Tebicon process structuring at Böhm + Wiedemann:
Lead times reeduced 30% while simultaneously moving to multi-machine operation.
Fast. Accurate. Flexible. These are the customer requirements that Böhm + Wiedemann must meet. The company can do this profitably only if the many unique pieces can be manufactured at a cost on a mass production scale. The basis for achieving this goal is a standardized manufacturing process.
Böhm + Wiedemann Feinmechanik AG designs and manufactures precision parts from a wide variety of materials. As a renowned supplier in the racing, aerospace engineering as well as optomechanics and research industries, the company manufactures prototypes, small and mid-sized series, individual components, complete assemblies as well as entire machines. Böhm + Wiedemann combines the tradition of skilled precision engineering with the consistent application of modern CNC technologies at their sites in Eching (near Munich) and in Cologne.
The industrialized manufacture of unique parts is the goal
"Since the process was structured by Tebicon, we have been manufacturing industrially, even for a lot size of 1." Christian Fach, member of the board at Böhm + Wiedemann AG in Eching.
Following a benchmark analysis, Böhm + Wiedemann decided to implement the Tebis software technology. "We mostly wanted to improve the process reliability in manufacturing and to reduce lead times, said Christian FachFach, a board member at Böhm + Wiedemann, regarding the decision. The Tebis Simulator provides the option to create NC programs based on the exact tool geometry and a virtual machine model. Thus, potential problems are identified and can be resolved long before machining on the actual machine. The previously used programming system was limited in this respect.
"We have the highest demands on speed, compliance with deadlines, capability to find solutions, and quality," explains Fach, "This can be achieved only with standardized manufacturing processes. Our goal is the industrialized manufacture of unique parts.“
Restructuring manufacturing using Tebicon
Because it was extremely important to implement the new software and especially the new manufacturing processes quickly and smoothly, Tebicon was asked to perform the work. "We were sure that the project could be realized faster and more effectively in this way," says Fach. After all, this task is "business as usual" for the Tebicon consultants and so they can access much expertise in this area. "Standardization must be a central theme throughout the entire manufacturing process, which means that it is far more complex than conversion from Lotus Notes to Outlook, for example," explains Fach. It was obvious that the manufacturing processes had to be restructured. One of the points to be considered is that the company manufactures an extremely large spectrum of parts from the wide variety of materials with a corresponding array of different tools. This places high demands on programmers, machine operators, and tools, and makes it even more difficult to standardize manufacturing processes across both sites.
With Tebicon, the affected parties become the parties involved in the solution
The NC programmers at Böhm + Wiedemann work with exactly structured specifications.
From the analysis of existing manufacturing processes and working methods in Eching and Cologne, a detailed project plan was created. The introduction of the software as well as the structuring of the manufacturing processes were defined and realized within three months. As the first step, the Tebicon specialists drew up the structures and standards required for the work processes. From the beginning, the employees affected by the future changes, were involved in the solution and realization process. Years of experience from many successful projects have shown that this cooperative procedure in particular ensures acceptance by and cooperation of all project stakeholders. This is a major prerequisite for fast and lasting success of process modifications.
The drilling and milling tools mapped in the tool database are the cornerstone
All components – cutters and holders – were measured individually, stored in the Tebis tool library, and assembled there into tool assemblies.
In order to achieve process reliability, every NC program is calculated in Tebis with precise consideration of the tool geometry. For this reason, not only the cutters, but all holder components must be entered and maintained in the Tebis tool library. Therefore, creation of the tool library has crucial significance. "The tool library is the cornerstone of every well-functioning manufacturing site and the basis for a virtual machining process. Without it, standardization of the manufacturing processes is senseless," explains Marc Fuest, the responsibleTebicon consultant.
Consequently, the components – cutters and holders – were measured and recorded in the Tebis tool library. All NC programs can now be programmed with exact virtual tools and – after the check in the Tebis Simulator – transferred collision-free to the machine operator. The obvious side effect is that holders and tools that were no longer required were recorded and sorted out.
Seamless process reliability thanks to the introduction of ToolControl
Using ToolControl, the programmers can check whether the calculated toolpaths can be manufactured collision-free with the real tools at the click of a button in the tool presetting.
A central storage facility with a tool presetting was established in Eching near Munich and the ToolControl process solution developed jointly by Tebis and Zoller GmbH & Co. KG was implemented.
Comprehensive standardization of the manufacturing process leads to success
The optimized and standardized process for Böhm + Wiedemann – from data input to the workshop – was finally defined by the Tebicon consultant in conjunction with all participants and documented in a set of rules. Subsequently, all employees were trained in the use of the Tebis technologies, prepared for their new work methods, and supported by specialists during the start phase.
The figures speak for themselves
Within just three months, the Tebis technologies were implemented and uniform and standardized manufacturing processes were defined for both sites. The previous extensive manufacturing documentation was replaced with a paperless flow. The greatest benefit was the reduction of the lead time, which was reduced by up to 30% at both sites. The programs run independently and more stably, enabling a multi-machine operation.
"All stakeholders can be very satisfied with the result," Christian Fach sums up. "Even my expectations for the support by Tebicon have been fulfilled 100%. We now manufacture with exactly planned expenditure based on defined work sequences, even at a lot size of 1."
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