The Challenge
A Pune-based automotive Tier-1 supplier was struggling with capacity. Their existing wire EDM machines — purchased over 8 years ago from a different manufacturer — were delivering 140 mm²/min cutting speeds and experiencing frequent breakdowns.
Their requirements:
- Cut 200+ die components per month
- Maintain ± 0.01 mm accuracy consistently
- Reduce machine downtime below 5%
- Achieve payback within 18 months
The Solution
After detailed analysis of their parts, materials and volumes, Berlin's application engineers recommended two Hyper Series CNC Wire Cut EDM machines configured for their specific needs.
Key specifications selected:
- Table travel: 500 × 400 mm (adequate for 95% of their parts)
- Cutting speed: Up to 300 mm²/min
- Accuracy: ± 0.010 mm
- Auto wire threading for unmanned night shifts
The Results
Month 1 (Installation + Training)
- Machines installed and commissioned in 3 days
- Operators trained over 1 week
- First production parts cut within 10 days
Month 3 (Full Production)
- Throughput: 2.1× previous capacity (from 200 to 420 parts/month)
- Accuracy: Consistently within ± 0.008 mm (better than spec)
- Uptime: 97.3% (vs 82% on old machines)
- Power consumption: 22% lower per part
Month 12 (ROI Assessment)
- Payback achieved in 14 months (ahead of 18-month target)
- Additional revenue from increased capacity: ₹48 lakhs
- Maintenance cost: 60% lower than previous machines
- Zero unplanned breakdowns
Customer Quote
"Since installing three Berlin Wire EDMs on our line, throughput has doubled and downtime is measured in minutes, not hours. Their service is the reason we keep coming back."
— Production Head, Automotive Tier-1, Pune
Key Takeaways
- Modern machines deliver dramatically better productivity than 8+ year old equipment
- The Hyper Series' 300 mm²/min speed is a genuine production advantage
- Auto wire threading enables profitable unmanned night shifts
- Berlin's local service network ensures rapid support when needed
- ROI on premium machines is faster than budget alternatives due to higher output and lower downtime