4.0 event met with great interest
Pokolm and Tebis show off digital manufacturing
4.0 – the magic of digital manufacturing. With this motto, Tebis AG and its collaboration partner Pokolm informed visitors on September 28, 2016 about the potentials of digital manufacturing. The joint event at Pokolm in Harsewinkel was well-attended, with over 30 participants.
Visitors to the fully booked event had the opportunity to learn about the advantages of digital manufacturing in technical presentations and discussions with experts. Digital manufacturing can help improve a company's resource efficiency, flexibility and competitiveness in the global economy. Emphasis was placed on how Tebis 4.0 and Proleis 4.0 can be used for complete digital control of production with a fully transparent flow of information. Tebis 4.0 knows manufacturing environments and processes and makes components so intelligent that they "know" in detail how they're manufactured. And ID GmbH's Proleis 4.0 manufacturing planning and control system (MES system) knows the data, the capacities and the planning and controls all processes, from inquiry to final product.
Jens Lüdtke, Head of Tebis AG Consulting, spoke about digital die manufacturing and Industry 4.0. Based on his experience, the topic of 4.0 is currently perceived by many die manufactures as being too abstract and complex, and too far from their own reality. But Lüdtke had encouraging news: Industry 4.0 is a key topic for even small and medium-sized companies. There's no one-size-fits-all solution, but every company has to decide for itself how to proceed to implement Industry 4.0 – because the prerequisites for this implementation, such as a clearly structured manufacturing process, are not the same for all. Many individual modules combine to result in Industry 4.0 manufacturing, and some of them have long been implemented.
Tebis Project Manager Helmut Vergin discussed CAM in mold manufacturing. He presented the individual areas in mold manufacturing, such as prismatic machining, deep-hole drill machining, free-form machining, rib machining and others, and described examples of how Tebis typically proceeds in these industry processes. The same activities pertain to each process: simple preparation of the component, automated programming of the tools and optimization, such as the number of machining tools. A standardized manufacturing procedure like the one developed by Tebis is one of the key factors for implementing Industry 4.0.
Stephan Galozy, also a Product Manager at Tebis AG, reported on CAD in die manufacturing. Small-parts automation is already possible today with the end-to-end Tebis process. Tebis functions for real offsets in die surfaces, outline surfaces including relief and exact solids including all stock allowances ensure fast, efficient and high-quality data processing. The tryout process in draw die manufacturing, which is still characterized by manual steps, is time-consuming and cost-intensive. Tebis die surface design simulates springback, incorporates overbend in the die surface design as well as automated radius relief and establishes transition-free pressure surfaces. This enables a dramatic reduction in reworking of the die, while simultaneously increasing reliability with fully designed die surfaces.
Dr. Klaus Dieter Born, managing director of ID GmbH Erndtebrück, presented the Proleis 4.0 process management and control system to the participants.
Proleis 4.0 supports single-part manufacturing in die and mold manufacturing and enables highly flexible production with a lot size of one. This is possible through end-to-end organization and planning, comprehensive manufacturing control and a high degree of adaptability. Proleis knows all the necessary manufacturing data and all the properties and the status of storage areas, and resources and machines are easily accessible and process errors are immediately detected and corrected. The new Proleis 4.0 operating concept also simplifies work with role-specific apps, touch control and better visualization of the process status.
After the presentations, visitors were able to discuss their concerns in detail in individual discussions with the experts at the specific booths. The event met with overall positive feedback from visitors. According to their statements, they found the presentations very inspiring and illuminating. A magician kept the mood light during breaks, at the evening meal and even in the conference room. He established a relationship between his magic and the presentation topics: A magician has to work seamlessly with synchronized processes and automatically functioning tricks. The same applies to manufacturing: There's no magic in working fast.