More than just die manufacturers – R&R Formentechnik automates with Tebis

Björn Katthage, Managing Director of R&R Formentechnik GmbH, describes the Tebis AG CAD/CAM solution as the key element in his manufacturing

Over the years, we have worked closely together with Tebis to develop a system that goes far beyond simple paperless solutions. It is the key to end-to-end digital processing and greater efficiency in our production. It was clear to us from the outset how important it was to position ourselves for the future. You have to be looking far ahead to survive as a company in this difficult market environment.

Björn Katthage explains: "With this background, we did not and still do not see our collaboration with Tebis as a quickly installed individual software solution. Instead, we were much more concerned with developing a scalable, future-proof infrastructure right from the start. The solution we developed together with Tebis is now the heart of our entire manufacturing system." Björn Katthage recalls the first steps: "We have been using Tebis since our company was founded in 2011. But at first, we only used a fraction of the potential of this CAM software. Of course it's not enough to simply purchase CAM software. The system is only as good as the knowledge anchored in it. The management basis and structure have to be designed specifically for this. In 2019, we decided to lay the foundation for our future automation with Tebis and established a technology concept for this, focusing on efficiency and future viability. The in-house team we then formed was highly motivated and digital-savvy across the board. We were eager to explore the potential of Tebis and to proactively further develop it to adapt the solution to our requirements. We see the path to automation as a common development process, and this perception is mutual: Throughout this process, we can contribute our vision, our innovative strength and our technical proposals and can work on an equal footing.

We worked together, scrapping pallets of old tools, classifying the remaining inventory and revising the databases for consistent records. All tools were digitally reproduced in Tebis, based entirely on articles and components. Standardization has advantages for procurement, simplifies programming and finally reduces the setup effort in manufacturing. Further classification of the tools, such as "eco"/"high-performance", ensures the cost-effective use of carbide tools. For example, cutters have up to 700 cutting parameters linked to strategy, material and machine. After standardization, expensive and sensitive tools are only used where appropriate, thus extending their service life.

The NC automation system based on the restructured tool management system can now automatically determine the required tools and select the appropriate strategy based on the geometry to be machined, the material and the selected machine. The large number of standard drilling operations typical for the company can now be completed in minutes. 

The digitized tool management is scalable and each tool is fully traceable by its article number. Björn Katthage explains:

Of course we were not interested in order for its own sake. This project was driven by clear economic considerations. The current quality and clarity of our tool inventory are impressive. We manufacture at high quality and with essentially no rejects. In other words, our process is absolutely safe.