Today we take a first visit to the HORAGE factory, which is located just 5 minutes away from the atelier in the shadow of a very large black coloured building with a crown on the top 😊. We’ll meet the key players and have an introduction to what happens here.
Hi Jürg, tell us a little bit about yourself and what you do at HORAGE!
My name is Jürg Poulfer, originally from Schüpfen near Bern [Ed: the political capital city of Switzerland, but much smaller than Zurich & Geneva]. I’m responsible for running our little factory here in Biel. My background is in mechanics and I started out with an apprenticeship in metal turning. Before joining HORAGE in 2023 I spent most of my career working for a company making medical components. In that branch, which is also very strong in Switzerland they use pretty much the same machines and technologies as in watchmaking, but the parts made are bigger.
I was always fascinated by watchmaking. From a mechanical and metal working perspective I would say mechanical watchmaking is the Holy Grail. You are making and manipulating such tiny parts which are really pushing the limits of what machine tools are capable of.
Can you give us an overview of what processes take place at the HORAGE factory?
So we are focussed on the manufacturing and finishing of the parts required for our movements. In terms of metal working processes, we can turn, mill, cut gears and do some of the finishing work.
Our work here is split between production of series components, toolmaking and supporting the engineers in R&D.
What materials do you work with, and which are your favourites?
We work with a mixture of metals: primarily brass, copper beryllium alloy, steel, stainless steel and occasionally titanium. My favourite of these metals is brass and my least favourite is titanium.
Can you manufacture all of the callibre here in the factory?
We can make a lot! All of the bridges and main plates, most axles and wheels in the geartrain. There are some gear sizes we can’t do yet and some components are highly specialist, for example screws. The parts we can’t make are sourced from local suppliers in Switzerland.
We have to balance between what is possible and what is practical. Changing the machines from making different parts can take up-to 6 hrs of work time. Our workflow is determined by which material we are using and what the various machines can do, rather than being based on say making parts for K2 one week and K-TMR the next.
At HORAGE our philosophy is that all components are subject to a process of continuous scrutiny and improvement. So as a result, we don’t produce big batches of specific parts that would for example be enough for say 18 months. We usually make 300-500 pcs of a part and then change. This is less efficient in terms of machine time per part but allows us to stay flexible and agile, and if a part is updated we are not wasting a big stock of obsolete components.
If you won machine tool lottery, what would be top of your shopping list?
I think another CNC machine with an automated material feed, which would allow us to work more efficiently... and a conventional milling machine so we can do more tool making in-house. Any more than this and we will need to move to a bigger building again…..
Thanks for sharing your time with us Jürg!
It was great to get a glimpse into the metal working side of HORAGE and I’m sure we will be back to look at some of the processes in greater detail.
Which parts of the watch would you like to learn about next?
Definitely made a lot of progress in the past 3 years and with Juerg on board we master nearly 70% of parts on machining level now. We have always been strong in all levels of engineering, supply-chain and assembly, because this is what we focused first and this is what ultimately will decide over the quality level we can deliver. Machines should only be bought when all the rest is under control. Most people think machine first, because the underestimate the IP-foundation required to make real use of expensive machinery.