Haidlmair Case Study - Cam Logic, Inc.

Industrial machinery and heavy equipmentHaidlmairInjection molding tool maker saves time, enhances quality and eliminates errorsProductsNX, Teamcenter,PLM ComponentsBusiness challengesDesign and manufactureprecision moldsMeet restrictive lead timerequirementsEliminate quality risksPrevent data misinterpretationEnhance NC programmingaccuracyKeys to successNX CAM for NCprogramming workNX CAD and Mold Wizard fordesign process automationTeamcenter for all designand manufacturing data andprocess managementManufacturing ResourceLibrary for cutting toolmanagementResultsReduced design cyclesEliminated data conversionerrorsStreamlined informationflow to shop floorHaidlmair uses NX andTeamcenter to enable consistentinformation flow from top floorto shop floorThink big in plastics moldingFrom toys to office machinery to household products to packaging and automobiles, there are very few things in everydayuse that are not made, at least in part,using synthetic materials. Josef Haidlmairsaw the potential of this technology andbegan employing new wire-cut electricaldischarge machining (EDM) technologyin 1979 to develop molds for makingplastic parts.Today, Haidlmair GmbH is a leadingsupplier of injection-molding tools,predominantly for the production of largerand more complex parts used for productssuch as automobile radiator grilles anddishwasher panels. What has madeHaidlmair grow into a group of companieswith more than 450 employees andnearly 60 million Euros annual turnover,however, is the company’s reputation formaking superior high-efficiency moldsused to produce crates and containers.www.siemens.com/plm

Results (continued)Unified procedures andworkflowsImproved process stabilityShortened lead times“ Top among the advantages ofcutting tool management usingthe Manufacturing ResourceLibrary is that all properties arehereditary, which makescombining properties easy.”Christian RielAssistant Operations ManagerHaidlmairFor example, all five parts of collapsiblecrates are produced with a single “shot”of plastic. The molds for bottle crates aredesigned to enable the use of softer material for the handle areas of the crates, aswell as in-mold-labeling. This adds to theappeal of the crates while making theproducts easier to carry.The design process used by Haidlmairallows the molds to be compact and alsoshifts most of the weight away frommoving parts, thus reducing overall product weight. This turns out to be a majoradvantage in molds for large containerssuch as garbage bins.Early adopters of 3Dmodeling technologyIn the past, customers typically providedHaidlmair with a drawing of the parts thatneeded to be molded. Part of Haidlmair’ssuccess can be attributed to the earlyadoption of computer-aided design (CAD)with 3D modeling technology, using NX software, a comprehensive and integratedCAD, computer-aided engineering (CAE)and computer-aided manufacturing (CAM)system from Siemens PLM Software.Its sheer size alone makes injectionmolding a 1,100 liter garbagecontainer an impressive task.“Our work using NX begins as soon as acustomer provides us with information onthe parts they require, which are usually inthe form of 3D models,” says Christian Riel,

Weighing 62 tons, the mold comes with a weight reduction of 40 percent over conventional tools, resultingin cycle time and energy savings for each shot of a similar scale.Haidlmair’s assistant operations manager,who is in charge of process management.“The parts often require some modification, such as fixing impractical draftangles. Such issues, as well as other properties required for smooth injection molding, must be addressed during the earlystages of mold design.”Haidlmair engineers use NX Mold Wizardfor this purpose. In a step-by-step process,this NX add-on helps automate and optimize the mold design process. NX enablescomprehensive data import of third-partydesign files and provides part design capabilities. Automation of mold-specificdesign tasks is boosted by such featuresas manufacturability checking, advancedparting tools, automatic core and cavityinsert creation, shrinkage calculation andadjustment, cooling layout tubes andfittings and automatic bill of materials(BOM) creation. There are also libraries ofstandard mold components, includingmold bases, ejector pin posts, sliders andlifters. “Design work for what are usuallyrather complex molds would take muchlonger without the help of NX,” says Riel.“Using NX means that our design engineers do not need to spend time manuallydesigning all the detail.”“ Design work for what areusually rather complex moldswould be much longer withoutthe help of NX.”Christian RielAssistant Operations ManagerHaidlmair“Our engineers have allexperienced the numerousbenefits of finding – ratherthan searching for – datausing Teamcenter. They alsofind the time spent fulfillingbureaucratic tasks is greatlyreduced due to the approvalworkflow process usingTeamcenter, which theyconsider a huge benefit.”Christian RielAssistant Operations ManagerHaidlmair

“The efficiency of the processof locating the right tool iseven greater than expectedbecause NX supports findingtools even with 10 percentdeviations of their nominalsizes.”Stefan PendlCAx Systems AdministratorHaidlmairHaidlmair engineers have also used NXCAE software for some time to generatethe mesh used in mold flow calculations.More recently, the use of NX CAE wasextended to include structural analyses forparts, which helps Haidlmair make surehandles or corners in crates and containersare strong enough to withstand expectedloads.High-speed metal cutting using powerfulnumerically controlled (NC) high-precision3- and 5-axis machines has partly superseded the use of EDM. NX CAM is used toprogram these complex NC machines andprovides advanced simulation and verification capabilities, as well as feature-basedmanufacturing for NC programmingautomation.Data from a companywide repositoryIn 2008, Haidlmair started usingTeamcenter software from Siemens PLMSoftware for PLM tasks. “Collaborationamong our engineers is enabled via theTeamcenter portfolio, including automatedBOM transfer to the ERP (enterpriseresource planning) system for procurement,” says Riel. “Our engineers have allexperienced the numerous benefits offinding – rather than searching for – datausing Teamcenter. They also find the timespent fulfilling bureaucratic tasks is greatlyreduced due to the approval workflowprocess using Teamcenter, which theyconsider a huge benefit. Consequently, in2013 Haidlmair started a project to fullyintegrate all associated third-party designoffices and freelancers into theTeamcenter system.”“ The use of Teamcenter has considerablyaccelerated and simplified work for allinvolved, including people on the shopfloor who do all the postprocessing toport programs to the machine selectedfor each job.”Christian RielAssistant Operations ManagerHaidlmair

“The use of Teamcenter has considerablyaccelerated and simplified work for allinvolved, including people on the shopfloor who do all the postprocessing to portprograms to the machine selected for eachjob,” says Riel. “Data access is via webbrowser, so all information, including 3Dviews of all parts and tools, is availablethroughout the company.” The processwas made even smoother with the introduction of a custom add-on module thatenables postprocessing directly usingTeamcenter.In 2011, Haidlmair introduced cutting tool “Our work using NX begins asmanagement using the Teamcentersoon as a customer providesmachining resource manager utility, which us with information on theis also used for machinery units, fixturesparts they require, which areand clamping tools as well as templates.usually in the form of 3DThis greatly reduced tool administrationmodels.”because cutting tools are represented asChristian Rielcomponents as well as assemblies, includAssistant Operations Managering the holders. These tools are includedHaidlmairvia 3D visualization for reality checks toeliminate error. “Top among the advantages of cutting tool management usingTeamcenter is that all properties arehereditary, which makes combining properties easy,” says Riel.“Consistent information use andintelligent automatic supportfunctionality – from part design toprogramming to tool handling atthe machine – help us increaseproductivity while enhancingquality and process stability,” saysChristian Riel, assistant operationsmanager at Haidlmair.

“Collaboration among ourengineers is enabled viathe Teamcenter portfolio,including automated BOMtransfer to the ERP systemfor procurement.”Haidlmair is a leadingmanufacturer ofinjection molds fortransport containers,such as modern bottlecrates that includeelastomeric handlecomponents and foilintegration, all to beproduced in one shot.Christian RielAssistant Operations ManagerHaidlmairIncreasing process efficiency viaManufacturing Resource Libraryand GeolusAlthough Haidlmair had been using thirdparty direct numerical control (DNC) software for distributing the programs to themachines, company engineers recentlybegan rolling out NX CAM software on theshop floor to enable operators to perform2.5-axis programming for pockets withoutresorting to the machine’s programminginterface. This further enhances dataconsistency and eliminates interfaces andthe potential for inaccuracy.In parallel with this development,Haidlmair switched from using a machinetool library to implementing theManufacturing Resource Library (MRL)from Siemens PLM Software. The MRLhelps NX CAM users find, select andretrieve tools for use in CNC programmingfrom within the NX user interface withoutengaging a number of the capabilities ofTeamcenter.“The efficiency of the process of locatingthe right tool is even greater thanexpected because NX supports findingtools even with 10 percent deviations oftheir nominal sizes,” says Stefan Pendl,Haidlmair’s CAx (computer-aided technologies) systems administrator. Convincedthat powerful search mechanisms cansubstantially increase efficiency, Haidlmairhas also acquired a license of Geolus software from Siemens PLM Software forevaluation. The software’s unique ability to“ Using NX means that our design engineersdo not need to spend time manuallydesigning all the detail.”Christian RielAssistant Operations ManagerHaidlmair