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18 MoldMaking Technology May 2015 Case Study / Software Steve Killoran of Hi-Tech Mold & Engineering inspects tooling for future projects. milling processes by an average of 20 percent, a result that's since been replicated on the shop floor. In 2012, shortly after implementing the surfacing module, the company expanded departments handling deep boring and electrode machining. This proved an ideal time to implement improvements identified during the second part of the process analysis—improvements geared toward what is essentially NC automation. "By using NC templates including feature recog- nition and machine-specific tool libraries, we achieve a signifi- cantly higher quality with shorter throughput times," says Tim Cheyne, application specialist. "We achieve faster and better results with fewer personnel." The Tebis Simulator has also become firmly established in the process chain. "All components, including the machine, tools and all retracts, are taken into account," Cheyne explains, adding that the company's use of simulation extends beyond collision avoidance. "We also use the Simulator as a planning tool for configuring the workpiece fixture and positioning. Thus, we can machine every component with the smallest pos- sible machine." Cheyne adds that the time and cost savings resulting from the software upgrade also have ripple effects. For instance, using template technology to automate previously manual tasks frees the company to focus on more value-added activi- ties. "Thanks to the template technology, even new employees without programming experience are able to create simple NC programs after only one week of training," he says. "We har- ness the unleashed potential to develop new ideas, to refine processes and to advance our employees." stations quickly rose from there, and the company also uses various other modules from the Tebis family of products, such as organizers, simulators and electrode manufacturing. Today, the software is utilized end-to-end in mold manufacturing, from job preparation to finished part. Given Hi-Tech's focus on product design, Tebis' capability for smooth surface finishes wasn't the only important factor in the company's choice of software. CAD functionality played a role as well, says Kevin Taverner, vice president of operations. "The data exchange with Catia works smoothly," he explains. "Data redun- dancy is reduced to a minimum, and all necessary specifica- tions are retained. And geometries can be quickly adapted after import, thanks to the integrated CAD functionalities." The relationship between the two companies goes beyond Hi-Tech's use of Tebis software. They also work cooperatively to improve moldmaking processes. In late 2011, a close analysis of Hi-Tech's operation crystallized two opportunities for new efficiencies. First, using modules from the supplier's boundary representation (BREP) product family during job preparation could speed downstream machining. Second, NC libraries and template technology could help streamline programming and help the company make use of its full potential. Unleashed Potential One particular BREP module, the Tebis Surfacer, is now considered an essential element of the machining process at Hi-Tech. The module enables combining any number of surfac- es to reduce the overall number of segments. According to the supplier, this helps optimize the entire surface. During trials at Hi-Tech, the company found that the module could shorten Steve Killoran (left) discusses operations with Tebis's Michael Thiessen. Tebis doesn't just supply software to Hi-Tech Mold & Engineering; it works with the mold manufacturer to improve its processes. FOR MORE INFORMATION: Hi-Tech Mold & Engineering / 248-852-6600 / hitechmold.com Tebis / 248-524-0430 / tebis.com