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
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Otto Bihler Maschinenfabrik GmbH & Co.KG Lechbrucker Str. 15
D-87642 Halblech | Tel. +49-8368/18-0 | Fax: +49-8368/18-105
[email protected] | www.bihlernc.de
lines. Low tool heights, several units next to each other – the
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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
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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
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6 | To p i c
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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
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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.
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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.
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10 | Forum
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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.”
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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.”
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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.
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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
[email protected]
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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.
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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
[email protected]
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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.
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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.fi[email protected]
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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
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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,
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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, [email protected], 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, [email protected]
Photo credits: Bihler, Bildunion/10002, verlag moderne industrie, Picture-Alliance/ASA/Guido Cantini, Pieron, Simon Toplak, Trumpf
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