A phoenix rises from the ashes

The managing director came across Tebis somewhat by chance. Hürlimann explains: "One of our customers used Tebis and achieved faster and better results than with other software solutions that we were working with. When other customers and colleagues from the industry experienced the same results, we decided to test Tebis." And this was how the software found its way into the company's every-day tasks. Hürlimann also tapped into additional consulting on process optimization and management from Tebis Consulting.

This task was assigned to Markus Rausch, a consultant at Tebis Consulting and a trained industrial mechanic with a degree in mechanical engineering. He also had practical experience as a production manager and deputy managing director in a medium-size mold manufacturing company. He first analyzed all processes and procedures of the afflicted model and mold manufacturing company and spoke with employees in manufacturing and management. This was a completely new experience for Hürlimann. "It is truly interesting to have one’s own processes evaluated from outside. Of course, we wanted to be faster, better and bigger; the only question was how."

While major projects in foundry model making were originally the mainstay for the model and mold manufacturer, the product portfolio was expanded, including orders from areas like aerospace and motor sports. "Formbar thereby gradually evaded the ongoing price drop in foundry model making that resulted from the increasing outsourcing of production to Eastern Europe," explains Rausch. The company also received many orders from abroad – this was not a problem in itself. But the heavy currency fluctuations in the Euro compared with the Swiss Franc gave rise to additional worries. "We therefore wanted to establish a stronger presence for Formbar in the Swiss market," says Rausch.

A very important point for the consultant: Always including the employees in every analysis and implementation, answering their questions and discussing their concerns in order to ensure a successful change. Through coaching and training sessions, Rausch sensitized managers as well as managing directors to the changes and associated employee needs. Hürlimann recalls: "The meetings and training sessions really did improve acceptance, and our new bonus system provided additional motivation."

Formbar also invested in new machinery. The absolute highlight of the restructuring was the acquisition of the FZ 33 Compact 5-axis CNC gantry milling machine. This was the third in our bundle of CNC milling machines, which already included a Zimmermann FZ30 5-axis CNC gantry milling machine and a Quaser MV-304C 3-axis milling machine. "This machine perfectly complements our existing machinery. It has a traversing range of 4 x 2.5 x 1.5 meters, is extremely flexible and is more than twice as fast as our existing 5-axis gantry milling machine," says Kaspar Hürlimann enthusiastically. Its enormous performance spectrum enables the manufacturer of components for all types of industry.

The measures taken bore fruit: Within a year, Formbar had achieved a significant plus in efficiency and process reliability. Machine run times and sales have since doubled, with no change in the workforce. The increased flexibility resulted in many new customers: Formbar is now positioned for a viable future in the Swiss market. In addition to casting models, the company now also manufactures parts for the motor sports, aerospace and automotive industries. It benefits from the enormous wealth of experience of its employees and the flexibility of its machines.

From the beginning, Hürlimann absolutely wanted to rank among the best; now he has achieved this. "This shows that we selected the right consultant. Tebis Consulting has given us competent support, Hürlimann emphasizes. However, the managing director is not resting on his laurels and is further developing the company. An ATOS Compact Scan 12M optical measuring system from GOM has been in use since January 2019. Tebis was also included in this process and Hürlimann is continuing to plan the future with the CAD/CAM/MES provider. New this month, one of the fastest gantry milling machines, a 4 m x 3 m x 1.5 m Zimmermann FZU, is now available in the new air-conditioned production building. "I'm looking forward to it. The collaboration with Tebis is great. Motivated employees and ultra-modern infrastructure provide for both customer satisfaction and fun at work."