Author:
Jürgen Kromberg, Ganzheitliche Produktion
Eight years ago now, IT Specialist Marco Bauer took over an
exciting contracting company with eight employees and four machining centers.
Today there are more than 190 employees and around 40 NC machining centers. You
soon notice that, alongside the usual technology required for a manufacturing
JobShop, there is a huge variety of other technology and no paper. The true
secret to the success of the newcomer, who freely admits he has no idea about
turning and milling, was full digitization.
Although, his admission isn’t entirely true. The IT
specialist had previously been a builder in a metalworking company. Working in
production, he noticed just how much paperwork, besides just the workpiece
drawings, accompanied the manufacturing contracts at the machining centers.
However, at the time, he knew there was no other real alternative.
Fast-forward to today and there are better options for
generating digital working plans, including time and cost calculations, which
are not only paperless, but also much quicker and cheaper to implement.
But one thing remains true; the firm with the biggest edge,
is the one that can massively reduce the pre-production costs to create a
sizeable advantage over their competitors (especially as a service provider).
The disadvantage? This isn’t the kind of edge you can
simply buy, install and run. It’s something you have to generate and develop yourself.
But at BAM GmbH this was quite simple, for two main reasons. Firstly,
because their young CEO (Bauer was just 24 when he took over the company) was a
fully signed-up and pioneering digital protagonist. And secondly, because the
digitization of the then-small JobShop developed hand-in-hand with the company’s
expansion. Bauer concedes, »In an existing organization with an established
production planning system, moving from analogue to digital processes would
certainly require a lot of persuasion and persistence.« But he is convince »The
effort is worth it. Certainly, we consciously invest in the most modern
manufacturing equipment for machining and sheet-metal machining, as well as for
3D printing, but having your business and technical administration digitized is
the key for high efficiency and has the most growth potential. Without the
immense advantages that digitization allowed us, we wouldn’t have grown so
quickly.«
BAM GmbH started eight years ago as a prototype operation
with the initial idea of growing as an online business. And this is, of course, where the advantages of digitally generated offers are most
evident (as most orders are single-piece runs or lots of one). The calculation
algorithm functions fully automatically and is complete within seconds. Bauer
sets the scene, »We calculate around 3,000 requests per month over this rapid platform.
We’d never manage that with traditional paper methods unless we had a really
big and extremely pricey, dedicated calculations department.« They simply
wouldn’t be profitable, or would have to make parts extremely expensive.
The BAM GmbH digital business predominantly (but by no
means exclusively) deals with 3D-printed parts, for which – by the nature of
what it is – there are already 3D-CAD models. These are the perfect
input for a fully automatic, digital calculation of the work plans and price
within seconds. Bauer explains »The 3D-printing customers for additive
manufacturing, who are digitally oriented anyway, have no problem sharing their
construction data for their products with us so we can calculate the quote.
It’s the opposite for the ‘subtractive’, that is, the typical machining
customers – we almost always have a bit of back and forth there about data
protection and security. We get plenty of objections to simply uploading and
sending highly sensitive construction data to the internet.«
But one has to wonder why, since »The same companies,
however, have no problem sending their construction data, fully unencrypted,
via email. For the digital JobShop business model, Germany is definitely one of
the toughest markets in the world. And that’s why we’re – as far as we know –
still the only digital contracting manufacturer here.«
It’s a business that has achieved incredible and rapid growth
in just eight years and, for example, within the last two years, invested 25
million euros in more manufacturing equipment. If you ask the Executive
Majority Shareholder Bauer, how a medium-sized enterprise like BAM GmbH
finances this kind of huge investment? He’ll tell you »certainly not on credit
from a bank. For two reasons. Firstly, BAM GmbH achieves a much higher profit
margin than your typical JobShop, thanks to increasing digitization in place of
time and cost-intensive administrative processes. And secondly, the Unger
family (German auto-parts billionaires featured on Forbes.com) have been
shareholders for some time now, and we agree completely on our joint business
strategies. And so, BAM GmbH is able to finance its investments almost entirely
without the involvement of banks.«
Answering our questions (from the upper left, clockwise): Marco Bauer, Josef Wittmann, Ralf Schnurr, Marcel Alter, Jürgen Güntner.
And on the subject of collaborative, streamlined (anything-but-standard),
business approaches, let’s not forget the unusually broad variety of options
that this contracting manufacturer offers. BAM GmbH offers comprehensive
precision manufacturing of all kinds (including honing), but primarily turning,
milling and drilling, as well as 3D printing for metal and plastic, and
industrial sheet-metal working with lasers/ punching, bending and welding. And
last but not least, BAM’s special-purpose machinery for plant engineering. And
all of this, wherever possible, is automated on the workpiece side to allow for
24/7 operation.
Is
this young company not perhaps overstretching itself? Bauer can explain, »Our
aim is to be the one-stop-shop for everything, online. We want to fulfil our
customer orders to a high professional level, as simply, quickly,
professionally and cheaply as possible, and that requires us to have the most
comprehensive offer of technical services.« He reiterates, »The investment
required to achieve this is possible thanks to the increasing digitization of
our processes, which makes us leaner. When we’re selecting which manufacturing
equipment to invest in next, we always consciously choose the newest
developments.« He explains this logic: »These are the options that, if they
meet our needs, promise us the greatest benefits and returns.«
Advantage MT 733 two plus: Option to work autonomously, off the bar or with (via robot handling systems) pre-formed/cut slugs/blanks.
An example of these far-from-usual investment decisions
includes the three machines, which were first presented at the 2018 AMB in
Stuttgart, and which BAM GmbH ordered.
+ For example, the Artery Universal multifunctional turning
center, which was presented by Weisser Söhne, is spectacular in many aspects,
not least its design. BAM GmbH opted for this, alongside the milling head
capable of performing the ‘High Dynamic Turning’ process, in order to use the
‘FreeTurn’ tools from Ceratizit. Josef Wittman, Head of Manufacturing, explains
the decision: »No. As striking and unusual as the design of the ‘Artery’ is, that wasn’t
what persuaded us to invest. It was actually the very high-quality workmanship
and the HDT concept with the view to more efficient turning than has
yet been possible. Not to mention the extremely high long-term precision, even
with lengthy cycles of high cutting capacity, that we’ve come to expect from
Weisser-Vita – also possible thanks to the HDT. That is really the talking
point.«
+ Then, the equally universal HyperTurn 45 G3 by Emco. No,
not a spectacular development, but one that has impressed pragmatic and
demanding users like BAM GmbH. Wittmann says, »It's very compact for
its operational range, has a relatively small footprint and is very productive,
with two tool turrets, especially as it bridges delivery and empty routes very
dynamically. This machine is perfect for small components.« He emphasizes, »Unfortunately,
unlike for milling/drilling, there isn’t such a comprehensive and coherent
product offer for various working areas from one provider when it comes to
turning. We could also opt to invest in others, in addition to turning, like
those at Hermle AG – we have 13 machining centers from them with various
working areas.«
+ Last but not least, from STAMA the MT 733 two plus was
another BAM new investment after the 2018 AMB – and was also the reason for
this user report. A ‘Project Machining Center’, is how Wittmann
describes this newly developed multifunctional milling-turning center. He
explains, »We had a request from one of our existing customers for around
15,000 parts per year for a geometrically
very demanding component made from aluminum forge material with 40 tools, and
we knew that we’d need very special manufacturing equipment for this potential
job.« Handy, then, that there were regional machine representatives effectively
creating a hinge between machine users and manufacturers. Like the
Berner+Straller GmbH sales representation with their three offices in Nuremberg,
Munich and Dresden, who represent, among many other notable machining brands,
STAMA and Weisser Söhne. Sales Engineer Jürgen Güntner reports, »We knew both
the particular project requirements of our customers, BAM in Weiden, and of course
the newly developed MT 733 two plus from STAMA, and thought that they’d be a
good pairing. So we brought the two together at the AMB 2018.« And Wittmann
remembers, »We knew immediately, right then, that the MT 733 two plus was
exactly what we needed for the potential project order – our evaluations just
confirmed that.«
Advantage MT 733 two plus: Two independent, five-axis working areas for autonomous turning and milling.
And why did they decide in favor of the MT 733 two plus, as
the tallest in the range? Wittmann explains, »This configuration level is the
most versatile and, as a contracting business, you need the most versatile manufacturing
tools you can get.« He reminds us, »The MT 733 two plus works both from the
left on bars and also with rear loading via the portal loader for handling
pre-formed or pre-cut parts. That was a key criterion for our decision.« He
continues, »It’s also technologically versatile, as the first spindle on the MT
733 two plus offers an enormous 59 kW, while the second spindle, with its 15 kW, reaches up to 20,000 rpm.
We can both mill precisely, and efficiently drill tiny holes, with 120 bar coolant
fluid pressure to ensure processes reliability and, of course, we can achieve
optimal turning too.« STAMA Sales Engineer Marcel Alter emphasizes, »Thanks to
the fully symmetrical portal principle, and also the polymer concrete base
frame, the MT 733 two plus offers fantastic static rigidity and low dynamic
flexibility, which also works in favor of a long cutting-edge service life and
high precision.« Wittmann sums up, »This turning/milling machining center also
has the advantage of two autonomous, five-axis working areas for optimal
machining. Also, when OP20 is finished, the part, which is machined on six
sides in two clamping positions, can be removed automatically from the rear –
this reduces the processing time again.«
And even with the order of 15,000 parts per year with a
time-per-piece of four minutes, the MT 733 two plus isn’t at capacity. As we come
to the end, Bauer confirms, »No, of course it’s not. But we’re sure that we
will win more contracts for it. Thanks to our extensive digitization of both
administrative and technical processes, and our workpiece-side automation –
partially with robot cells we have developed ourselves – BAM GmbH is extremely
competitive.«
Powerful: The coolant fluid system for both spindles with 120 bars each for high process reliability.
Another BAM-man joined us in our research. Ralf Schnurr’s
business card describes him as a Technology Evangelist, which he explained to
us, »Translated, it means ‘the bearer of good news’. It’s my job to publicize
and promote how digitally forward-thinking we are, in the hope that our digital
methods are accepted by more and more customers – I’m a bit like a digital
missionary.« So once again, and always, anything but standard. And that’s the
key to their success.
For more information: https://bam.group/en/