Industrial machinery and heavy equipment ANGER MACHINING

Automotive machine tool maker uses Teamcenter to reduce engineering cycle time by 30 percent and to map engineering and manufacturing bills of materials

Products , NX, Teamcenter

Business challenges Market demand for increased productivity per shop floor area Elevated precision requirements Customer demand for flexibility Dwindling batch sizes

Keys to success Master complex mechanics Design machines and modules using Solid Edge Implement comprehensive simulation HCX transfer centers from ANGER MACHINING invert the logic of traditional machining centers: It is not the Use NX CAM for NC spindle that moves to the part. Instead, the part – mounted on a movable clamping fixture (black, center) – is moved against the spindles that are mounted on the machine’s frame in part-specific groups. programming Use Teamcenter for data and process management Siemens PLM Software solutions cycles. The enormous costs of such lines can only be reduced if parts are produced Provide ERP integration enable ANGER MACHINING to deliver enhanced transfer line in large enough quantities without any alterations. The space requirement of productivity and shorter lead Results these lines is high and the parts transfer times across stations limits the available accu- Reduced engineering cycles racy. On the other hand, due to systemati- by 30 percent Minimized lifecycle costs cally inherent idle times, universal Implemented and handled a Complex metal parts for engines and machining centers do not typically achieve modular design principle transmissions are traditionally produced in the required high level of productivity. transfer lines, where they are passed from Their tool spindle configuration – meant as one machine dedicated to certain process- a compromise for handling various ing steps (turning, milling, grinding, etc.) machining operations – also results in a to the next following rigid manufacturing loss of precision.

www.siemens.com/plm Results (continued) Lowered design costs by 20 percent Achieved 100 percent collision freedom Accelerated project lead time

These complex machines were designed using Solid Edge.

ANGER MACHINING GmbH (ANGER) transfer Productivity and flexibility combined centers combine the benefits of transfer “Ever shorter innovation cycles and the lines and machining centers. In the machine advancing individualization of final prod- concept invented by the company in 1984, ucts result in reduced quantities and it is not the spindle that moves to the part. shorter production lifecycles of the individ- Instead, the part is moved against many ual parts,” says Dietmar Bahn, general spindles, each of them optimized for its manager of ANGER MACHINING. “This cre- specific task: The spindles are mounted in ates significant challenges for companies part-specific groups, which enable several investing in new machinery, especially in machining steps to occur simultaneously. the automotive sector.” This optimization and faster part move- ment within only one machine greatly Recognizing this, ANGER designed a new reduces cycle time. series of flexible transfer centers for Due to the spatial con- medium- to large-volume manufacturing. centration, a transfer Two of these ANGER HCX transfer centers center can replace two were ordered by a Japanese customer for to eight conventional the machining of valve bodies. The multi- machining centers, spindle heads and turret revolver heads of minimizing installation these machines are not mounted directly area, energy consump- onto the machine frame, but on replace- tion and maintenance, able carrier modules. Without compromis- consequently reducing ing precision or machining speed, this and lifecycle costs. This is an automatic tool changer as well as a why the revolutionary zero point clamping system make it easier machine concept is to reconfigure the machine for new parts, well established in the combining the benefits of the successful automotive industry transfer center technology with maximum around the world. investment protection. Engineering utilizes comprehensive 3D process simulation via NX CAM. “ Teamcenter helps us depict a comprehensive digital value chain.”

Dipl.-Ing. Roland Haas Head of Technology and R&D ANGER MACHINING

Simulation and reality environment. The selected technology “ With comprehensive simula- “We took a leading role in the transfer seg- needed to be able to adapt to the uncon- tion of the machining pro- ment in terms of control technology as ventional architecture of ANGER machines, cesses based on NX CAM well when we introduced the current HCX and import computer-aided design (CAD) from Siemens PLM Software, transfer center series to the market in data directly to the simulation without we offer our customers 2007,” says Roland Haas, head of technol- custom programming. For many years, improved efficiency and pro- ogy and research and development (R&D) ANGER machines have been comprehen- cess reliability and were able at ANGER MACHINING. “When you have sively designed using Solid Edge® soft- to significantly improve our parts moving as fast as lightning only a ware from product lifecycle management competitiveness.” fraction of a millimeter away from up to (PLM) specialist Siemens PLM Software. Dipl.-Ing. Roland Haas 100 tool tips, and massive parallel machin- Head of Technology and R&D ing operations, it is a necessity to perform “Because complete data consistency is ANGER MACHINING a full virtual 3D process simulation, and important to us, and because, in a busi- not just for collision prevention.” ness based on long-lived investment goods such as ours, a future-proof system Data consistency decisive for software with reliable support from its manufac- choice turer is decisive, NX computer-aided man- The software for virtual production control ufacturing software from Siemens PLM was meant to simplify mechanical and Software won that race against five other process-related operations and provide a systems,” Haas recalls. “Support by the comfortable and safe programming software supplier extended all the way to Consistency from the design to the axes Using the 3D design model as an input, NX CAM enables ANGER’s engineers to quickly generate NC programs to effectively machine these parts. Error-free machining on the shop floor is enabled by the inte- grated machine tool simulation using NX CAM. “The advanced machine tool simula- tion in NX CAM is critical to reliably pro- gram the ANGER FLXBL machines that use innovative technology for changeover and tool change,” says Markus Schürz, design engineer at ANGER. “To master the high level of complexity, the machines are equipped with Siemens’ SINUMERIK 840D sl controllers and SIMOTION drive technol- ogy. The Siemens software and equip- The modular Anger FLXBL is the first transfer center that can be reconfigured within a few hours and is perfectly suited for the machining of workpiece variants. With a pallet loading unit, ment assures full data consistency from replaceable multi spindle heads and an automatic tool changer, it makes it easier to reconfigure the design to each single axis.” the machine for new parts. Without compromising precision or machining speed, it is suitable for production in smaller quantities or shorter production life cycles. It is controlled using a “With comprehensive simulation of the SINUMERIK 840D sl from Siemens. machining processes using NX CAM from Siemens PLM Software, we offer our cus- tomers improved efficiency and process “ To master the high level of designing the machine kinematics accord- reliability,” says Haas. “With NX CAM, we complexity, ANGER ing to our specifications. For a comprehen- were able to significantly improve our machines are equipped with sive production simulation, we only need competitiveness,” says Haas. Siemens SINUMERIK 840D sl to add the contract-specific parts from computer numeric controls Solid Edge to the basic virtual machine.” Teamcenter – an important step toward and SIMOTION drive technol- the digital factory ogy, the programs which are Real-time simulation reduces Mastering complexity is also the goal that generated using NX CAM. changeover and reconfiguration times drove the company to install Teamcenter® This assures full data consis- With comprehensive simulation of the pro- software, also from Siemens PLM tency from the design to duction process, users can develop effi- Software, throughout the company. each single axis.” cient manufacturing processes and “For us, adopting Teamcenter represented generate optimized numerical control (NC) Ing. Markus Schürz an important step toward the digital fac- programs with automated collision detec- Design Engineer tory,” says Haas. “The software helps us tion. NX is used both for process engineer- ANGER MACHINING visualize the links in and between our ing and for programming the machine machines and production processes, tools on the shop floor. It is also used by depicting a complete digital value chain. sales during conceptual phases to provide To reduce tangible complexity and be able evidence that requested functionality will to make the right decisions faster and on a indeed be fulfilled. sound foundation, we link Teamcenter with our most important software tools, Integration of the 3D design model and from the enterprise resource planning consistent workflow management provide (ERP) system to Solid Edge CAD software. an optimal basis for decision making as Teamcenter helps us depict a comprehen- well as fast planning and calculation results sive digital value chain.” for both products and processes. In the HCX series, ANGER used comprehensive Schürz notes, “For example, we pass bills machine tool simulation to cut design of materials from Solid Edge on to the costs by 20 percent and improve average manufacturing process planning system, lead times for a contract by 30 percent. With comprehensive simulation of the production process, users can economically produce their parts early, verify them with automated collision detection and generate optimized NC programs. where data is separated to better suit pro- “Centralized data management is the cor- duction needs, and then passed on to pur- nerstone of the globally networked sys- chasing. Ultimately, custom design and tems of the future,” says Haas. “For us, it commercial order processing work are per- makes a lot of sense to embrace Siemens fectly synchronized.” PLM Software standards on a broad basis since they are already considered the About 30 users are working with state-of-the-art by our customers in the Teamcenter to develop proposals and doc- automotive industry. Aside from the tech- umentation as well as workshop tasks on nical properties of the software, a signifi- the basis of common data with assured cant part of this success is owed to the validity. As a result, they expend far less problem-solving expertise of Siemens PLM effort than previously required for the Software sales partner, ACAM search and validation of documents and Systemautomation GmbH.” for the fulfillment of ever-growing docu- mentation requirements.

First Teamcenter project completed ahead of schedule Teamcenter not only provides ANGER with a simple and consistent way to trace which parts were used in which machine, it also recommends existing parts and assem- blies, enabling the firm to greatly increase the use of common parts.

“When we introduced Teamcenter, we obviously had to review the data and rear- range it in unaccustomed ways,” says Schürz. “This has paid off nicely, though, as we were able to complete our first Teamcenter project – an HCX transfer cen- ter used for the multiple machining of valve blocks for automatic transmissions – well ahead of schedule.” Since early 2013, about 30 users have been working with Teamcenter to develop proposals and documentation as well as workshop tasks on the basis of common data. With assured validity, they are able to exchange data with the ERP system. As a result, they expend a lot less effort searching and validating documents. Solutions/Services Solid Edge www.siemens.com/solidedge NX CAM www.siemens.com/nx Teamcenter www.siemens.com/teamcenter SINUMERIK www.siemens.com/sinumerik SIMOTION www.siemens.com/simotion “ …we were able to complete our Customer’s primary business ANGER MACHINING specializes first Teamcenter project – an in the development and pro- duction of Transfer Centers HCX transfer center used for the for the machining of serial components with especially high precision requirements multiple machining of valve for the automotive industry and related metalworking blocks for automatic companies. With three subsid- iaries in Germany, USA and Japan and numerous sales and transmissions – well ahead of service partners, the company has successfully established schedule.” itself on the global market since its foundation in 1982. Markus Schürz www.anger-machining.com Design Engineer ANGER MACHINING Customer location Traun Austria

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