A. Erglis GmbH, Modell- und Formenbau, CAD-CAM-Technik

A Tebis customer for the past 22 years

In addition to its wide range of functions, this model and mold maker in Heilbronn, Germany, especially values the Simulator's seamless integration into the system. The Tebis Simulator ensures a reliable process workflow, even during the night shift and on weekends. 

At Erglis the machines operate around the clock. The company specializes in high-end composite models and molds, especially for the automotive and aerospace industry, and they meet the demand for more efficiency through a high degree of flexibility and productivity. This model and mold manufacturer uses end-to-end support from Tebis, and the current Version 3.5 software package contributes efficiently to the creation of an ideal design and production process. "We have been working with Tebis for 22 years, and our designers and programmers are perfectly attuned to the system," explains Rainer Eckelt, master model-maker and Managing Director of Erglis. "The very clear and unambiguous structure of the software enables us to work efficiently. The intuitive operating processes simplify the design and programming, enabling operators to focus on the essentials.“

End-to-end and flexible Tebis installation

Erglis utilizes Tebis throughout – from the interface workstation with all design functionalities, to six CAD/CAM stations for programming, three Organizers on two Zimmermann FZ37 machines, and one DMC 105 V, to the three measuring station modules. The company also uses the "floating" system: Each programmer can access the required modules for their programming requirements from a pool of licenses available to the entire company, and return the licenses to the pool when their calculations are completed. The programming becomes very flexible, with no major expenses.

Nearly every work piece is unique – hence, design and programming are essential functions. A wide diversity of employee knowledge is emphasized at Erglis: The designers also program and vice versa. " With its high degree of consistency, the Tebis software is very helpful because flexibility is mandatory for us," stresses Eckelt. "We work in two shifts plus an unmanned night shift, because the machines need to be working day and night."

"We hardly use any paper" – only an image of the setup position and a list of the required tools is printed
Thanks to the close linkage between programming and simulation, high process reliability is ensured by executing the collision check – especially when timing is tight

The Tebis Organizer enables manufacturing with as little paper as possible

This requires a continuous flow of information. "We hardly use any paper," Eckelt explains. "All information is stored in the system. If the operator at the machine needs clarification, the Tebis Organizer provides access to the entire file and all relevant data." The Organizer provides the same data as the design and programming modules: "This is very useful, in particular when questions arise," he adds. "The designer and machine operator can open the same view on their monitors and be assured that they are talking about the same structures."

Simulation provides a "reassuring feeling"

An important factor for high productivity is that component setup is already defined during the design phase. "We have set up zero point clamping systems on our small machines and created modular clamping systems for the larger installations," the master mold maker explains. "Components can usually only be programmed effectively if the clamping devices are taken into account. For this reason, we store them in the system as standards." The mold makers especially value the seamless integration of the simulation in the programming environment. "We have stored our machines, including all relevant clamping systems, in Tebis and so we can use this data repeatedly," Eckelt explains. "Thanks to the close link between programming and simulation, we can ensure a very high process reliability by executing the collision check. This is reassuring to me, as I’m the person ultimately responsible. This year, for the first time, we were able to have the machines running unmanned over the Easter holiday. The planning function of the Tebis Simulator is of course also helpful in the programming process. The component can be placed on the machine to virtually define the right setups, tools, and tilt directions."

Detailed representation of the machine and the modular setup system with work pieces. The control of the machining by the Tebis Simulator is the essential element that affords a sense of security when the machine runs throughout the weekend
Zimmermann FZ 37 in use. Thanks to collision control via the Simulator, there can be no damage to either the machine or the components

If a work piece needs to be machined on different machine at short notice, its feasibility can be quickly and easily checked in the simulation: for example, if the work piece needs to be higher due to a different machine kinematics. This simplifies the work and significantly increases flexibility.

Automation creates new standards

"Another benefit of Tebis is its high degree of NC automation," Eckelt adds. "Similar components can be programmed in the same way, thanks to NC templates. Depending on the required quality, machine, and tools used as well as desired tolerances and other factors, all machining can be predefined. These templates are not static – they can react flexibly to changes in the design model."

Close contact with the software partner is important for the Heilbronn company. "They clearly listen to what we specify as requirements or request as supplementary functions," says Eckelt. "Generally relevant solutions are integrated into the next release. When we faced major challenges, the Tebis experts have frequently helped us – quickly and nonbureaucratically. For this reason, the Tebis software is an important factor in terms of using our machines efficiently, economically, and with high process reliability."