«We no longer simply
sell them a machine, we help them become competitive»

Joseba has been with ZAYER for over 21 years, currently in charge of machine programming, applications and quality control.

INTRODUCTION

ZAYER milling machines and machining centers are complex machines, equipped with advanced technology for machining parts with high precision and high quality. We manufacture a range of custom-developed products, adapting to the needs of each customer segment and each project. We contribute our know-how of over 60 years as machine tool manufacturers, and our products stand out for their innovation, performance, and high level of design.

But working with such advanced machines also has its drawbacks. One of them is the commissioning and providing solutions to the client’s needs at their own facilities , which can sometimes be complex. That’s where our protagonist today, Joseba Laburu, ZAYER Programming Technician, comes in.

INTERVIEW WITH JOSEBA LABURU, ZAYER PROGRAMMING TECHNICIAN

Good morning, Joseba. How would you describe your career at ZAYER and your current work?

Hi! I can tell you that I’ve been with ZAYER for 21 years, the last 15 of which have been in the programming, applications, and quality control department, although I actually started out assembling rams and soon after moved to the technical support department. At ZAYER, we’ve always served our customers as quickly as possible to help them get the machine up and running. For a few years, I specialized in providing this service, working at the customer’s site, outside the factory.

As I mentioned, I then moved to Programming and Quality Control, where I’ve remained for 15 years. If I had to define what I do, I’d say I continue to provide custom programming solutions. On the other hand, there’s also a creative side to my work, as I develop new applications to adapt machines to each client’s specific needs. Once these developments are fully implemented, we integrate them into our entire product range. In this way, we continuously offer faster and more complex automation solutions, which provide significant improvements for our clients.

Let’s take it one step at a time. What are the needs that you usually address for clients?

Common Machine tool operations 

ZAYER’s milling machines and multifunction machines are programmed using complex codes that we offer to customers in automated packages. However, every customer is unique; the operations they want to perform, the conditions of their manufacturing plant, the knowledge of their operators, etc., vary considerably from one customer to another. This variability means that in some cases they require our assistance.

There may be a lack of knowledge or training when entering variables into the program, when configuring geometries, or a lack of understanding of the different functions and Apps that the machine offers.

These drawbacks , especially if the operators lack experience, can be difficult to detect. There’s a tendency to focus on the machine and overlook the possibility of an error may stem from the programming itself in the CNC control.

We already know that machine downtime results in significant losses of time, materials, and resources, which are costly for the customer. So, I try to detect all incidents and help the customer program their machine to ensure excellent machining quality.

What points do you usually emphasize the most?

Programming Errors

As I mentioned, a lack of understanding when entering variables into the program or configuring geometries are common. So is a lack of comprehension of the various functions and Apps we offer, leading to their misuse. All of this can cause operational issues that the client is unable to resolve.

Falta de mantenimiento

Another source of problems, although increasingly less frequent, is inadequate maintenance. Our milling machines and multi-function machines operate with extremely tight mechanical systems and tolerances to maintain very high machining quality. This combination means that wear, dirt, or minor deviations significantly affect machine performance. Over time, dirt and debris accumulate, and minor issues can escalate into more substantial problems, eventually causing machine downtime.

Material shifting during machining, overheating, or unusual noises are all signs that something is wrong. Most often, signs of insufficient maintenance appear as minor deviations, such as non-conforming surfaces that don’t meet required standards.

Vibración 

Vibrations during operation affect the machine, reducing its efficiency and profitability. These vibrations can be detected long before the human ear can hear them, using vibration and ultrasonic frequency monitoring to identify small operational deficiencies. We also help our clients verify these types of deviations.

Machine Calibration

Over time and with use, the machine’s geometry changes and requires calibration updates. While our department performs certain calibration processes, we’ve also developed applications that allow the machine to self-calibrate . This way, the calibration process is resolved through intuitive cycles for the operator.

Overheating

It is necessary to specifically adjust the parameters of each machine to prevent overheating, which is especially common when machining large parts and during long machining cycles. The thermal stability of the machines is vital to prevent spindle overheating, and ambient temperatures vary considerably. Therefore, significant experience is often required to precisely configure the operating parameters of each machine to suit its specific environmental conditions.

Training

Training the operators who will be working with the machine is crucial: human error is common in manufacturing, whether it’s in data entry, program configuration, or tool selection. Operators must receive thorough training and often need a direct channel to our quality and programming department until they are familiar with their machine’s specific settings and protocols.

On the other hand, you mentioned that you have a creative role in App
programming. Tell us how you do it.

App development

Buyers of ZAYER milling machines require highly customized solutions. Keep in mind that over 70% of our machines come with Apps installed. At ZAYER, we adapt the machine to the customer’s needs, which makes our customers demanding when it comes to these solutions. We work alongside them until we find the Apps that meet their needs, collaborating as a team on their project.

The client seeks to machine a specific part at their company, in their own facilities, using a fast, effective, and efficient machining process that handles all the necessary operations. Often, this requires us to adapt an existing App or even create a new one, customized for this client. This changes the game, because we no longer simply sell them a machine; we help them become competitive. We become their «tailors»; machining experts, or technologists, in addition to suppliers. We are an integral part of their own machining projects.

In this way, the work we do programming these applications is then offered to other clients, «standardizing» them in new Apps. Thus, technological development is key, and we are increasingly asked to solve more complex and specific needs. It never stops!

How interesting. Given the complexity of your work, what would you say
is the biggest challenge you face?

Challenges for a programmer

Any problem that occurs with a machine tool can be very costly for our client. Often it’s due to a lack of training, and they need help. What arises suddenly for them, without warning, affects my schedule, so personally, the most difficult thing is organizing my day-to-day life around unexpected trips. Sometimes they give us just a week’s notice, and I have to rearrange things.

Therefore, it’s important that our clients adopt preventive maintenance programs with us, minimizing these types of unforeseen issues. And of course, we can provide support through our technical service department, ensuring your operators gain increasingly in-depth knowledge about your machine.

We’ve learned a lot from your experience, Joseba. Thank you for the interview!