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Throughput times reduced by 30%

Tebis Consulting’s process structuring at Böhm & Wiedemann:

Fast. Precise. Flexible. These are the customer requirements that Böhm & Wiedemann must meet. The company can do this profitably only if a wide range of unique pieces can be manufactured at mass-production costs. The foundation 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 automotive, aerospace, optomechanics and research industries, the company manufactures prototypes, small and mid-sized series, individual components, complete assemblies and 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, both in Germany.

  • The goal is the industrialized manufacture of single parts

    Following a benchmark analysis, Böhm & Wiedemann decided to implement the Tebis software technology. "We mostly wanted to improve process reliability in manufacturing and to reduce lead times," said Christian Fach, 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. This means that potential problems can be identified and resolved long before machining on the actual machine. The programming system the company used previously was limited in this respect.

    For Böhm & Wiedemann’s customers, even fractions of a second are critical for victory or defeat. "We therefore have the highest demands on speed, compliance with deadlines, the ability to find solutions, and quality," explains Fach. "These objectives can only be achieved with standardized manufacturing processes. Our goal is the industrialized manufacture of single parts.”

  • Better structures with new tools

    Because it was extremely important to implement the new software and especially the new manufacturing processes quickly and smoothly, Tebis Consulting was asked to perform the work. "We were sure that the project could be realized more quickly and effectively in this way," says Fach. After all, this task is "business as usual" for Tebis Consulting, whose consultants draw on broad expertise in this area. "Standardization must ultimately 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 broad spectrum of parts from a 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 Tebis Consulting, the affected parties become the parties involved in the solution

    A detailed project plan was created from the analysis of existing manufacturing processes and working methods in Eching and Cologne. The introduction of the software and the restructuring of the manufacturing processes were defined and realized within three months.

    The NC programmers at Böhm & Wiedemann work with precisely structured specifications.

    In the first step, the Tebis Consulting specialists drew up the structures and standards required for the work processes. From the very beginning, the employees affected by the future changes, were involved in the solution and implementation process. Years of experience in many successful projects have shown that this collaborative procedure in particular ensures acceptance by and cooperation of all project stakeholders. This is a major prerequisite for a 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. Not just the cutters but also all holder components of the drilling and milling tools are 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 is the basis of the virtual machining process. Without it, standardization of manufacturing processes has little meaning," explains Marc Fuest, the responsible consultant from Tebis Consulting.

    The components – cutters and holders – were therefore measured and recorded in the Tebis tool library. All NC programs can now be programmed with precise virtual tools and – after checking in the Tebis Simulator – transferred collision-free to the machine operator. An obvious consequence is that holders and tools that were no longer used were registered and sorted out.

  • Comprehensive standardization of the manufacturing process leads to success

    The optimized and standardized process for Böhm & Wiedemann – from data input to the workshop – was conclusively defined by the consultant from Tebis Consulting in conjunction with all the participants and documented in a set of rules. All employees were then trained in the use of the Tebis technology, prepared for their new work methods and supported by specialists during the initial 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. As a result, far less intervention by machine operators in the manufacturing process is necessary. The previous extensive manufacturing documentation was also replaced with a paperless flow. The greatest benefit was the reduced lead time. Lead time was reduced by 30% at the Eching site and by an amazing 50% at the Cologne site. In addition, one machine operator can now operate two machines instead of one.

    "All participants can be very satisfied with the result," Fach sums up. "Even my expectations for the support from Tebis Consulting have been fulfilled 100%. We now manufacture with precisely planned expenditures based on defined work sequences, even for a lot size of one."

Overview

Quote

Since the process was structured by Tebis Consulting, we have been manufacturing industrially, even for a lot size of one.

Features

Focus:

New process structuring for profitable industrial manufacturing of single parts

Benefits:

  • Experienced consultants from Tebis Consulting
  • Personnel involved in the change
  • Optimal and standardized process

Sector:

Machinery and equipment, Component manufacturing

Company:

Böhm & Wiedemann Feinmechanik AG

Location:

Eching, Cologne, Germany

Interviewee:

Christian Fach

Position:

Board of Directors

Published:

2012

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