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Optimize Automated Production Processes

Weiler Process Solutions (WPS) combines application expertise and documented testing to improve automated grinding, deburring and other surface conditioning processes in high-volume production.

 

Increase Throughput  /  Improve Consistency  /  Reduce Total Cost Per Part

Weiler application expert discussing challenges in a grinding operation.

Improve More Than the Product

Production challenges rarely result from a single variable. Abrasive selection, machine parameters, material, part requirements and operating practices can all affect productivity, quality and cost.

WPS evaluates the complete process. Our application experts work with your team to understand current performance, identify improvement opportunities and develop a solution for your specific equipment, application and operational objectives. Testing under production conditions helps validate the solution and document measurable results before implementation.

Download the WPS Overview

Improve the Performance of Your Entire Process

WPS brings process, expertise and partnership together to help manufacturers achieve meaningful operational improvements.

Cold roll grinding.

Increase Productivity

Increase Productivity

Reduce cycle times, remove production bottlenecks and increase throughput.
Weiler wheel grinding a turbine blade.

Improve Process Stability

Improve Process Stability

Reduce variability, rework and waste while improving part quality and consistency.
Computer screen showing abrasive and bond mix.

Optimize Performance

Optimize Performance

Extend wheel, brush or abrasive life, reduce dressing and changeovers, and support greater output.
Bevel wheel grinding a gear.

Lower Total Cost Per Part

Lower Total Cost Per Part

Balance productivity, consumable performance and operating costs to reduce total cost per part.
Metal conditioning wheel grinding a steel slab.

Improve Sustainability

Improve Sustainability

Reduce waste and energy use while optimizing consumable inventory.
Cold roll grinding.

Increase Productivity

Increase Productivity

Reduce cycle times, remove production bottlenecks and increase throughput.
Weiler wheel grinding a turbine blade.

Improve Process Stability

Improve Process Stability

Reduce variability, rework and waste while improving part quality and consistency.
Computer screen showing abrasive and bond mix.

Optimize Performance

Optimize Performance

Extend wheel, brush or abrasive life, reduce dressing and changeovers, and support greater output.
Bevel wheel grinding a gear.

Lower Total Cost Per Part

Lower Total Cost Per Part

Balance productivity, consumable performance and operating costs to reduce total cost per part.
Metal conditioning wheel grinding a steel slab.

Improve Sustainability

Improve Sustainability

Reduce waste and energy use while optimizing consumable inventory.

Turn Your Production Goals Into a Proven Process

Whether you are installing new equipment or optimizing an existing operation, WPS helps close the gap between current performance and your production objectives. Our team works alongside yours to develop, test and implement a solution tailored to your application.

Weiler Process Solutions process diagram

The WPS Process:

  • Understand Your Objectives: We begin by defining your production priorities, application requirements and measurable performance goals.
  • Custom Design: Our experts evaluate the application and design a solution tailored to your equipment, material, part requirements and objectives.
  • Initial Setup: We optimize machine parameters for the abrasive or brush and conduct an initial test to confirm the proposed design.  
  • Confirm Results: An extended check test validates performance and documents the results against the established baseline.
  • Seamless Implementation: We develop a controlled conversion plan to integrate the recommended products and process improvements into your operation.
  • Continued Partnership: Regular follow-up provides ongoing technical support and helps maintain performance after implementation.

WPS in Action

Every production application is different. These case studies show how WPS testing and documentation helped address each customer’s specific process challenges and performance objectives.

Steel processing facility

Steel Processing Facility Regains Production Hours

A custom steel processing facility regained 1,494 production hours and realized $277,000 in total annual savings.

Roll grinding application

Roll Grinding Improvement Delivers Annual Savings

A hot mill roll grinding operation increased material removal rate by 56%, improved G-ratio by 28% and achieved $340,200 in annual savings.

Helical gear grinding

Gear Manufacturer Increases Output by 28%

A helical gear manufacturer increased output by 28%, reduced cycle time by 27% and reduced dressing frequency by 51% to eliminate a production bottleneck.

A Process Built for Long-Term Improvement

"I consider Weiler to be a long-term partner. Their history of meeting our specific application needs has been world-class."

- Gary S., General Manager, Rolling Operations

Improve Your Automated Process

Are cycle time, output, part quality or consumable performance limiting your operation? Tell us about your automated grinding, deburring or surface conditioning process. A Weiler application expert will contact you to discuss your goals and determine whether a WPS assessment is the right next step.