{"id":11920,"date":"2021-03-25T05:54:28","date_gmt":"2021-03-25T05:54:28","guid":{"rendered":"https:\/\/mfgtechupdate.com\/?p=11920"},"modified":"2022-07-25T06:00:38","modified_gmt":"2022-07-25T06:00:38","slug":"topsolid-enabling-up-to-a-30-increase-in-efficiency","status":"publish","type":"post","link":"https:\/\/mfgtechupdate.com\/topsolid-enabling-up-to-a-30-increase-in-efficiency\/","title":{"rendered":"TopSolid, enabling up to a 30% increase in efficiency."},"content":{"rendered":"<p>Meusburger Georg GmbH &amp; Co KG is known worldwide in tool, mold and machine production as a supplier of high-precision standard parts. In addition to standard products, the Vorarlberg-based company also offers customized special products. In order to ensure its continuing economic viability as well as to counteract the shortage of skilled workers, the company decided that a paradigm shift was needed when it came to programming. Thanks to TopSolid, supported by Evoltec, considerable increases in order processing efficiency have been achieved. By Robert Fraunberger, x-technik<\/p>\n<p>The facts of Meusburger\u2019s success speak for themselves. From a one-man operation at its founding in 1964 it has grown into a concern employing 1,670 people worldwide (1,000 of them in Vorarlberg), and with currently around 130 apprentices it is also one of the largest training companies in the region. In addition, the company is a market leader in the field of high-precision standard parts with, worldwide, more than 22,500 customers in the tool, mold and machine production business benefiting from the advantages of standardization. The product portfolio comprises around 96,000 catalog items and ranges from high-precision standard parts and selected products for workshop requirements, through hot-runner and control technology, to the WBI\u00ae knowledge management method and solutions for efficient corporate management in the field of ERP\/PPS software.<\/p>\n<p><strong>Smart production tools<\/strong><\/p>\n<p class=\"align-center\"><img loading=\"lazy\" decoding=\"async\" class=\"alignleft\" title=\"The orders are manufactured on high-quality machining centers using various control stations.\" src=\"https:\/\/cdn.www.topsolid.com\/fileadmin\/_processed_\/a\/7\/csm_Evoltec-Meusburger__124__3b13ab2956.jpg\" width=\"200\" height=\"133\" \/><\/p>\n<p class=\"align-center\"><em>The orders are manufactured on high-quality<br \/>\nmachining centers using various control stations.<\/em><\/p>\n<p class=\"align-center\">\u00a0<img loading=\"lazy\" decoding=\"async\" class=\"alignleft\" title=\"Machine operators are supported by viewers, which have a TopSolid license offering full read rights.\" src=\"https:\/\/cdn.www.topsolid.com\/fileadmin\/_processed_\/4\/c\/csm_Evoltec-Meusburger__127__28e6fd4075.jpg\" width=\"200\" height=\"133\" \/><\/p>\n<p class=\"align-center\"><em>Machine operators are supported by viewers, which have a TopSolid license offering full read rights.<\/em><\/p>\n<p>&nbsp;<\/p>\n<ul>\n<li>Mission: To install a CAM system for programming special orders.<\/li>\n<li>Solution: TopSolid, supported and implemented by Evoltec.<\/li>\n<li>Benefits: Up to 30% increased efficiency, significant quality improvement, maximum process reliability.<\/li>\n<\/ul>\n<p><strong>High level of integration<\/strong><br \/>\nMeusburger\u2019s top priority is to ensure that its own products meet the highest possible quality standards. For this reason, only the very best raw materials are processed, after undergoing an in-house hardness test and spectral analysis.<\/p>\n<p>Stress-relief annealing of all steel grades in one of the three annealing furnaces, which is carried out according to Meusburger standards, creates the best conditions for further processing of the parts with low distortion. The world\u2019s largest central standard parts warehouse, covering more than 18,000 m\u00b2, guarantees the constant availability of practically any product.<\/p>\n<p>Meusburger is equally uncompromising when it comes to mechanical production. With around 300 modern CNC machine tools and highly automated panel and round-part production, the Wolfurt plant processes around 180 metric tons of steel per day.<\/p>\n<p><strong>Paradigm shift in custom manufacturing<\/strong><br \/>\nThe majority of the products manufactured at Meusburger are catalog goods and are therefore produced as part of a highly automated process. Custom products constitute a far smaller proportion of orders. These are assigned to the Custom Processing department. Here, around 30 employees work on high-quality machining centers. Thanks to the expertise of the skilled workers, a good 60 percent of all orders were programmed directly on the various CNC machines until two years ago.<\/p>\n<p>\u201cWe also programmed, for example, free-form surfaces or drilling patterns using two external CAM systems,\u201d says Stefan Muxel, Order Processing\/CAM Team Leader at Meusburger, who adds: \u201cOur team is highly proficient in programming and this kept us very efficient for a long time.\u201d<\/p>\n<p>Nevertheless, about three years ago, the company decided to invest in a new CAM system that would optimally cover all of Meusburger\u2019s requirements \u2013 2D, 2.5D, 3D, turning and wire EDM:<\/p>\n<p>\u201cThe goal, firstly, was to steadily expand the field of custom manufacturing and, secondly, we looked forward to obtaining higher productivity as well as flexibility from an external programming system. We also wanted to counteract the shortage of skilled workers,\u201d says Muxel, explaining the paradigm shift at Meusburger.<\/p>\n<p class=\"align-right\"><img loading=\"lazy\" decoding=\"async\" class=\"alignleft\" src=\"https:\/\/cdn.www.topsolid.com\/fileadmin\/_processed_\/3\/d\/csm_Evoltec-Meusburger__99_1_6691dc46ac.jpg\" width=\"79\" height=\"98\" \/><em><strong>\u201cWhat won the day for Evoltec and TopSolid was the\u00a0package as a whole, with its functionality, post-processor\u00a0technology, blank tracking, and the high level of\u00a0competence of the entire team.\u201d<br \/>\nStefan Muxel, Order Processing\/CAM Team Leader at\u00a0Meusburger.<\/strong><\/em><\/p>\n<p>&nbsp;<\/p>\n<p class=\"align-center\"><img loading=\"lazy\" decoding=\"async\" class=\"alignleft\" src=\"https:\/\/cdn.www.topsolid.com\/fileadmin\/_processed_\/8\/c\/csm_vertikal_350_B1_7ada3d1104.jpg\" width=\"277\" height=\"159\" \/>\u00a0 \u00a0\u00a0\u00a0<img loading=\"lazy\" decoding=\"async\" class=\"alignright\" src=\"https:\/\/cdn.www.topsolid.com\/fileadmin\/_processed_\/2\/e\/csm_Evoltec-Meusburger__31__0503d639e6.jpg\" width=\"300\" height=\"159\" \/><\/p>\n<p class=\"align-center\"><em>For Meusburger, a major advantage of TopSolid is the high level of process reliability provided by the parametric post-processor.<\/em><\/p>\n<p><strong>Rigorous selection process<\/strong><br \/>\nAfter a general search process, which involved in particular also contacting well-known companies in the Vorarlberg region, ten CAM providers were tabled as contenders, and these were thoroughly put through their paces in several selection rounds: \u201cAs far as custom machining is concerned, we happen to be, after all, contract manufacturers and we don\u2019t know today what parts we will have to manufacture tomorrow. We currently cater to around 1,200 customers with special orders, so we have to handle a great deal of data, which is quite challenging,\u201d says Stefan Muxel, who also therefore prepared very demanding benchmark parts for testing the candidates. \u201cThis meant us being able to separate the wheat from the chaff relatively quickly.\u201d<\/p>\n<p>In the end, final negotiations were held with three CAM system suppliers and the requirements were laid down in a very comprehensive set of specifications: \u201cEvoltec with TopSolid prevailed on account of presenting the best overall package,\u201d summarizes the Order Processing Manager. Mario Malits, Managing Director at Evolving Technologies GmbH (Evoltec), can clearly recall the one-year stress test: \u201cThe Meusburger team was extremely well prepared and left absolutely nothing to chance. Even we couldn\u2019t offer everything right away, but I still think we were able to convince the client through our know-how and TopSolid\u2019s extensive capabilities.\u201d<\/p>\n<p>According to Mr. Muxel, the fact that the selection process was so extensive and took so long was due to the decision \u2013 as already stated \u2013 not to leave anything to chance: \u201cFor us, the changeover would definitely be decisive in the success, and indeed future, of our custom manufacturing.\u201d<\/p>\n<p class=\"align-right\"><img loading=\"lazy\" decoding=\"async\" class=\"alignleft\" src=\"https:\/\/cdn.www.topsolid.com\/fileadmin\/_processed_\/5\/8\/csm_Evoltec-Meusburger__108_1_f9fb3fa03c.jpg\" width=\"67\" height=\"87\" \/><em><strong>\u201cThe cooperation with Meusburger is an absolute milestone for us, as we have never gone through such an elaborate and demanding selection process before.\u201d<br \/>\nMario Malits, Managing Director at Evoltec<\/strong><\/em><\/p>\n<p>&nbsp;<\/p>\n<p class=\"align-center\"><img loading=\"lazy\" decoding=\"async\" class=\"alignleft\" title=\"Meusburger also relies on TopSolid for training.\" src=\"https:\/\/cdn.www.topsolid.com\/fileadmin\/_processed_\/8\/e\/csm_Evoltec-Meusburger__150__87569b70af.jpg\" width=\"300\" height=\"200\" \/><\/p>\n<p><strong>Extensive groundwork<\/strong><br \/>\nSince the idea was to change the programming while ensuring unrestricted operations, a supporting project plan was worked out, to introduce TopSolid step by step:<\/p>\n<p><strong>Smart production tools<\/strong><br \/>\n\u201cIn addition to employee training, we had to start virtually from scratch and create thousands of tools, fixtures, clamping systems, etc., as well as a cutting database based on the infeed. We also had to create around 200 machining methods for automatic programming,\u201d says Muxel, outlining the mammoth task. \u201cThe topic of clamping equipment alone was extremely complex, as these are all 100% self-developed. The clamping devices all position themselves parametrically in terms of length, width, height, etc., and everything has to be queried and checked in advance,\u201d adds Armin Huber, CAD\/CAM application engineer at Evoltec. Of course, this immense preparatory work certainly pays dividends in the ongoing process, because all this automation reduces costly non-productive time.<\/p>\n<p><strong>Unrivaled parametric post-processor<\/strong><br \/>\nIn parallel with the training, Evoltec developed and programmed the post-processors. \u201cWe supply a parametric post-processor that runs on all controllers with absolute process optimization,\u201d Mario Malits is keen to stress. This is an advantage that Stefan Muxel is ready to confirm: \u201cIn my opinion, Evoltec\u2019s post-processor customization is unrivaled. Clearly, employees must first be able to take advantage of these extensive capabilities.<\/p>\n<p>The fact is that we haven\u2019t had a crash since the changeover. This is no G-code simulation, but the post-processor takes into account all the parameters that we need for production.\u201d Especially for 5-axis, and even more importantly for turning-milling centers, TopSolid alongside with the Evoltec post-processor is a rock-solid combination. For CAM programmer J\u00fcrgen Fussenegger, who also played a key role in the success of the project, TopSolid\u2019s blank tracking, which can be calculated on the basis of Parasolid or using triangulation (STL), depending on the component, is also very efficient as well as being highly accurate: \u201cWith TopSolid, programmers see what the part currently looks like every cycle, as if they were using 3D glasses.\u201d<\/p>\n<p><strong>TopSolid in continuous use<\/strong><br \/>\nCurrently, 20 fully fledged TopSolid workstations are in use at Meusburger, divided between calculation, programming and training. All machine tools are also equipped with viewers. \u201cThese viewers are practically fully fledged TopSolid workstations, not allowing machine operators to actually change anything, but enabling them to view all information on screen in a paperless environment,\u201d says Armin Huber, pointing out yet another advantage.<\/p>\n<p class=\"align-right\"><img loading=\"lazy\" decoding=\"async\" class=\"alignleft\" src=\"https:\/\/cdn.www.topsolid.com\/fileadmin\/_processed_\/8\/b\/csm_Evoltec-Meusburger__90_1_a666d5698c.jpg\" width=\"70\" height=\"92\" \/><strong><em>\u201cThe blank tracking in TopSolid in particular offers programmers the perfect support, since it allows you to see what the part currently looks like at any point during each cycle.\u201d<br \/>\nJ\u00fcrgen Fussenegger, CAM programming at Meusburger<\/em><\/strong><\/p>\n<p class=\"align-center\"><img loading=\"lazy\" decoding=\"async\" src=\"https:\/\/cdn.www.topsolid.com\/fileadmin\/_processed_\/d\/4\/csm_Evoltec-Meusburger__136__6880b5af20.png\" width=\"200\" height=\"133\" \/>\u00a0<img loading=\"lazy\" decoding=\"async\" src=\"https:\/\/cdn.www.topsolid.com\/fileadmin\/_processed_\/5\/7\/csm_horizontal_250_B_2_5185ea68e7.jpg\" width=\"200\" height=\"135\" \/><\/p>\n<p class=\"align-center\"><em>Work is currently underway on the implementation of horizontal machining centers.<\/em><\/p>\n<p>Also in use is the Boost Milling module, a milling strategy developed in house by TopSolid for thrifty and efficient machining. \u201cBoost Milling is a milling algorithm with optimized cutting conditions for pocket machining and for the roughing of 3D parts, and is available as from version 7.14. Among other things, the cycle supports multicore technology and is unlimited in terms of lateral tolerance. The milling paths consist of trochoidal, concentric circles and parallel lines,\u201d Mr. Huber goes on to say.<\/p>\n<p><strong>Optimized preliminary costing of panels<\/strong><br \/>\nThe technical brief also included a not-so-everyday solution for the fastest possible preliminary costing of special panels, using an existing Meusburger knowledge database: \u201cWe load third-party data (Step) into TopSolid and use it to create a bore and milling analysis. No programming is done here, we only analyze the CAD component,\u201d explains Mr. Malits, whose team added this function to TopSolid. Based on these analyses, data such as depths, radii, volumes or heights are transferred into a neutral format. Meusburger\u2019s own program uses this data to establish automatic preliminary costing which, according to Mr. Muxel, is very accurate: \u201cThis allows us to process about 90% of requests automatically and provide a quote within 24 hours.\u201d<\/p>\n<p class=\"align-center\"><img loading=\"lazy\" decoding=\"async\" class=\"alignleft\" src=\"https:\/\/cdn.www.topsolid.com\/fileadmin\/_processed_\/2\/9\/csm_Evoltec-Meusburger__156__3f5fa093c2.jpg\" width=\"300\" height=\"200\" \/><\/p>\n<p class=\"align-center\"><em>Thrifty and efficient machining is made possible, especially through optimized cutting conditions for pocket machining and the roughing of 3D parts, thanks to the Boost Milling module.<\/em><\/p>\n<p><strong>Increased process reliability, quality and efficiency<\/strong><br \/>\nAt Meusburger, it took about 1.5 years to complete the switch to TopSolid, with the result that they now benefit from amazing time savings. \u201cWe are currently achieving an increase in efficiency of up to 30 percent, depending on the job requirements, with a significant increase in quality and absolute process reliability. This means that we can reduce component clarifications by up to 95%, and with absolutely no rejects,\u201d says Stefan Muxel, who is absolutely convinced of what has been achieved so far. Currently, eight programmers work continuously with TopSolid, and approximately 8,500 special orders can be processed per year.<\/p>\n<p>The fact that a long-term partnership has developed here is thanks not least to the people involved: \u201cThe Evoltec team was able to convince across the board with its know-how and consulting expertise. Communication is always direct, and we are each able to benefit from each other to the fullest extent!\u201d concludes Stefan Muxel, exuberant in his praise.<\/p>\n<p class=\"align-center\"><img loading=\"lazy\" decoding=\"async\" class=\"alignleft\" src=\"https:\/\/cdn.www.topsolid.com\/fileadmin\/_processed_\/d\/f\/csm_Evoltec-Meusburger__166__22ec3d80e9.jpg\" width=\"300\" height=\"200\" \/><br \/>\n<em>Thanks to the high technical competence of the project partners, all Meusburger specifications could be successfully implemented (from left to right): Stefan Muxel and J\u00fcrgen Fussenegger (both Meusburger) with Mario Malits and Armin Huber (both Evoltec).<\/em><\/p>\n<p>&nbsp;<\/p>\n<p class=\"align-right\"><img loading=\"lazy\" decoding=\"async\" class=\"alignleft\" src=\"https:\/\/cdn.www.topsolid.com\/fileadmin\/_processed_\/a\/8\/csm_Evoltec-Meusburger__106_1_dcc4190a0b.jpg\" width=\"81\" height=\"104\" \/><em><strong>\u201cMeusburger is a place where true professionals are at work, and where even experienced programmers can learn a thing or two. The fact that the project has been so successful is in no small measure due to the high level of competence of the project team.\u201d<br \/>\nArmin Huber, CAD\/CAM application engineer at Evoltec<\/strong><\/em><\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignleft\" src=\"https:\/\/cdn.www.topsolid.com\/fileadmin\/_processed_\/0\/6\/csm_IMG_Luftaufnahme-Wolfurt__SALL__AIN__V1_b8cd04a47e.jpg\" width=\"300\" height=\"200\" \/><\/p>\n<p><strong>The User<\/strong><br \/>\nMeusburger is the market leader in the field of high-precision standard parts. Customers worldwide enjoy the benefits of this standardization and of the company\u2019s 55-plus years in steel processing. The product portfolio ranges from high-precision standard parts and selected products for workshop requirements, through hot-runner and control technology, to the WBI\u00ae knowledge management method and solutions for efficient corporate management in the field of ERP\/PPS software. All this makes Meusburger a reliable and global partner for the tool, mold and machine production industry.<\/p>\n<p>contact TopSolid India \u2013 www.topsolid.com<\/p>\n","protected":false},"excerpt":{"rendered":"<p>Meusburger Georg GmbH &amp; Co KG is known worldwide in tool, mold and machine production as a supplier of high-precision standard parts. In addition to standard products, the Vorarlberg-based company also offers customized special products. In order to ensure its continuing economic viability as well as to counteract the shortage of skilled workers, the company [&hellip;]<\/p>\n","protected":false},"author":2,"featured_media":11932,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[1],"tags":[],"class_list":["post-11920","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-uncategorized"],"_links":{"self":[{"href":"https:\/\/mfgtechupdate.com\/wp-json\/wp\/v2\/posts\/11920","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/mfgtechupdate.com\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/mfgtechupdate.com\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/mfgtechupdate.com\/wp-json\/wp\/v2\/users\/2"}],"replies":[{"embeddable":true,"href":"https:\/\/mfgtechupdate.com\/wp-json\/wp\/v2\/comments?post=11920"}],"version-history":[{"count":1,"href":"https:\/\/mfgtechupdate.com\/wp-json\/wp\/v2\/posts\/11920\/revisions"}],"predecessor-version":[{"id":11933,"href":"https:\/\/mfgtechupdate.com\/wp-json\/wp\/v2\/posts\/11920\/revisions\/11933"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/mfgtechupdate.com\/wp-json\/wp\/v2\/media\/11932"}],"wp:attachment":[{"href":"https:\/\/mfgtechupdate.com\/wp-json\/wp\/v2\/media?parent=11920"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/mfgtechupdate.com\/wp-json\/wp\/v2\/categories?post=11920"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/mfgtechupdate.com\/wp-json\/wp\/v2\/tags?post=11920"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}