Greater flexibility and significantly higher machine utilization

The CAD/CAM specialists work in all areas in the company. Catia is often used for design, due to specifications from car manufacturers. "Otherwise, we rely entirely on Tebis," Ostermann reveals. "And it's been this way right from the start. We’ve been using this program package since 1989, and we were probably one of the first Tebis users in our region. We were there at the beginning with Tebis. It was never a one-way street: The software has also incorporated quite a bit of Schäfer expertise. And we’re still involved in a lively exchange with the developers at Tebis to this day."
The ability of the software to efficiently process even highly complex geometries has predestined it for model and mold making tasks. But it goes far beyond that.

Tebis is also ideally suited for a number of other tasks like closing surfaces. Tebis is our tool of choice for this task, because this software package has always been able to do this much faster than all the others.

Along with the sophisticated programming, the programmers at Schäfer also see the user guidance as a major plus; it’s modified for each task and permits the use of different working methods. 

"A bumper is always a bumper,” Ostermann affirms.

Although the individual products often look very different from one another in the end. But the material, the stepover, the machining strategy – all this remains essentially the same. We can use feature identification to determine key features and then use templates to efficiently convert these to executable programs.

Routine tasks that are repeatedly performed—such as positioning holes for clamping systems, creating fill surfaces for roughing, and generating blanks—can be seamlessly integrated into rule-based CAD templates. The software can use this CAD data for automated CAM programming. All the programmer has to do is select the part and specify the machining direction. Tebis does all the rest. The user remains flexible and can quickly and easily modify parameters like the length, radius and direction of elements with a mouse click. 

The Tebis experts precisely measured each machine again so that the actual data also matched the models.

There were relevant deviations in the machining heads, in particular: for example, a tip on the spindle that wasn’t present in the original digital model. Nor were the hoses all where they should have been based on the model. We’re now on the safe side with the newly measured digital twins, and we can reliably check for collisions in the simulation.

All clamping devices on the machine are also precisely measured and digitally recorded. "We installed columns on the machines, some movable and some fixed," the Deputy Production Head explains. "We clamp plates on these columns to set up the blank. A fixed grid and zero-point clamping systems provide for fast setup for most parts. Zero-point clamping doesn't pay off for every part." The Tebis experts also provided support for setting up the comprehensive tool libraries that contain all of the machining tools, including their geometries and cutting data. These libraries are another important prerequisite for digitalized processes.

Where we previously had seven operators for the seven machines that are operated in two shifts at Schäfer, four to five operators are now sufficient, despite the significantly increased throughput.

No jobs were lost – on the contrary, we were able to train some of the machine operators to be good programmers. This means that we can also make very good use of our new potential and easily handle the increased programming workload.

The transition to Tebis 4.1 was very well prepared. The model makers also took the opportunity to scrutinize its overall processes along with the experts from Tebis subsidiary Tebis Consulting. "Working with those responsible at Schäfer, they examined all the processes and structures from the top down and looked very closely at how things are done here. They then worked out corresponding recommendations for action," Ostermann reports.

"In principle, we already knew in advance where the problem points were. We also knew we had to do something about it – but we didn't know exactly what. What we worked out with Tebis Consulting is goal-oriented and really takes us further."