Zaigler Maschinenbau was founded in 1954 and over the course of its existence has specialized in contract manufacturing and large-part machining for various industries, such as the printing industry, plastics processing, energy producers and mechanical engineering in general. Zaigler's strength lies in responding to the requirements of industries with particularly "large" needs. The company from Kulmbach in Upper Franconia specializes in the machining and production of particularly large components that can weigh up to 50 tons. Thanks to its manufacturing expertise, the quality of its products and its adherence to delivery deadlines, it has been able to continuously expand its customer base. The fact that IT and automation solutions provide a decisive competitive advantage was recognized by those responsible over 30 years ago. The machine manufacturer has been relying on software solutions from Coscom since 1986. In addition to CAD/CAM software, the company gradually expanded its production IT with a tool and production database and completed it with machine simulation for virtual machining. With the help of this end-to-end process solution, the company has succeeded in significantly reducing programming times, increasing productive machine running times and digitizing and archiving its manufacturing expertise.

More flexible processes thanks to data consistency along the production chain

Coscom ProfiCAM VM offers the decisive advantage: the programming time for a complex component has been reduced from twelve to two weeks thanks to modern 3D programming. © Coscom Computer

Coscom Profi CAM VM brings significant acceleration: The programming time for a complex component has been reduced from 12 to 2 weeks thanks to modern 3D programming. The Profi Kinematik VM machine simulation secures the programming result in the virtual machining concept for high process reliability.

With the help of the Profi Kinematik VM machine simulation, all machining processes can be checked virtually in advance of production in order to optimize runtimes and avoid collisions. The Coscom data management solutions Tool and FactoryDirector VM provide all digital tool, technology and article data for this purpose.

Fast from XXL to batch size 1

As Zaigler also only produces individual parts or small batches, the company has a veritable "treasure trove" of tools. Around 40,000 tools, components, complete and special tools of considerable value are required for this purpose. With the ToolDirector VM tool management system, employees can maintain an overview and put together the right tools at the touch of a button. The networked tool management system ToolDirector VM ensures 1:1 reproducible tool sets for repeat orders in the tool store and also feeds the entire CAD/CAM process with simulation-capable tool and technology data.

Additional flexibility is required by contract manufacturer Zaigler for the machining of large components up to 15 m in size and weighing up to 50 tons. The 30 CNC machines and machining centers must also have the corresponding dimensions to ensure this.