When Karl and Walter Bräm founded the company in 1965, the vision was to establish partnerships with customers who required development and production services. To meet the market’s varying requirements, the founders deliberately invested in a company structure focused on technical development. Adhering to this strategy, the company’s operations have developed from dedicated craftsmanship to highly automated production of components – both short series and one-offs.
Raphael Bausch and Martin Bräm – securing Swiss jobs by realising the founders’ vision
Bräm AG now supplies precision parts not only for the textile, welding, automotive and medical technology industries, but also for use in tool production. Located in Dietikon, the company’s operations employ 35 people and cover everything from prototype, one-off and series production to the manufacture of punching and forming tools, jigs and special machines. A wide spectrum with the Bräm “ideas factory” supplying turnkey solutions for customers all around the world.
Investment in the latest technology is a central theme in the company’s history. The first EDM machine was installed as early as the end of the 1960’s. Today, there are five die-sinking EDM machines and five wire EDM machines. Six milling and machining centres meet the demand for simultaneous milling in five-axis machines and the machining of hard metals. At the beginning of the 80’s, taking its first step into medical technology, the company was the first in Switzerland to invest in laser technology. Six surface and cylindrical grinding machines supply high quality finishes that can be even further improved in various subsequent operations.
Early analyses of production costs had shown that reduced set-up times were critical for short lead times and high productivity. Thus, towards the end of the 90’s, set-up stations were installed for the EDM and milling machines. “We were one of the first companies in Switzerland to use palettes throughout the entire process chain,” remembers Raphael Bausch, technical manager and head of production.
The middle of November 2005 saw the installation of an automated EDM cell, a Roboform 350 and a WorkMaster from System 3R. Shortly thereafter, the company’s resources were expanded by the addition of an automated milling cell, a Fehlman Picomix served by a WorkPartner. The decisive factor in selecting System 3R for the new cells was the structure, user friendliness and open architecture of the software from the Swedish automation specialists. “It is ‘upwardly’ open and fits in with current ERP systems. Thus, we do not have any interface problems,” relates Martin Bräm. He continues: “Partnering System 3R and our existing palette system went without a hitch. However, when connecting the feeding machine, there were some problems. These were quickly resolved.”
The cells enable automated production irrespective of series size. A large part of the responsibility for efficient production rests with machine operators. With the delivery date as the starting point, the operators organise the work. They are also responsible for delivery being made on time. “We put our best personnel on these jobs,” says Raphael Bausch, explaining the allocation of responsibilities. “Although supervisors set the framework conditions, our production operatives are better qualified to carry out the work itself. They are directly involved and would never allow problems to arise at important communication and process interfaces.”
Parallel with automation, other operating procedures were connected (just like the factory’s CNC machines) to the data network and thus became an integral part of a harmonic whole. Consequently, from planning to finished product, there are links ensuring the completeness of the process chain. Furthermore, as early as the development stage, interfaces enable data to be exchanged with customers.
Through these investments and comprehensive know-how, Bräm AG has established itself as a supplier of technologically advanced precision parts. It is with some pride that Martin Bräm divulges the company’s distinctive position: “Owing to our expertise, we are often brought in when others have hit their limits. This has also qualified us as strategic suppliers of precision parts for the Paul Scherrer Institute.” Amongst other things, the institute, which is part of the Swiss Federal Institute of Technology (ETH), undertakes solids and material science research. Clearly enough, this places severe demands on the quality and performance of the components used in its projects.
Efficient production cell – WorkPartner doubling the spindle hours of a Fehlmann Picomax 60-m
To ensure flexibility in the machining of copper electrodes, the milling department has its own order preparation service. This is responsible for writing CAM programs and planning milling strategies, machine use and weekly schedules that split operations into day and night shifts. Appraising the investment in robots, Martin Bräm states: “Automatic pallet changing on the machine table and at the spindle increased annual machine hours from 1,780 to 3,565. Other advantages include the high process reliability with WorkShopManager. The latter manages machining programs, offset values, magazine positions, the composition of batches and the presentation of batches to the machines. Additionally, the structured workflow has created a calm and harmonious work climate. This has a positive impact on the company’s total efficiency.”
Because palettes were already used there, the increase in the number of machine hours is not as marked in the automated EDM cell. Raphael Bausch reveals: “EDM hours have increased almost 40%. This shows that our investment was correct. Previously, lack of capacity sometimes forced us to hold back. However, we can now contact new customer groups.”
Given that the positive results of automation are already evident, the company’s management team is convinced that the factory is well on the way to 24/7 production. By avoiding the transfer of production to low-wage countries, the founders’ vision has secured jobs not only for Bräm AG but also for the company’s customers.
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Layout drawings:
Fehlmann P60 & WorkPartner
Charmilles Roboform 350 & WorkMaster 1250/75
Related links:
Automation in general
WorkPartner
WorkMaster
WorkShopManager