us to provide them with a comprehensive,

reliable and innovative programme from our range of competences

at all the principal production sites in the world. This is what we do.

This is how MAPAL is set up.


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As a competent tool partner, MAPALalso offers a comprehensive range ofcustomer services. For MAPAL cus-tomers, savings in costs start r ight atthe project planning stage. By usinginnovative and reliable tool concepts,

MAPAL's tool experts show t he way

from low-cost production of a compo-nent t o saving cost ly addit ional opera-t ions. Tool Management w it h MAPALoffers the right t ool, at the right t ime,at t he right place, at an economic priceand guarantees profitable production.


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Reaming andfine boring tools

For 50 years, using reamers and fineboring tools with guide pads, MAPALhas set the highest qualit y standardsfor cutt ing wit h geometrically definedblades. The MAPAL principle guaran-tees the dimensional stabili ty and form

of the bore within just a few microns,reliably and economically. While theguide pads are specifically designedfor t heir t ask (guiding the tool in thebore), the blades, which are preciselymatched to the machining task in cut -t ing material and cutt ing lead, dealwit h cutt ing the material. Whethercast iron, steel or other materials,MAPAL tools always achieve remarka-ble result s.

Just as MAPAL has successfully intro-duced the idea of single-blade reamersinto the industry, signif icant advan-tages have also been off ered by thenew High Performance Reamers. Usingthe HFSHead Fit t ing System and it s

high level of accuracy, this tool con-cept meets the requirements of manycustomers for high qualit y and easytool handling. One way heads alsoensure a high level of economy for t hiscompletely new system. For specialtools the successful combination ofvarious cutt ing systems brings com-pletely new forms of rat ional produc-tion methods.


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PCD tools

In the area of tools wit h PCD blades

MAPAL has emerged as one of the prin-cipal manufacturers in t he last tenyears. The programme for t his productline includes precision gun boringtools, circular interpolat ion mil lingtools and end mills, and a successfulface milling head system with replace-able mil ling cartridges.

Modern and high-precision clamping

systems combined with precisiongrinding quali ty for maximum dimen-sional stabili ty and concentricity openup numerous options for f ixed andbrazed MAPAL PCD tools, not onlyin HSC operations.


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With the precision machining ofbores as a start ing point , MAPALspecial t ools now of fer completesolut ions for the machining ofcubic parts. MAPAL deals inten-sively with production optionswhich are made possible by theuse of slide tools and generatingslide tools. For these technicallydemanding solut ions, generat ing

slide tools, which can be used on

Generating slide tools and special toolswith ISO elements

machining centres at l it t le costor no cost at all, have been par-t icularly progressive develop-ments. In t he area of specialtools with ISO elements, ourspecialists' t remendous experi-ence and numerous innovativeideas produce extremely suc-cessful t ool concepts for gunboring and mill ing.


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Clamping systems

HSK and HFSare key terms when it

comes to clamping tools accuratelyand safely. Modern production tech-niques are also significantly influencedby both systems. The HFSHead Fitt ingSystem with replaceable heads is acompletely new development atMAPAL and opens up new perspectivesfor modern production t echnology interms of easy handling, high change-over and concentricit y accuracy andversati le use.

Solid carbide tools

To provide a complete range of compe-tences in bore machining, MAPAL alsooff ers a product line of excellent spe-cial and standard tools in solid carbide.This range from simple drills to t helatest high performance drill. Toolswhich achieve reaming quality in asingle pass are a particular highlightin this product line.

Coatings developed especially forboring and the use of super cut t ingmaterials PCD and PCBN are furt herfeatures which increase the perfor-mance of MAPAL solid carbide t ools.


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Sett ing devices

The precision of surface, form and di-mension which can be achieved wi thMAPAL tools with guide pads are at thetop end of what is feasible with geo-metrically defined blades. To manu-facture to micro-precision reliably andrepeatedly wit h every new blade and

every new tool, MAPAL offers specialtool sett ing devices which make set-t ing easy. Mechanical and electronicversions are included in the supplyprogramme.

Customer services

With CTS Complete Tooling Services MAPAL has gained a leading positionin the area of customer service. Pro-duction planning, maintenance, man-agement and optimisation: the servicepackage takes MAPAL's experience andcompetence from t he process designstage to permanent process optimi -sation in all customer service areas.

MAPAL CTSguarantees optimumresult s for your special applicat ions and at reduced costs. Many years ofint ensive and customer-orientatedcollaboration make MAPAL a specialistalso in the service area.


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Realizing the impossibleInnovation


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We believe that real innovations provide the thrust for the develop-

ment of a company. But for innovations we must create freedom in our

employees thinking and acting. It is only f reedom which wil l lead to

new ways that drive technology forwards.

And: Innovations must be presented to the customers with force,

courage and pace. Only then wi ll they bring the company success.

MAPAL was and is decisively involvedin t he development of new t echnolo-gies. At the MAPAL development cen-tre experienced specialists deal inten-sively wit h subjects such as minimalquant it y lubrication, high speed andhigh performance cutt ing (HSC andHPC) and the machining of specialmaterials. Today hardened steels,sintered materials, CGI or ADI playan important role in this. MAPAL cus-tomers profit from this technologicaladvance with tools which offer greatereconomies and qualit y.

Minimal quantity lubrication TOOLTRONIC


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Innovations are a feature of all MAPALproducts. Many of these innovations

relate to the solut ion of tasks withwhich our customers confront uson a daily basis. Often unusual waysare adopted for this and almost un-achievable targets reached. In prin-ciple, the objective is to f ind new toolideas which achieve savings potent ialof more than 30 %. A modern rangeof machines in MAPAL's developmentcentre allows trials to be carried out asclosely as possible to how the opera-t ions wil l run subsequently at the cus-

tomer's works.

By working doggedly on new tasks,but also by making large and smallsteps wi th current problems, MAPALinnovat ions repeatedly lead to newpaths and new opportunit ies in cutt ingoperations. Examples such as machi-ning cast i ron wit h PCD, hard machi-ning with multi -bladed tools or thedevelopment of the HFSHead Fit t ing

System demonstrate expert ise, a rich-ness of ideas and creative potential.

Hard machining

HFS Head Fitting System

wit h radial clamping

Face milling heads with PCD

and PCBN replaceable cart ridges


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Absolutely precisePrecision


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The precision which can be achievedon the part relates directly to t he pre-cision of the tool. With the diversityand number of MAPAL's special toolsconsistent and thorough quality assur-ance represents an indispensable andfundamental principle for t he products'success. The use of modern machiningmethods combined wi th decades ofexperience guarantees that the toolsachieve the highest precision.

Precision is MAPAL's promise to the market and consequently an ongo-

ing and self-evident obligation on our Company. Our customers can rely

on this. And they know it .


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The high precision of MAPAL toolsreflects directly on the customers' pro-duction. For finish machining MAPALoffers interesting tool concepts wit hwhich previously necessary semif inish-ing operations and even addit ionaloperat ions, such as grinding or honing,

can be dispensed with entirely. The re-duction in production costs and thesimultaneous increase or assuranceof machining result s under batch pro-duction condit ions is the aim of everyMAPAL tool we offer.

The requirements for circular andcylindrical f orm and surface finishwhen producing valve bodies forautomati c transmission systems areless than 4 m, wit h addit ional SPClimitations. MAPAL tools achieve thisquality thanks to their precision and

the MAPAL principle. In a furtherexample a crit ical surface requirementis achieved when machining a steeringbox wit h a particular cutt ing lead. Theresult lies with a dominant waviness ofWDc at < 0,2 m. This means thatthere is no need for cost ly addit ionalmachining on the bore.


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Absolutely dependableReliability


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If one is constantly in dialogue with customers as we are reliabil it y

in all areas and at all levels of t he company is an essent ial maxim for

peoples dealings. How can one otherwise face the customer?

The provision of process-orientated,comprehensive and customer-focusedsolutions defines the way MAPAL ope-rates. This includes much more thanmanufacturing eff icient t ools, preci-

sion blades or accurate clamping devi-ces. Reliable customer services cove-ring all products are ult imately theguarantee of their sound and profi tablefunct ion. Service is an evermore im-portant factor in MAPAL's understand-ing and the capacity which is reservedfor this is suitably large. MAPAL is opento finding innovat ive ways when offer-ing customer services. Considerableexperience in t he machining of cubicparts provides the necessary back-

ground.


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The demands set by the customer withregard to process reliabili ty has a Cpkvalue of 1,67. Production reliabili tyincreases as the Cpk value increases.3 to 4 times the values, for example, isachieved when machining the camshaft bearing bore in cylinder heads.

Diameter tolerances and concentricityresult s for t he individual journals inrelation to each other are accuratelymaintained, both for t he cam shaft andthe crank shaft bearing bore, by meansof the guide pads in MAPAL tools.

Reliable partners and reliable toolingbring about t he appropriately high pro-cess reliabilit y for t oday's require-ments. This means that when they arefi t ted onto the spindle, the tools im-mediately produce the right quality,the blade cuts for a long and precisely

determined t ime and the preparationand tool supply is properly organised.MAPAL has the right products to offerfor all these factors and as a result pro-vides reliable production.


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Dialogue with technologySharpening the senses


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Dialogue wit h technology constant, uninhibited and free. For this we

need to win over our younger employees. This is the only way we will

find the new ideas, pioneering solut ions, real innovations which the

manufacturing economy needs.

The people at MAPAL navigate the con-fl ict ing f ields of defining tasks andapplying possible solut ions by con-tinuous dialogue. This dialogue is wit h

other people but also with technologyitself.Chip form, wear or t he surface of t hepart they all provide informationabout possible improvements. And thistechnical dialogue is conducted int er-nationally. All personnel at MAPALsites in Europe, America and Asia workresponsibly t ogether wit h and for tech-nology within their area of work; bydoing so they contribute to the success

of the MAPAL Group and t o the suc-cessful use of tools by customers worldwide.


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A prerequisite for quali fied personnelis good general and advanced training.Today, because developments aremoving even faster, it is important torecognise this for t he old and the

young. It is in acknowledgement ofthis that MAPAL guides and challengesit s employees and offers general andadvanced training in t he various areasof work.There is also dialogue and associat ionwith universit ies and research inst i-tutes. By commissioned work orworking t ogether on combined pro-

jects, fundamental trends are investi-gated and solut ions worked out to-gether.


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We are constantly in dialogue with technology at all levels of t he

company, hour by hour, day by day. This means that opportunit ies are

explored which present themselves in a wide variety of technical f ields

to the customers' advantage and for constantly opt imised andeff icient product ion processes.


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The Company Aalen, Mapal

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