Thanks to hybrid workstations, the CNC milling cutters not only operate the machines, but also program them. © HERMLE

"As we manufacture individual parts, we didn't want to save on the machine. That makes no sense for us. The machining centers have to be fully equipped so that we can also fulfill new orders," says Thomas Fuchs and smiles: "True to the motto: better to have than to need."

The software writes the code independently and replaces the programmer

The special feature, however, is the FAMS (Fuchs Automated Milling Software) software developed by FWM specifically for this purpose. It writes the code and thus replaces the programmer and the person who inserts the component. "We only have to read in the CAD data, FAMS does the rest," explains Johannes Voit, also Managing Director at FWM.

22 hours of operation, around two hours of set-up time - the C 22 U runs unmanned most of the time. © HERMLE

The team worked on it for several years and the program can now prepare the majority of components for machine processing fully automatically. "Our typical batch size is 1," explains Thomas Fuchs. "We were looking for a solution that would not only handle the parts handling, but also significantly reduce the programming effort. HERMLE supported us in the development of the software and stood by our side as a partner with its expertise." The system's capabilities were thus fully utilized and, despite two-shift operation, the company was able to produce 24 hours a day, five days a week.

Series production of individual parts

In addition to the "C 22 U", FWM also machines on four "C 400 U" machines from HERMLE. "We rely on redundant machines so that our own software works identically everywhere," says Johannes Voit.

The first machining center was added to the machine park in 2018, and the others followed virtually every year. "I like buying machines," admits Thomas Fuchs mischievously. "But seriously, these machining centers are simply first-class and our CNC millers love working on these machines."

The FWM team: Managing Director Thomas Fuchs, Deputy Head of the CNC Milling Department Maximilian Skarba and Managing Director Johannes Voit, together with Andreas Glumpler, Hermle Sales Field Service (from left). © HERMLE

Johannes Voit adds: "Our experience has been positive all round, not only with the precision, but also with the service. The Hermle technician is usually here within a few hours of the error message and fixes the problem." The fact that all machining centers from Gosheim have the same design and every technician is very familiar with them also plays a role.

Two of the "C 400 U" are automatically supplied with workpiece carriers by the "HS flex" handling system. "Getting into pallet handling was a milestone for us," says Johannes Voit, looking back. "It allowed us to introduce our workers to the topic and show them the possibilities."

Hybrid workplaces

"Our philosophy is to use our machines to attract qualified specialists into production," adds Thomas Fuchs. "We have a young team and our colleagues are very eager to learn."

Like all employees, Maximilian Skarba programs directly at the machine. © HERMLE

This is why FWM also relies on hybrid workstations: The CNC millers not only operate the machines, but also program them and gradually expand their CAM skills. "This makes our jobs very interesting," the managing directors are certain.

The "HACS - HERMLE Automation Control System" and "HIMS - HERMLE Information Monitoring Software" control and monitor robot and handling systems. This allows working times and tool deployment to be planned in advance and NC programs and zero points to be easily assigned. Changes to the schedule are possible at any time. In addition to a compact live view, the monitoring tool also offers detailed status histories and message logs.

A shortage of skilled workers and staff availability are two factors that speak in favor of automation

The investment in the new robot system has paid off. "I've done the math: Without this system, we would need a good nine more people in the hot phase of a project - and another machine on top of that," explains Thomas Fuchs.

His partner adds: "If we manufacture unmanned, we reduce the cost per part. A shortage of skilled workers and staff availability are two other factors that speak in favor of automation. This allows us to maintain our capacities and supply our customers on time and in high quality."

Source: Maschinenfabrik Berthold HERMLE AG, Udo Hipp