transfer - Bihler.de
Transcription
transfer - Bihler.de
TRANSFER the bihler technology magazine | issue 2008 Tr e n d : M e t a l - p l a s t i c c o m p o s i t e s bihlership: an inclusive partnership >10 Innovative forming/laser cutting system >20 The future of laser technology >21 d e f r i t >6 e n a a u g n l t s c l i s ç a i i a n h h s o DECISIVE ELEMENT OF BIHLER COMPLETE SOLUTIONS HIGHLY DYNAMIC, UNIVERSALLY APPLICABLE! Driving force for productivity in the bihlerNC range: The highly dynamically clocked, fully maintenance-free GSE tapping units. Can be flexibly used with Bihler machines as well as with presses, indexing table machines and transfer Otto Bihler Maschinenfabrik GmbH & Co.KG Lechbrucker Str. 15 D-87642 Halblech | Tel. +49-8368/18-0 | Fax: +49-8368/18-105 info@bihler.de | www.bihlernc.de lines. Low tool heights, several units next to each other – the compact K-types make it possible. Increase your productivity with Bihler tapping units! TRANSFER E d i t o r i a l / c o rnut b en r it ks | 3 the bihler technology magazine | issue 2008 Neon tubes. Several decades ago, Bihler was the first company to use metal-plastic composites for the sockets, thus making it an early pioneer in this forward-looking technology. Nowadays, it is primarily complex assemblies that demand the joint use of the two materials. 4 6 News Investing in the future 5 To p i c Key technology in an optimized value added chain 6 To p i c Inauguration of the largest Deckel-Maho Gildemeister universal milling machine in Füssen. 6 Dear readers, the wave of consolidations among suppliers to the automotive, electrical and electronics industries shows no signs of calming. To be successful in tomorrow’s markets, it will be necessary to form networks, show innovation, be prepared to take risks and gain maximum value added from manufacturing operations. The capability of innovative metal-plastic composites technology is one of the focuses of the current issue of Bihler Transfer. We at Bihler place great emphasis on close cooperation with our partners to ensure that both parties benefit. This promotes mutual trust, respect and openness. We are happy to have had the opportunity to spend two days in our offices discussing the entire spectrum involved in partnership-based cooperation with many of our customers. “bihlership” was the name we gave to this event at which we received many stimuli and ideas which will allow us to provide our customers with even better support in the future. Just how innovative partnership can be is demonstrated by the Bihler/Trumpf/itec joint project in which three market leaders have combined their skills. The result is a highly versatile combination system that can be used for the manufacture of pilot series and small runs of coil parts. I hope that you will very much enjoy reading the current issue of Bihler Transfer. Metal-plastic composites for complex assemblies are a key technology of the future. 10 10 Forum All in the same boat Bihler continues to extend its range of services for customers and partners. 14 14 Solution Machining complex geometries Pieron is one of the first Bihler customers to use the new multifunctional GRM 80P with its new machine concept. 16 16 Application Metal lives Dawedeit has been a Bihler partner for 36 years. 18 Application Friends and partners 18 ZETKA and Bihler make good neighbors. 20 Solution Innovation through consolidated skills New forming/laser cutting system. 21 20 In demand Changes in laser technology Interview with Trumpf President and CEO Peter Leibinger on the future of laser technology. 21 Mathias Bihler transfer 2008 4 | News Combined systems for complex assemblies Bihler technology is used to achieve smoother washing machine operation: a complete production line manufactures up to 45 shock absorbers per minute. Modern shock absorbers absorb the vibrations which occur in washing machines and ensure the desired level of smoothness during operation. One well-known producer of system components for dishwashers and washing machines manufacturers these hybrid parts using Bihler technology. The sequencing of two different Bihler manufacturing systems offers crucial advantages in this application. At the start of the process, the Multicenter MC 120 produces the two metal parts for the absorber housing. These are then fed automatically to the FMS 2500 assembly system. Here they are equipped with their insides which consist of seven individual parts. The combination of these two systems in a production line makes it possible to manufacture 45 complete shock absorbers per minute. p Controlling complexity ”Factory of the Year”: The toughest benchmark competition for manufacturing companies, conducted by the Verlag Moderne Industrie and A.T. Kearney. Category: “Outstanding complexity management”. Winner: Siemens A&D’s Amberg manufacturing plant. The experts in low-voltage switching technology carried off the award due to their exceptional level of performance and skilful production of a multifaceted range of products. For many years, Bihler technology has made a great contribution to the company’s success. Every day, several thousand electrical and electronic parts and complex assemblies are produced on a total of 18 Bihler systems. Overall, the Technical Center manufactures more than 1,500 different metal and 500 plastic components and parts. In this highly complex environment, Amberg’s experts have developed a fast, versatile value-added chain and cut product launch times by a half. Their reward was the much sought-after award. p Siemens A&D’s Amberg manufacturing plant was named as “Factory of the Year”. Bihler is delighted that its close partner has achieved this award. News | 5 Bushes, bushes, bushes… The GRM 80B is a compact new bush forming machine that is impressive due to its process reliability and innovative tool concept. The Bihler RM 40B bush forming machine has been in successful use for a year. Now, Bihler is presenting the machine’s even more talented sibling at the EuroBLECH trade fair. The compact GRM 80B offers demanding manufacturers of larger, high-precision bushes advantages such as high-quality production, process reliability and an innovative tool concept. Standardized components make it possible to react swiftly to the individual needs of the target markets. It is possible to switch production for different bush dimensions and batch sizes and also achieve short setup times simply by changing the active tooling components. All this makes this production system the perfect tool for both small suppliers and internationally active global players in the highly competitive bush market. p Trade fairs 2009 TATEF Istanbul / Turkey 31.03. - 05.04.2009 MACH-TECH Budapest / Hungary May 09 STANZTEC Pforzheim / Germany 16.06. - 18.06.2009 MACH-TOOL Poznan / Poland 6.06. - 19.06.2009 MOTEK Stuttgart / Germany 21.09. - 24.09.2009 MSV Brünn / Czech Republic 14.09. - 18.09.2009 Bihler-Tec Halblech / Germany 06.10. - 09.10.2009 Metalform USA 15.11. - 18.11.2009 BLECHEXPO Stuttgart / Germany 01.12. - 04.12.2009 TOL Expo Paris / France 17.11. - 20.11.2009 Investing in the future Managing Director Mathias Bihler expresses his delight at the introduction of what is currently the largest Deckel-Maho Gildemeister universal milling machine at the Füssen site. The manufacture of high-tech production systems demands highly-qualified professionals and first-class manufacturing equipment. That is why Bihler places special emphasis on the ongoing training of its workforce and continuously invests in its modern machine pool. With the largest Deckel-Maho Gildemeister universal milling machine ever, Bihler has now extended its capacity at its Füssen site and raised the “Bihler Quality” quality label to new heights. At the versatile and adaptable DMC 340 U, it is possible to machine large-volume series production parts of up to 16 tonnes in 5 axes. Bihler uses the system to manufacture all its machine baseplates and the Combitec press. This massive milling machine is also available to interested third-party companies that want to manufacture their own products. p transfer 2008 6 | To p i c transfer 2008 To p i c | 7 Metal-plastic composites Key technology in an optimized value added chain Small and midsized suppliers, in the automotive and electronics industry, continue to be confronted with a strong trend toward consolidation. Large manufacturers and suppliers demand their own suppliers to exhibit a high level of flexibility and innovation. While, in the past, it was sufficient to supply high-quality individual parts, the future will see the trend shift toward increasingly complex assemblies. Combinations of metal and plastic form the basis for the required assemblies and their association means that this key technology represents an optimized value-added chain. In particular in the automotive industry, the supply sector is learning to change. One forwardlooking technology consists of using metal-plastic composites in complex assemblies such as those used in automobile transmissions. “High raw material and energy costs are forcing the automotive industry to look for new technological solutions that not all German suppliers will be able to provide,” concludes a study conducted by the auditing and consulting company Ernst & Young which questioned 150 German automotive industry suppliers. According to Ernst & Young, it is primarily the technologies of the future that will pose problems: “Companies which fail to make the transition now because they cannot cope with the enormous cost of innovation will soon be threatened with extinction.” This viewpoint is complemented by an observation resulting from a survey conducted by the trade and industry chambers of Arnsberg, Hagen and Siegen: “In the automotive sector, the customer’s wish for a greater variety of vehicles and equipment variants requires production to become more versatile. Manufacturers have responded to this by shifting to increasingly modular production units.” It is claimed that this is also the reason for the emergence of integrated supplier systems and the concentration on a small number of module or system suppliers. The study confirms the trend that is also confronting metalworking companies. The future of the supply industry, and not only in the automotive sector, lies in assemblies, mostly in the form of metal-plastic composites. While, for Although metalplastic composites have a long tradition, their complexity is increasing all the time. many years, the manufacturing technologies used for plastics and metal were strictly separate, the two technologies have now grown much closer together. And this process will continue: For example, it is already possible to feed punched parts via a cleaning machine to an injection molding machine where they can be molded. At present, molding is still a very time-consuming operation as the molding unit cannot achieve the cycle times dictated by the presses or punching/ bending machines and is therefore only of limited relevance for manufacturing large runs. As a result, the established procedure is still to mechanically combine separately produced punched and bended parts with the plastic parts. “The aim of the hybrid technology is to combine metal and plastic quickly and automatically,” says Mathias Bihler, Managing Director of Otto Bihler Maschinenfabrik GmbH & Co. KG. Hybrid assemblies are becoming more complex all the time and it takes a lot of components to form a single assembly. Any company that fails to invest in the forward-looking technology of metal-plastic processing now will be poorly prepared for the future. That is why we are seeing more and more alliances being formed between metal and plastics processors. This makes it possible to exploit synergies and act as a single partner vis-à- u transfer 2008 8 | To p i c vis the customer. “Plastics technology already forms an integral part of Bihler technology, we have developed unique solutions and processes that have created very great competitive advantages for our customers,” states Mathias Bihler. It has become clear that it is primarily the automotive and electronics industries that are driving this combined technology forwards. However, demand for it is also growing strongly in the fields of medical and communications technology. The reason is clear: The greater the level of automation, the more different technologies have to interact to achieve the manufacture of a Changes in the supply industry using high-quality part. the example of the automotive sector Mathias Bihler: “Any manufacturing company in a country where the Automobile manufacturers wage costs are very high should try to automate Large suppliers in order to reduce production costs by improving the valueNew middle layer: added chain. ” u Networks / cooperations / suppliers of assemblies Component suppliers The wave of consolidations in the supply industry has resulted in a new middle layer: In the future, component suppliers who merge and position themselves as assembly manufacturers will be doing business with the large suppliers. transfer 2008 Increasing value added “Growing quality requirements and short product lifecycles at a time of rising costs as well as the burgeoning number of product variants are increasingly placing special requirements on the innovative capacities of the entire value-added chain. Particularly in recent times, globalization has exposed manufacturers to significant price pressures and these have been passed on to supplier,” continues the study by the three CTIs. If you consider the manufacturing operations of the major suppliers today, you can still generally define three traditional areas: the manufacture of metal parts, assembly and the plastics sector. Here, the use of the hybrid technology can achieve an optimization of the value-added chain by coupling the plastics sector with the manufacture of the metal parts. “The assembly sector, which historically has played an important role in businesses, will not continue to exist as a separate sector in the future. Companies will need to rethink their approach,” forecasts Mathias Bihler. “We must continuously develop precise concepts of economic efficiency to demonstrate that a punching-bending-assembly process guarantees a very high level of value added – one of the reasons being, for example, that the transport between the individual manufacturing and assembly sites is eliminated. It also prevents the loss of component quality during transport.” Only if various operating steps can be brought together at unchanged or even enhanced quality is it then possible to achieve a high level of automation and consequently optimize the value-added chain. This means that the further development of everyone involved in the manufacturing process is absolutely vital since the transfer of expertise ensures future success. Close cooperation Costs and price pressures are the main problems faced by suppliers to the automotive industry in southern Westfalia. However, they apply to all businesses located in this region. When asked about counterstrategies, the questioned companies primarily referred to rationalization measures and a changeover to other markets. Only very few counted on horizontal or vertical cooperations. However, it is precisely here, in regional and supra-regional networks, that major competitive advantages can be obtained. The enterprise network known as Automotive-Cluster Rhein-Main-Neckar has therefore set itself the aim of bringing together the expertise of the region and initiating cooperations. This will make it To p i c | 9 possible to maintain and increase value added in the region. The impetus to form the Automotive Cluster came from the entrepreneurs themselves. Volker Schier, Managing Director of Bertrandt Ingenieurgesellschaft mbH in GinsheimGustavsburg: “We are often unaware of the potential of our neighbors and therefore feel obliged to search for project partners from far away.” Collaboration and cooperation – Mathias Bihler is another who considers these to be an important topic: “Engineers who are developing metal/plastic products often come to us with instructions to merge the two materials in a reliable way on our own machines. They then work together with Bihler’s experts to find a solution tailored to meet the customer’s needs.” The key thing is to satisfy market requirements, a task which is synonymous with shorter production cycles and high-quality, complex components. Suppliers are changing In recent years, the structure of the supplying companies has changed visibly – and most clearly so in the automotive industry. The top of the pyramid was, and still is, occupied by the car builders, followed by the major suppliers with their own supply sector and specializing in a given production technology. The consolidation process in the supply industry has resulted in the emergence of a new “middle layer” between the large and small suppliers. This new layer no longer relies on a single technology but is instead vehemently committed to the process of assembly production. “The automobile manufacturers demand complete assembles which can be used immediately,” says Mathias Bihler. And these assemblies very often consist of metal-plastic composites. Using intelligent manufacturing solutions, a high level of automation and an extensive understanding of all the technologies involved in production, that is to say with innovation, it will be possible to shape the future of the supply industry. The FHDW’s (Economic Academy) Center of Automotive sums up these developments in its study “Innovation Skills: Factors of Success for Automotive Suppliers”: “Companies which are successful in the long-term usually possess significantly greater innovation skills for which an empirically secure innovation strategy and professional innovation processes play a central role.” p Intelligent metalplastic composites are resulting in the optimization of the value added chain. The electronic and optical monitoring of the process guarantees error-free operation. transfer 2008 10 | Forum transfer 2008 Forum | 11 bihlership for the optimization of service performance All in the same boat What do today’s customers expect from service and partnership? This question, and the ways Bihler can extend its range of offers in these fields, was the subject of a two-day seminar in Halblech. The atmosphere was relaxed. 19 decision-makers representing ten key users of Bihler technology took up the invitation to Halblech to spend two days talking about service, partnership and how they could be extended. They included small, midsized and large companies, suppliers to the automotive and electronics industry, and OEMs. In the large conference room, Managing Director Mathias Bihler thanked the participants for coming and defined the event’s objectives. “Bihler would like to hear about its customers’ requirements and wishes so that it can offer them even greater support in the future. As part of genuine, inclusive partnership with optimized service processes – in short “bihlership.” Axel Schnöring, from Schnöring: “The advantages of Bihler technology – even in the case of simple parts – must be communicated more widely and more forcefully.” Service far beyond technical support This philosophy mirrored the participants’ expectations. In particular, they demand tailored services which go far beyond technical support. “We want close, clearly structured cooperation as early as the product development stage. Continuous technology transfer is of decisive importance for us,” said Thomas Riedler of Tridonic.Atco. And for Axel Schnöring, Managing Director of the company of the same name which acts as a supplier of springs, assemblies and punched/bended parts, the most important thing a strong partner should provide is customerspecific training. “Only with highly qualified u Matthias Sandhas, from A. Raymond: “An extremely important point for us lies in reducing setup times. We would therefore like to see Bihler employees in our premises more frequently so that they can record and optimize the setup processes.” transfer 2008 12 | Forum In workshops, group discussions and one-to-one conversations, Bihler’s customers were able to formulate and exchange their ideas and wishes concerning service and partnership as part of a two-day seminar. Jörg Heldmann, from Saint-Gobain: “More exchange of information between Bihler users, optimization of delivery times and the prices of spare parts!” u Manfred Götz, from Schaeffler: “I very much appreciated the workshop. It clearly showed that different Bihler customers experience similar problems. I hope that Bihler will draw its conclusions from the ideas and continue to improve.” transfer 2008 employees can we successfully complete our ever more complex tasks.” In addition, the discussions closely examined topics such as the reduction of setup times and the availability of spare parts. Intensive groupwork in the workshops During the first of the two afternoon workshops, Prof. Dr. Christian Donhauser chaired a discussion of Bihler’s current offer in the field of customer support. The participants were asked to consider this critically and formulate any special requirements. The result: the most important demands were 100 % spare parts availability, the shortest possible delivery times and a costoriented, modular spare parts structure. Additional requirements included a proactive approach on the part of Bihler and optimum accessibility of technical support – preferably seven days a week. The idea of a “bihler-bay preowned machine exchange” and the range of services available from the Bihler Academy were also intensively discussed. The second workshop dealt with the topics of development partnerships and process development. Expectations such as “early involvement in product design and a comprehensive design partnership” were voiced. The idea of a Bihler technology platform aroused special interest in the context of the frequently discussed issue of technology/know-how transfer. Matthias Sandhas from A.Raymond: “Using the example of our linewalks, Bihler should visit customers’ premises to assess production in cooperation with other Bihler users. This would be Forum | 13 Rudolf Gropper, from Rosenberger: “A truly interesting workshop for which I even postponed my vacation for a week so that I could sit in the same boat. The issues discussed were very interesting. Great challenges are waiting for us and for Bihler.” Thomas Huck, from Tridonic.Atco: At the two-day event in Halblech, Bihler heard many stimulating ideas from its customers which will be evaluated and implemented in a new, individualized customer service concept. “The high availability of spare parts and the associated question – stored at Bihler or in our own company – is of special importance for us. We also place value on machine maintenance and further training since these help us improve our value added.” an excellent opportunity to exchange knowledge.” Expectations completely satisfied This was just one of many ideas which Bihler’s “My expectations concerning the workshops were managers listened to with great interest during completely satisfied. The event was an excellent the two-day event. “The task now is to develop example of a truly inclusive partnership,” said the appropriate implementation strategies and Thomas Doppelbauer from Hilti warmly, speaking restructure service activities at Bihler,” concludes Thomas Doppelbauer, as he did so for all the other participants. Bihler’s Sales Manager Ludwig Mayer. “We shall from Hilti: Mathias Bihler thanked the participants for their most certainly present the first results in October “A great deal of structured commitment, the intensive exchange of experiat EuroBLECH.”. input was provided during the ence and the stimulating ideas they had contribworkshop. And in truth, this uted. The success of the event confirmed him in event is exactly the inclusive his wish to organize other meetings of this type at partnership that Mr Bihler regular intervals. In the meantime, the wind spoke about. I very much liked outside was blowing strongly. It seems that it, too, the scope of the participant wanted to play its part in moving bihlership level.” forward even faster. p In small groups, the participants discussed ideas and improvements in the field of Bihler’s service offering. Bodo Tillmann, from Kostal: “It’s now up to us customers to define internal aims and do our homework. We can’t just expect things to come from Bihler. We also have to ask for them.” transfer 2008 14 | Solutions Pieron, Bocholt Machining complex geometries Everyone knows that technical springs are synonymous with Pieron. This family-run company from Bocholt is a specialist in this field. At the same time the production of clamping rings and punched/ bended parts is growing in importance. Pieron GmbH is one of the first Bihler customers to use the multifunctional GRM 80P with its new machine concept. Christian Fehler, Sales Manager at Pieron GmbH, is convinced: “Hightech products demand extremely precise processes.” Pieron GmbH’s product portfolio includes wire parts, punched/ bended parts and clamping rings as well as technical springs. transfer 2008 solving complex tasks, there is also more space for the integration of all of Bihler’s key technologies such as welding, screw insertion and tapping. Adherence to the smallest tolerances Pieron GmbH is proud of producing in Germany. “We are very different from companies that manufacture in low-wage countries. Our customers demand top-quality, high-precision “When I saw the Bihler GRM 80P for the first time, products. Our products – whether springs, I knew straight away: This has to be the one,” remembers Frank Bitschinski, Production Manager clamping rings or punched/bended parts – fulfill these requirements and guarantee reliability,” at Pieron GmbH.”The external press, which is says Managing Director Gisela Pieron. And versatile in its use, gives our production extra Burkhard Schauf, Bihler company representative options.” Thanks to the arrangement of the twofor the North-West region who looks beyond the point eccentric press next to the work plate, the GRM 80P now offers considerably more free space. production capacities of Bihler manufacturing machines to consider the entire value-added As a result, the entire width of the plate can be chain, adds: “The development, design and used for a wide range of bending, forming and production of technically sophisticated products, assembly operations. including the material, transport and wage costs – It also possesses variably mountable units which when all the factors are taken into account, the offer different nominal capacities and strokes use of investment-intensive Bihler machines is depending on the application. When it comes to Solutions | 15 Frank Bitschinski, Production Manager at Pieron GmbH: “The GRM 80P gives our production department more options.” economic. As a production location, German is totally competitive at the international level.” It therefore only makes sense that Pieron manufactures the brake plates for automobile brake systems on Bihler’s GRM 50, GRM 80, GRM 80E and, more recently, GRM 80P highperformance machines. Modern production methods make it possible not only to machine complex geometries but also to respect the smallest tolerances. “High-tech products like brake plates that demand perfect quality require extremely precise processes,”, says Christian Fehler, Sales Manager at Pieron GmbH. “We develop tailor-made solutions, a fact that our customers greatly appreciate.” In its use of the GRM 80P, Pieron provides an impressive demonstration of the great scope of application the machine offers. At a single machine, Pieron is able to use two presses: on the one hand the GRM 80 P’s new, external press module and, on the other, a second press Pieron GmbH, Bocholt Since 1925, Pieron has been producing technical springs for practically every sector of industry but with a main focus on automotive, electrical/ electronics and sports items applications. “At 70 percent, companies from the automotive sector form our largest customer group,” says Christian Fehler, Sales Manager at Pieron GmbH. The product portfolio includes wire parts, punched/bended parts and clamping rings as well as the technical springs. Pieron is able to provide a variety of solutions fully independently due to its in-house design, development, manufacturing and toolmaking facilities. According to Managing Director Gisela Pieron: “Our employees form the basis for our success. That is why we have great confidence in them and entrust them with responsibility.” mounted as an additional tool. “Precisely in the case of complex parts, this flexible arrangement is indispensable,” says Bitschinski. Responsible for the success of Pieron GmbH (left to right): Frank Bitschinski, Sven Pieron, Gisela Pieron, Björn Pieron, Christian Fehler and Georg Rennen form the management team of this family run business. Perfect interaction Pieron GmbH is proud of its own high-precision toolmaking capability which provides perfect support for design instructions. “For us, the compatibility of the tools for Bihler machines is very important,” says Fehler. “We can react flexibly depending on the particular requirement.” To design its tools, Pieron uses Bihler’s bNX – next generation design software. “bNX is a software solution that supports the entire design and manufacturing process. This provides us with an open, versatile and configurable 3D system for development and design, drawing creation as well as for simulations and manufacturing activities,” explains Burkhard Schauf. At all times, the close contact between Pieron and Bihler is characterized by a high level of trust. According to Fehler: “A two-way exchange of information and know-how transfer benefit both companies and therefore also their customers.” p Contact Burkhard Schauf Representative for North-West region Tel. 0 23 58/25 72 71 burkhard.schauf@bihler.de transfer 2008 16 | Application Dawedeit, Lüdenscheid Metal lives Since 1971, Dawedeit GmbH has been producing at its Lüdenscheid site. And for the last 36 years, the company has been a close cooperation partner in Otto Bihler Maschinenfabrik GmbH & Co. KG’s toolmaking operations. A success story for both companies, with the biggest winners being the customers. The core business of the Lüdenscheid-based Dawedeit GmbH is toolmaking. This is one of the reasons for its intensive partnership with Bihler. “Metal lives,” says the company’s founder and Managing Director Gunter Dawedeit as he presents a recently manufactured punched/ bended part produced on one of Bihler’s GRM-80E machines. Gunter Dawedeit is proud of what he has achieved with his brother Siegfried. After starting a small business almost 40 years ago, they now employ 75 people in their family-run company, including as many as four design engineers. Dawedeit specializes in the development and manufacture of complex tools, while also producing punched and formed parts in-house. “We see ourselves as solution providers and accompany our customers from the original idea, through the tool construction stage and on to production,” says Gunter Dawedeit. At the same time, demand for the family-run company’s consulting skills is increasing. “Sometimes customers come to us simply with an idea or a manual prototype. We then examine the problem and find the best solution for economic series production,” says the Managing Director. Toolmaking for Bihler’s customers Dawedeit GmbH’s core business is toolmaking. And this is precisely the starting point for the intensive partnership with Bihler. When it sells production machines in northern Germany, Bihler Alongside the development of complex tools, Dawadeit also manufactures punched and formed parts in its own production shops using a current pool of 25 Bihler machines. transfer 2008 Application | 17 recommends its customers to commission their tools from Daweadeit. “A company which manufactures in close proximity to its customers and whose qualities we have trusted in for decades can react quickly and flexibly when situations change,” says Dietmar Stoer, member of the Bihler representative agency for the NorthWest region. And Gunter Dawedeit adds: “Our many years of continuously developing expertise in the construction of tools for Bihler machines have made us special. We guarantee great process reliability, long tool service lives and high utilization rates.” The tools developed by Dawedeit machine different types and qualities of strip materials from 0.05 to two millimeters in thickness and of widths of up to 100 millimeters. Dawedeit GmbH, Lüdenscheid Dawedeit GmbH has been developing and manufacturing high-precision tools since 1971. From the very first contact, the company’s engineers and technicians accompany customers in the realization of their projects. All their skill and experience are used for the in-house production of punched and formed parts. This approach provides customers with a richly appreciated process chain from design through toolmaking and on to production. With its forward-looking approach and activities, the use of state-of-the-art technologies and the commitment to creating perfect punched and formed parts make Dawedeit GmbH a reliable supplier and partner. Currently, Dawedeit uses 25 Bihler machines for a huge variety of products. “As far as precision and quality are concerned, Bihler’s production machines play a leading role,” says Gunter Dawedeit. All the tools manufactured for Bihler’s production machines are designed using special Bihler software. “This allows us to achieve a high level of reliability,” claims Siegfried Dawedeit. Despite this, it is essential to adapt the designed, constructed tools to the machine itself. “In effect, we always have Bihler machines belonging to our customers here in house and mount the tools on them. After the assembly, documentation and acceptance stages, the machines are then transported back to the customer.” When it comes to toolmaking, Dawedeit GmbH has no reason to fear competitors from low-wage countries. In this field, quality is the only thing that counts. However, in the field of large series production, international competition is very active. “We always approach our customers individually. That helps us come through even in the current market situation,” says Gunter Dawedeit. At the moment, the two directors are planning the handover to the next generation. Michael Dawadeit, a trained toolmaker who is currently responsible for quality management, will take over at the helm. “We’re taking it step by step,” explains the company’s founder whose calm, considered demeanor makes him immune to overhasty action. Mathias Bihler, Managing Director of Otto Bihler Maschinenfabrik, is also looking forward to working closely with the new management: Dawedeit has always been a loyal core partner, still is today and will continue to be so under its new management in the future.” p Dawadeit uses the GRM 80E to produce high-quality punched and formed parts. Contact Dietmar Stoer Representative for North-West region Tel. 0 29 22/8 03 92 67 dietmar.stoer@bihler.de transfer 2008 18 | Application ZETKA, Füssen Friends and partners The two production workshops operated by ZETKA Stanz- und Biegetechnik GmbH & Co. KG and Otto Bihler Maschinenfabrik GmbH & Co. KG Füssen branch are just a stone’s throw apart. Here, in Füssen’s Hiebelerstraße, the vibrant friendship and partnership of the two neighbors can be clearly felt. In ZETKA GmbH & Co. KG’s extensive production workshops in Füssen, 30 Bihler-machines combine with other equipment to manufacture topprecision punched and bended parts. One new addition is the Minster/Bihler HB 60E high-speed press which enables ZETKA to manufacture larger and heavier parts than in the past. To give it a secure basis in the competitive international environment, the company has specialized in two technologies. “In our company, we combine both follow-on composite and Bihler technology,” explains Zettlmeier. The company is economically successful, has just completed a major extension to its premises and the order books are full. “I can see no stagnation and no downturn, either in the short or medium term.” Quality and precision Department head, Ottmar Senn assesses an RM 40K used by ZETKA to manufacture metal vein clamps for a Bihler customer. ZETKA supplies its high-quality punched and bended parts made of strip and wire material to a variety of industries. transfer 2008 Founded by their fathers in 1968, the company’s fortunes are now managed by the two sons Klaus Zettlmeier and Christian Kallenbach. Approximately 135 employees play their part in the success of ZETKA Stanz- und Biegetechnik GmbH & Co. KG. “Founded as a two-man business, the company has never stopped developing and generates a healthy rate of growth,” recounts Application | 19 The Minster-Bihler HB 60E high-speed press has opened up new possibilities for ZETKA. It enables the metalworkers to produce larger and heavier parts than in the past. Kallenbach. Currently, ZETKA produces approximately 70 percent of its punched/bended parts volume from strip and wire material for the automotive industry. “We have a small but very loyal customer base consisting of some 20 major customers with whom we have been working very closely for many years,” explains Klaus Zettlmeier, describing one of ZETKA’s recipes for success. The Füssen-based company’s core skills lie in its inhouse tool design department and toolmaking activities, in its high level of quality consciousness and in its consulting services which have continuously grown in importance over the years. There are still certain customers who bring a completed drawing to ZETKA whose employees then develop and build the tools and produce and deliver the requested parts. However, a different type of customer relationship is becoming ZETKA GmbH & Co. KG ZETKA is a manufacturer of punched and bended parts made from strip and wire material for various branches of industry such as the automotive, electrical and electronics and other sectors. The company specializes in contact springs, electrical switching contacts with stainless steel coatings, threaded parts, flat-pin terminals, complex punched parts used in combination with plastics as well as punched parts still on the stamping strip. All toolmaking activities and design work are performed in-house. Qualified specialists, modern technical equipment and many years’ experience in the fields of toolmaking, production technology and measurement technology guarantee a uniformly high level of precision in both the tools and the series parts they are used to manufacture. Founded in 1968, ZETKA employs approximately 135 people at its Füssen site. increasingly prevalent. Klaus Zettlmeier: “The future belongs to joint developments between all the participants in a project and the focus will be on procedures designed to support production. Thus growing numbers of customers are coming to Kallenbach and Zettlmeier with just an idea. Product development is then carried forward in cooperation with all the companies involved in project, for example the plastics processors or finishers. “This approach brings together different skills and expertise is exchanged. This leads to an optimization of the process chain,” asserts Kallenbach. And Bernd Finzer, Bihler representative for Bavaria and Switzerland, adds: “Product development cycles are becoming shorter. It is the market’s requirements that have to be turned into a reality.” What at first glance appears to be a problem can, when considered in more detail, bring its advantages. “This type of development partnership represents our route to the future. We cannot be competitive in Germany simply by producing simple punched parts. We must employ our know-how, quality and understanding of our customers to assume the role of system supplier,” says Zettlmeier. ZETKA’s Managing Directors Christian Kallenbach (left) and Klaus Zettlmeier in front of ZETKA company headquarters in Füssen. A close association The close proximity of the two neighbors – ZETKA and Bihler – is also a way of life. Klaus Zettlmeier and Mathias Bihler have been friends since their childhood and both of ZETKA’s present Managing Directors completed their apprenticeships at Bihler. Alongside the customer-supplier relationship, the two companies have found other forms of partnership in the toolmaking sector. For example, ZETKA uses an RM 40K to manufacture a variety of metal vein clamps for a Bihler customer. Klaus Zettlmeier: “Networks with strong partners help secure future success.” p Contact Bernd Finzer Representative for Bavaria/ Switzerland Tel. 0 76 23/79 65 83 bernd.finzer@bihler.de transfer 2008 20 | Solutions Forming/laser cutting system Innovation through consolidated skills When three market leaders pool their skills and adapt these to the individual requirements of the other partners then innovations appear. This is proved, for example, by the joint project to develop a versatile combination system consisting of the extremely flexible Bihler BIMERIC NC system, forwardlooking Trumpf laser cutting technology and an itec axis system for the manufacture of pilot series and small runs of coil parts. From the drawing of the punched/bended part through to the finished product in the shortest possible time. An innovative joint project: The forming/ laser cutting system developed by Bihler, Trump and itec is primarily intended for prototypes and pilot series. The combination system was developed in cooperation with engineers from Trumpf and itec. It combines the strengths of the Bihler BIMERIC NC forming system with those of a Trumpf laser cutting system and an itec positioning/axis system. “The system offers users crucial advantages during the prototype production, pilot series and series ramp-up phases,” enthuses company head Mathias Bihler. “In particular, if the ultimate parts requirement is not yet clear.” The key: Because the laser is an integrated part of the system, changes to the part during the prototype and pilot series phases can be performed easily and at low cost. Currently, the prototype is still in the test phase. In this version, a steel band is first fed to the laser which cuts out the sheet. The “stamping strip” then passes through the BIMERIC’s central opening to the machine’s front face where NC units bend the plate to form the finished part. To make changes, it is simply necessary to modify the NC programs. Depending on the application, further processing modules can be flexibly integrated in the manufacturing process at this point. The combination system also vastly accelerates the route from the drawing to the actual part. For example, a sheet’s CAD data can be read in directly by the machine controller and implemented within a manufacturing process. This allows users to arrive at production-ready solutions in a much simpler and more economic way. “Given that this is the case, then whenever if it is necessary to produce very large numbers of parts, all that is needed is to manufacture the corresponding punching tool and transfer production to a highperformance Bihler punching/bending machine,” explains Mathias Bihler. Small runs also possible during series production However, the system’s scope of application is not limited to just the development and ramp-up phases. The increase in the number of product variants opens up further opportunities for the forming/laser cutting system. This is because, depending on the laser equipment, the system is also capable of producing small series runs flexibly and economically. It is also possible to integrate additional laser modules for welding and cutting workpieces by means of a laser network operating via the laser beam source. In 2009, the mature forming/laser cutting system will be available on the market. p In demand | 21 Wide-ranging scope of laser applications Changes in laser technology Trumpf GmbH & Co. KG in Ditzingen, Swabia, is one of the world leaders in laser and laser system technology for materials processing. For Peter Leibinger, Executive Vice President and Chairman of the Laser/Electronics Business Division, laser technology is undergoing a period of radical change. In an interview with Bihler Transfer, he and the Managing Director of Otto Bihler Maschinenfabrik GmbH & Co. KG, Mathias Bihler, emphasize the importance of long-standing partnerships such as the one that exists between Trumpf and Bihler. Bihler Transfer: Herr Leibinger, Trumpf is a technology leader in the field of lasers for industrial materials processing. How did your company come to specialize in lasers? Peter Leibinger: Originally, Trumpf was a mechanical engineering firm and only later did it become a laser specialist. The possibility of cutting steel sheets with lasers first emerged in the 1970s. This naturally significantly impacted on our core skills as a manufacturer of machine tools. At the end of the 1970s, we ordered the first lasers from the USA. However, because these lasers were only of limited suitability for industrial applications, Trumpf soon afterwards started to develop and build its own lasers in order to meet its customers’ requirements. Bihler Transfer: In what areas does laser technology have an advantage over other methods? Peter Leibinger: Lasers offer users advantages in very many areas. On the one hand, lasers are able to manufacture products which it would be impossible to produce in the same form using other production methods. This gives the user a unique characteristic differentiating it from the competition, with the result that the laser, used as a tool, can yield higher value added. In such cases, the relatively high investment costs can be depreciated very quickly. On the other, laser techniques can replace conventional processes. In this case, we talk about “substitution”. Over the last ten years, more and Peter Leibinger, Chairman of the Laser and Electronics Business Divisions at Trumpf, is well aware of the many possible applications of industrial lasers. u transfer 2008 22 | In demand u more of our customers have substituted laser technology for their conventional manufacturing methods. For us as laser manufacturers, this means that we must develop and produce absolutely stable devices which can be integrated without problems in the customers’ existing manufacturing processes. If we want customers to replace more of their alternative manufacturing processes with laser technology in the future then we must construct increasingly compact lasers, increase their energy efficiency and continue to adapt our sales prices. Bihler Transfer: Can you give us concrete examples of the two areas of application that you have mentioned? Peter Leibinger: In the photovoltaic sector, it would not be possible to manufacture thin-layer solar cells without lasers. One example of substitution is the welding of automobile bodywork. Here, laser technology is increasingly replacing resistance spot welding. In this field, a single laser interacting with a robot can do the work of up to ten spot welding robots. Moreover, the process is faster, the space requirement is reduced and users become more versatile and more easily able to create different bodywork variants. Another advantage: Lasers place the weld spots much more accurately. This increases rigidity while also reducing material consumption. This, in turn, naturally reduces production costs. Daimler uses a range of lasers developed by us in the manufacture of its C class. As a result, approximately 20 percent of all C class vehicles are laser-welded. Mathias Bihler: “The integration of laser technology in manufacturing processes demands a very good level cooperation between the individual companies.” Bihler Transfer: At the technological level, where does the future of lasers lie? Peter Leibinger: Laser technology is currently experiencing a huge technological revolution. In the field of laser technology, we are now witnessing what happened some 40 years ago with the advance from tubes through to the transistor. This is due to diode laser technology. Using this technique, the laser light is generated in a semiconductor and is used to pump a laseractive medium, i.e. a solid body. The highquality laser light generated by this process can then be guided to the workpiece via a fiber-optic cable. These so-called diode-pumped solid state lasers, i.e. disk lasers or fiber lasers, need less electricity and are easier to use than comparable lamp-pumped lasers. They offer a very high level of efficiency. Furthermore, it will soon be possible to use diode lasers directly without having to pass via the solid state laser. That is the radical change that is facing us and which could, in a few years, transfer 2008 result in the lasers in use today being replaced by direct diode lasers and diode-pumped solid state lasers. Nevertheless, in the medium term, we shall continue to further develop our current laser technologies. This applies not only to our solid state lasers but also to our CO2 lasers. Our micromachining lasers, which emit laser pulses in the picosecond range, are also currently undergoing a technological advance. Here, the impact of the laser energy on the material that is being processed is so short that no heat is transferred. This permits the micromachining of products and components that are sensitive to thermal influences. As you can see, laser technology is moving on apace. Bihler Transfer: Indeed, laser technology is moving forwards. Does that also mean that Trumpf’s user know-how is growing, or even that it needs to grow? Peter Leibinger: We will continue to extend our knowledge of the many applications. This process has two facets: In cases where we want to replace other methods, we can offer an advantage to our customers only by considering the entire process chain. This means that we do not just need to be experts in laser technology but must instead also know what process the laser can be used in and what steps are performed before and after it. Only then can we convince our customers of the advantages of using a laser as a tool. One example: If, thanks to the laser, customers have to perform less retouching work to their finished products or use less material than required by their previous production methods, then laser use has clear advantages in terms of costs and energy. Secondly, we must extend and further refine process monitoring. The laser process must be monitored and controlled online. In the case of a complex welding operation, this is very difficult because a large number of process parameters have to be analyzed on the fly. Mathias Bihler: The integration of laser technology in the mechanical engineering field demands a very good level of coordination and cooperation between the individual companies. This is the only way to mobilize reserves. We must invest even more intelligence in the overall manufacturing process in order to increase the flexibility of the value added chain and thus generate maximum productivity. Peter Leibinger: At the same time, we must not forget to reduce machine downtimes even further. Trumpf provides reliable remote customer service via the Internet. This allows us to switch to the customer’s laser, intervene online and restore operation or further optimize the machine In demand | 23 In a joint interview, Mathias Bihler and Peter Leibinger stressed the importance of a close, sincere partnership. parameters. Our service engineers solve approximately 80 % of all customer problems via remote diagnostics. Bihler Transfer: Have also noted that your customers now possess specialist knowledge beyond their own manufacturing operations? Peter Leibinger: Many of our customers, and especially those who have developed unique features in their production activities, have a very good knowledge of laser technology. Because of this specialist knowledge, many of them have a huge advantage over their competitors. In contrast, other customers are not able to acquire this level of specialist knowledge because they lack the necessary internal resources. In such cases, we are happy to help. However, we have to weigh up each situation and act prudently to check what knowledge exclusively belongs to each individual customer and what information we are entitled to provide. Overall, it is a difficult subject which demands both fair and open cooperation. Bihler Transfer: As far as partnership is concerned. Bihler and Trumpf have been working closely together for years. How important is this ongoing partnership with Bihler? Mathias Bihler: On the one hand, our company benefits from the innovations created by Trumpf. More importantly, though, we benefit from the excellent, long-standing cooperation between the employees at all levels. We exchange experience, understand the different technologies and are therefore able to develop the best solutions, including for our joint customers. Bihler is delighted to be part of this strong partnership with Trumpf. Peter Leibinger: For us, partnership is an important, a decisive point. Nowadays, it is no longer easy to experience genuine partnership. That is what is special about the partnership between Trumpf and Bihler. As Mathias Bihler has already said, we enjoy a close partnership based on mutual trust. There is much more to a business partnership than just the economic aspect: there is trust, respect and esteem. If all that is present, then you can achieve a lot together. Bihler Transfer: One of the achievements characterizing this excellent partnership is the joint Bihler-Trumpf-Itec project. How important are such projects? Peter Leibinger: Driving this type of project, adapting different technologies to Bihler’s machines, creating a complete product from its individual parts, all these are without doubt outstanding Bihler skills. For Trumpf, the joint project is a very good reference. Mathias Bihler: Our customers expect high quality, precision and reliability from our machines. And with the solutions provided by Trumpf, as in this joint project, we have a partner at our side who sets the same standards as us. I am already looking forward to future projects which will also help further demonstrate the synergisms between punching/bending machines and integrated Trumpf laser technology. p Imprint Bihler transfer – the Otto Bihler Maschinenfabrik GmbH & Co. KG magazine for customers, prospective customers and employees Person responsible: Pedro Gato López, Otto Bihler Maschinenfabrik GmbH & Co. KG, Lechbrucker Straße 15, D-87642 Halblech, Tel. +49(0)8368/18-0, Fax -105, www.bihler.de, info@bihler.de, Bihler’s technical editorial department: Vinzenz Hörmann Editorial and printing services: mk publishing GmbH, Döllgaststraße 7–9, D-86199 Augsburg, Tel. +49(0)821/34457-0, Fax -19, info@mkpublishing.de Photo credits: Bihler, Bildunion/10002, verlag moderne industrie, Picture-Alliance/ASA/Guido Cantini, Pieron, Simon Toplak, Trumpf HIGHEST PRODUCTIVITY IN BUSH MANUFACTURING! The new Bihler bushing machine GRM 80B produces highly productive bushing of outstanding quality. It is perfectly designed for cylindrical bushes and flanged bushes. Benefit from its short reaction and tool changeover times. Benefit from Bihler quality. Otto Bihler Maschinenfabrik GmbH & Co.KG Lechbrucker Str. 15 D-87642 Halblech | Tel. +49-8368/18-0 | Fax: +49-8368/18-105 info@bihler.de | www.bihler.de