Client Background
Our client is a well-known stone processing company based in Bavaria, Germany (name withheld upon client request). The company specializes in precision cutting of marble and granite for countertops and architectural façades. They utilize advanced 5-axis waterjet systems to process complex custom shapes, such as sink cutouts for kitchen worktops. Due to recent plant expansion, the client needed to relocate one of their waterjet machines to a new facility 30 kilometers away, while ensuring that cutting performance and system precision remained fully intact.
Project Challenges
System Complexity
The five-axis waterjet cutting machine integrates a 6500-bar high-pressure pump and a laser height detection module. After disassembly, the machine had to be restored with an accuracy of ±0.1 mm—demanding rigorous precision across mechanical, hydraulic, and control systems.
Production Continuity
The client required the relocation to be completed and production resumed within 10 days to avoid breach-of-contract penalties on pending sintered stone orders.
Our Solution
1. Precision Disassembly & Data Backup
High-precision components were carefully dismantled, and full parameter backups were taken from the CNC control system to minimize the time needed for reassembly and calibration. The machine’s internal piping was air-purged after draining to eliminate moisture and residue. We also thoroughly cleaned critical parts to prevent dust contamination during reinstallation.
2. Reassembly & Accuracy Restoration
At the new facility, the floor was pre-leveled to a tolerance of ≤0.02 mm/m to ensure optimal base alignment. After installation, an 8-hour idle test was conducted to validate axis stability and movement accuracy. A 45° angled test cut on sintered stone was used to verify final performance. The client's in-house QA team confirmed that cutting tolerances had been fully restored to within ±0.1 mm.
Project Outcome
The relocation was completed two days ahead of schedule, resulting in zero production downtime and successful on-time delivery of all sintered stone orders. The machine, now freshly reassembled and recalibrated, was praised by the client for its performance. The client has since recommended our services to their Austrian branch facility.