Living perfection WBA Aachener Werkzeugbau Akademie GmbH Aachen, 2016 Slide 1
The Aachener Werkzeugbau Akademie Tooling competence from Aachen University and research institutes in Aachen Focus Production Engineering and Technology Institute at the RWTH Aachen University 1906 founded 895 Employees 16,000 m² office space and laboratories WBA Aachener Werkzeugbau Akademie GmbH Central contact point for tool and die making companies Close collaboration with all institutes of the RWTH Aachen University and the Fraunhofer Gesellschaft in Aachen 25 Employees with an organizational and technological tooling focus and in the demonstration tool shop Execution of ca. 40 consulting projects each year + Further relevant institutes for tool and die making Institute of the Fraunhofer-Gesellschaft 1980 founded 453 Employees 3000 m² office space and laboratories Overview of chosen project partners Slide 8
Aachener Werkzeugbau Akademie: We shape Tool Making AACHENER WERKZEUGBAU AKADEMIE Applied Research & Development Specific Industry Solutions Client-oriented Consulting Professional Development Access to research projects of various institutes via the WBA as a research broker Individual research and development projects for partners of the WBA Development of specific industry solutions within consortial projects Knowledge transfer and networking in the Tool and Die industry Bilateral projects with technological and organizational topics of the Tool and Die industry Mutual concept development and project implementation Modular further education for non-academics and academics Coverage of all relevant technological and organizational subjects Demonstration Tool Shop Slide 9
Industrial partners of the Aachener Werkzeugbau Akademie Premium Partner Cooperation Partner Business Partner Partner Slide 11
The participation model for companies Premium Partner, Business Partner and Partner WBA Network Partner Business Partner Premium Partner Networking Activities Half-/Annual Meeting Community Applied Research & Development Projectchecks á 2,500 2 3 4 WBA Projects Use of Projectchecks Project prioritization 1 year for WBA Projects 3 years for WBA Activities 5 years for WBA Activities Project selection Annual report Print & Digital Professional Development Expert & Master 30% discount Events Module 30% discount 30% discount Seminar 30% discount 30% discount 30% discount Inhouse Seminar Participation Client-oriented Consulting Consulting Industry Project 10% discount 10% discount Demonstration Tool Shop Utilization of infrastructure Office rooms Machine park 175 h Part of participation model: 10,000 20,000 40,000 not included optional included Slide 13
Aachener Werkzeugbau Akademie: We shape Tool Making AACHENER WERKZEUGBAU AKADEMIE Applied Research & Development Specific Industry Solutions Client-oriented Consulting Professional Development Access to research projects of various institutes via the WBA as a research broker Individual research and development projects for partners of the WBA Development of specific industry solutions within consortial projects Knowledge transfer and networking in the Tool and Die industry Bilateral projects with technological and organizational topics of the Tool and Die industry Mutual concept development and project implementation Modular further education for non-academics and academics Coverage of all relevant technological and organizational subjects Demonstration Tool Shop Slide 14
The WBA research roadmap permits to systematically pursue the relevant Tool Making research topics Priority topics Accounting Added value Organization Tool technology Automation Manuf. Tech. Tool life cycle Development Manufacturing Utilization Recycling Selection of realized projects: Industrialization and process organization Knowledge transfer in the Tool and Die industry Simulation and processing simulation data Tools according to requirements Automation in manufacturing Integrated CAx chains Lean-indicators for the Tool and Die industry Systematic evaluation and qualification of suppliers Process Mapping for an optimized processing of orders Systematic failure analysis During the last years several research projects within the different matrix fields have already been conducted Slide 15
The WBA does research in tool and die making related topics and participates in publicly funded research projects Research projects with organizational focus (Qty.: 5) TEC Total Efficiency Control Topic: Calculation tool for life cycle costs of tools and dies ConTOOL Controlling of Resource Efficiency Throughout the Life-cycle of Tools Topic : Resource efficient tool life cycle Research projects with technological focus (Qty.: 10) Environment-friendly core shooting tool Topic : Environment-friendly core shooting tool Integrative production technology for high-wage countries Topic : Process technological phenomena for scanner based laserwelding Lead project E³-Production Topic : Analysis tool for resource efficient design of process chains Process simulation for Laser surface treatment Topic : Process simulation for laser hardening of free formed surfaces Evaluation of the benefit of planning processes in the small series production Topic : Evaluation of the benefit of planning processes Smart Tools Intelligent injection molding tools for product service systems Topic : Intelligent injection molding tools for product service systems Submitted research projects BMBF: Whispering Steel HiPr High-Precision mirco-forming of complex 3D parts Topic : Adaptive microforming in mass production AutoTeCH-EDM Automated Technology Development Topic : Optimization of Wire Cutting in CH-based dielectric fluid and more Submitted research projects BMBF: VisVerPro Visualization & Connection of Production processes Slide 16
Aachener Werkzeugbau Akademie: We shape Tool Making AACHENER WERKZEUGBAU AKADEMIE Applied Research & Development Specific Industry Solutions Client-oriented Consulting Professional Development Access to research projects of various institutes via the WBA as a research broker Individual research and development projects for partners of the WBA Development of specific industry solutions within consortial projects Knowledge transfer and networking in the Tool and Die industry Bilateral projects with technological and organizational topics of the Tool and Die industry Mutual concept development and project implementation Modular further education for non-academics and academics Coverage of all relevant technological and organizational subjects Demonstration Tool Shop Slide 19
Partners can benefit in different ways using specific industry solutions Mobile Applications Best-Practice-Circles Studies The Werkzeugbau Akademie develops different applications for mobile devices applied in the tool and die industry. Best-Practice Circles are a platform for exchanging methods, approaches and procedures of the project partners. The Werkzeugbau Akademie executes Studies together with various research institutes and partners for current topics in tool and die making. Examples of Applications: WBA IDA for failure recording and knowledge transfer Application to optimize milling parameters Continuous improvement process application Examples of conducted BP-Circles: Global Sourcing in Tool Making Research in Tool Making PPS-Software in Tool Making Creating networks of Tool Making companies Examples for Studies: World of Tooling Successful calculation in tool and die making Fast Forward Tooling Slide 20
The WBA develops and tests numerous Applications for the use in the tool and die making industry CIP (Continuous Improvement Application) IDA (Information Digitalization Application) App worktime documentation and creation of job cards Planning board Application for the visualization of dates in the WBA Slide 21
Die WBA publishes numerous publications specifically for the tool and die making industry Highlight: World of Tooling Status quo analysis of the worldwide tooling market Evaluation of 20 tooling relevant countries regarding market size, tooling competency and development potential Presentation of the results in the World of Tooling Radar Download for free under www.werkzeugbau-akademie.de With the numerous publications the specific know-how is accessible for the tool and die making industry Slide 22
Aachener Werkzeugbau Akademie: We shape Tool Making AACHENER WERKZEUGBAU AKADEMIE Applied Research & Development Specific Industry Solutions Client-oriented Consulting Professional Development Access to research projects of various institutes via the WBA as a research broker Individual research and development projects for partners of the WBA Development of specific industry solutions within consortial projects Knowledge transfer and networking in the Tool and Die industry Bilateral projects with technological and organizational topics of the Tool and Die industry Mutual development concepts and project implementation Modular further education for non-academics and academics Coverage of all relevant technological and organizational subjects Demonstration Tool Shop Slide 23
Consulting services of the WBA Aachener Werkzeugbau Akademie Engineering Tool standardisation Additive manufacturing CAD/CAM Planning & Steering Standard process chains 3-Layer-Model Synchronisation Manufacturing Technologies Technology evaluation and selection Automation Market Intelligence Global tool sourcing Supplier evaluation and selection Production $ Strategy Process Management Target-/Performance process Pricing Segmentation Calculation Cost transparency Benchmarking Strategic excellence position Operative Excellence Lean management Shopfloor management Layout Material flow Factory planning Tool Management Tool scheduling Tool availability Slide 24
The comprehensive benchmarking database portrays a holistic product range by using world wide data records World wide data records Employment structure South Africa Asia 16% 8% 15% 5% 3% Eastern Europe 2% Western Europe 10% 64% Germany 26% 51% 59,0% Holistic product range* < 50 50-100 101-200 35,4% 22,9% 18,8% 18,8% 16,7% 12,0% 201-500 > 500 9,0% Injection moulds * Mehrfachnennungen möglich Stamping tools Warm massive forming tools Cold massive forming tools Elastomere tool Die casting moulds Testing equipment/ devices Plants/ Special purpose machines Slide 25
Selected data records from the benchmarking- and EiP-database of the WZL and the IPT Mechanical Technologies Tooling Slide 26
Overview of selected project partners Mechanical Technologies Tooling Slide 27
Aachener Werkzeugbau Akademie: We shape Tool Making AACHENER WERKZEUGBAU AKADEMIE Applied Research & Development Specific Industry Solutions Client-oriented Consulting Professional Development Access to research projects of various institutes via the WBA as a research broker Individual research and development projects for partners of the WBA Development of specific industry solutions within consortial projects Knowledge transfer and networking in the Tool and Die industry Bilateral projects with technological and organizational topics of the Tool and Die industry Mutual concept development and project implementation Modular further education for non-academics and academics Coverage of all relevant technological and organizational subjects Demonstration Tool Shop Slide 28
The modular further education system of the WBA manages to educate employees with different qualification backgrounds Degree of qualification Seminar Seminar of WBA Consisting of: 1 day of attendance Module Module of WBA Consisting of: Preparation time 2 x 3 days of attendance Practical application Expert Tool Making 4 Modules of WBA Consisting of: 2 technical modules (electives) 2 organizational modules (electives) 1 expert thesis of 15 ECTS Senior-Expert Tool Making 10 modules of WBA Consisting of: 8 modules of 5 ECTS 1 expert thesis of 15 ECTS 1 senior expert thesis of 25 ECTS 30 months regular period of study Master Tool Making Extra-occupational Master of RWTH Aachen Consisting of: 10 modules of 5 ECTS 1 project thesis of 15 ECTS 1 Master thesis of 25 ECTS 36 months regular period of study Examination non-academic academic Graduation Graduation Graduation Graduation Graduation WBA certificate WBA certificate Expert (WBA) Senior-Expert (WBA) Master RWTH Aachen 0 ECTS 5 ECTS 35 ECTS 80 ECTS 90 ECTS Admission criteria None Admission criteria None Admission criteria Professional education Professional experience Personal aptitude Admission criteria Professional education Professional experience Personal aptitude Admission criteria University Entrance Diploma (B.Sc.) Professional experience Expenditure of time Slide 29
Certified further education for non-academics: Seminar program 2016 Contact Overview over seminar program 2016 Alexandra Hajn Anke Wolters Tel.: +49 (0)241 99016302 Fax: +49 (0)241 99016329 weiterbildung@werkzeugbauakademie.de News 5 completely new seminars New content of classic seminars 2 classic seminars as combi-seminar Executive Seminar: Strategy and technology 15.-17.02.2016 for successful tool making companies Production planning and control in tool making 02.03.2016 Global procurement of tools 12.04.2016 Manufacturing of design and functional surfaces in tool making 19.04.2016 Shopfloor management and layout planning in tool making 11.-12.05.2016 Polishing in tool making 01.06.2016 Surface technology and tool wear 02.06.2016 Industrialization of tool making 14.-15.06.2016 Classic and additive manufacturing technologies in tool making 19.-20.09.2016 Applied industry 4.0 in tool making 29.09.2016 Project management and process management 04.-05.10.2016 Operational Excellence: Lean tool making 10.11.2016 Cost transparency in tool making: From offer calculation 23.11.201 to productivity management Automation in tool making 05.12.2016 Milling technology in tool making 06.12.2016 Prestigious experts from practice Mr. Ringelmann, ZF Dr. Wahl, Audi AG Mr. Willmes, Kirchhoff Mr. Bertram, Böllhoff Mr. Bormann, Welser Profile Dr. Auer, Gerresheimer Dr. Boretius, Listemann Technology AG Mr. Söhner, Selectrona Mr. Walter, Siebenwurst Mr. Deck, Daimler AG Slide 30
Aachener Werkzeugbau Akademie: We design Tool Making AACHENER WERKZEUGBAU AKADEMIE Applied Research & Development Specific Industry Solutions Client oriented Consulting Professional development Access to research projects of various institutes via the WBA as a research broker Individual research and development projects for partners of the WBA Development of specific industry solutions within consortial projects Knowledge transfer and networking in the Tool and Die industry Bilateral projects with technological and organizational topics of the Tool and Die industry Mutual concept development and project implementation Modular further education for non-academics and academics Coverage of all relevant technological and organizational subjects Demonstration Tool Shop Slide 36
The Werkzeugbau Akademie enables the development and application of new concepts in a real manufacturing facility Characteristics of the Demonstration Tool Shop: Production of tool prototypes for research and development Platform for developing and optimizing new manufacturing concepts Test and production area for WBA partners Testing and transfer of industrial tooling principles Illustration of Tool Manufacturing process chains Educational platform Slide 38
The modern machine park of the Werkzeugbau Akademie comprises all process chain elements of Tool Manufacturing Design & Simulation Sawing Milling Electrode milling Turning Sägen Sägen Sägen Sägen Sägen KASTOverto A2 DMC 1035 V, C 40 U HSC Speed Hawk 550 NEF 400 Wire erosion Sink erosion Flat grinding Metrology Manual work area Sägen Sägen Sägen Sägen Milling Sägen Turning Cut 2000 Gantry Eagle 800 Smart-Line BD10 CMM Qi Welding Slide 39
Contacts of the Werkzeugbau Akademie Dr.-Ing. Wolfgang Boos, MBA WBA Aachener Werkzeugbau Akademie GmbH CEO Karl-Friedrich-Str. 60 D-52072 Aachen +49 241/ 990 16 302 +49 151/ 18 868 611 +49 241/ 990 16 329 w.boos@werkzeugbau-akademie.de Michael Salmen, M.Sc. WBA Aachener Werkzeugbau Akademie GmbH Head of industrial projects Karl-Friedrich-Str. 60 D-52072 Aachen +49 241/ 990 16 361 +49 241/ 990 16 329 m.salmen@werkzeugbau-akademie.de Gustavo Cabral, M.Sc. WBA Aachener Werkzeugbau Akademie GmbH Head of technology development Karl-Friedrich-Str. 60 D-52072 Aachen +49 241/ 990 16 304 +49 241/ 990 16 329 g.cabral@werkzeugbau-akademie.de Dr.-Ing. Kristian Arntz WBA Aachener Werkzeugbau Akademie GmbH Technical manager Karl-Friedrich-Str. 60 D-52072 Aachen +49 241/ 990 16 373 +49 241/ 990 16 329 k.arntz@werkzeugbau-akademie.de Slide 40