Lufthansa Technik comprises six business areas. One is the area of VIP Services, where production sets high demands on flexibility.
(l-r) Frank Pieterwas and Jan Horn, Lufthansa Technik; Julian Lüdecke, Zoller; and Ulrich Rienks, CAMTECH/Edgecam
Data consistency is provided, from the CAM system through to the machine.
Lufthansa Technik provides a large component spectrum for individual customer requirements.
The »venturion 450«, a CNC-driven tool presetting and measuring machine from Zoller.
For Lufthansa Technik, fast response to market changes is now possible.
A modern aircraft is a highly complex machine. The safety of passengers - as well as the reliability and cost-effectiveness of an airline's flying operations - depends on error-free functioning of the parts. For Lufthansa Technik AG (Germany), a full-service provider of technical inspection, retrofitting, maintenance, overhaul and painting, the spectrum of parts is considerable since customer wishes are extremely individual and maintenance and repair work can be unpredictable.
Next to safety, high quality demands are the focus for mechanical manufacturing in the aerospace sector. Individual requirements include the daily production of high quality components with new geometries.
Over the years, new requirements were added, which necessitated a greater variety of tool data. The distribution over several databases resulted in redundant data management. This led to increased inefficiencies and contained potential sources of error due to repeated manual entering of data. A solution was needed, and expandable systems and maximum data transparency were essential requirements.
Lufthansa Technik found a solution when it partnered with CAMTECH, master reseller for Edgecam in Germany, and Zoller.
In order to meet the individual production requirements for its customers, a tool pool of approximately 2,000 different, complete tools is utilized by Lufthansa Technik. Since 2000, the elaborate NC programs for these complex geometries have been programmed using the Edgecam CAM system, and since 2009 5-axis simultaneous operation has been utilized. Both prismatic parts and free-formed surfaces are milled here.
Following the purchase of a state-of-the-art machine pool, investments were also made in high-tech peripherals. The objective was not only to increase process safety, but in particular to ensure maximum flexibility in order to respond to market changes. Until this time, only a single manual tool presetting machine was in use. Labels were printed and the data was entered manually into the machine.
The CNC-guided »venturion« tool presetting and measuring machine has been in use since 2007. "We decided in favor of Zoller, following a cost benefit analysis," explained Planning Engineer Frank Pieterwas. "Decisive for us was the expandability and linking to the machines."
In addition to the potential of introducing a system-superimposed tool database, there were also a number of application details provided by Zoller that met specific customer requirements. "The graphic user interface for the otherwise laborious presetting of fine drilling tools, for example, or the fact that I can clearly view the cutting edge with the magnifying glass, were key factors in our decision," stated Mr. Jan Horn, CAM specialist at Lufthansa.
The basic machine had been successively extended over the years and Tool Management Solutions (TMS) had been added. "We wanted the Zoller database because it is a leading system," said Horn. "If a new tool is set up, it can be entered into the Zoller Tool Management database so that the name, description and the T-number are correct. Once entered, it can be used by all employees in a standardized manner throughout the entire process and can be found consistently."
The interface from Edgecam to the Zoller TMS had already been developed in 2011. In 2013, the Edgecam-CAM system, the tool memory of the CNC machines along with the Zoller tool presetting and measuring machine were all linked via the Zoller database. This ensured data consistency, from the CAM system on through to the machine.
All data is saved in TMS and accessed by the CAM system. The measuring regulations are saved in the database next to the tool and are available on the measuring machine. "Professional measurements are made at the push of a button and the tool data is transferred to the machine," said a Zoller spokesperson. "This ensures consistency and eliminates all sources of error due to manual entry. Multiple storing of data was thus abolished."
The tool data is now saved in the Zoller TMS database according to DIN4000 and is available in the Edgecam CAM system as a precise 3D model. The system programs using real data and outputs the data of those tools along with details on the simulation that was performed. These can then be assembled on the machine in the same way they were simulated. "Particularly in the case of complex processing methods, it is important to have the true tool data available for programming in order to avoid crashes," said a Lufthansa Technik spokesperson. "In addition, it saves enormously on time."
After the first six months of operation, the error rate had already dropped significantly and employees were given optimal support when looking for possible tools to satisfy individual customer requirements. "Of course, the savings cannot be quantified as in a series production," said Horn. "However, being able to efficiently search for tools is a major benefit. The flexibility for the employees is a big advantage due to continuous changes on the NC machines. Everyone simply downloads their NC program onto the machine. The tools are included and have standardized descriptions. Everyone can orient themselves everywhere, and all that is occasionally needed is a tool retrofit. I use a single set of tool data and it applies to all of the machines. Once I have written a program in Edgecam, then it also applies to all of the machines. All I need to do is change the post-processor, send the NC program and the process is completed. A big advantage with Edgecam is the simple, subsequent change of already programmed parts to other machines."
Lufthansa-Technik often has to respond to market changes extremely fast. Repairs and unique customer requirements are often unpredictable. High flexibility is necessary, especially to realize the external manufacturing ratio of up to 70%.
"We have created a perspective for the future with the introduction of these systems," is how Pieterwas summarized the benefits of the investment. "This also allows us to actively approach the external market. We are independent of our own assembly components. Operating systems, such as Edgecam and those from Zoller, allow us to respond in a flexible manner - and customers can continue to take off safely in the future."
The Lufthansa hangar in Hamburg employs some 8,000 staff for the maintenance, repairs and interior fitting of aircraft. Over 1,000 employees take care of VIP, business and government aircraft, covering the areas of maintenance, design and production. As a full-service provider of technical inspection, retrofitting, maintenance, overhaul and painting, the company can provide unique solutions for customers' aircraft.
For nearly 70 years Zoller has been a manufacturer of presetting and measuring machines, as well as a provider of technology and system solutions.
For more information contact:
Zoller Inc.
3753 Plaza Drive
Ann Arbor, MI 48108
734-332-4851
sales@zoller-usa.com
www.zoller-usa.com
Edgecam
25 North Lake Street, Suite 220
Forest Lake, MN 55025
866-334-3226
www.edgecam.com