The company’s core competence is focused on the production of high-quality roller burnishing tools for the automobile and hydraulics industry.  In this sector, G. & K. Schön in Korschenbroich rank among the leading specialist providers in Germany. For 14 years, those tools had been manufactured on a FEHLMANN PICOMAX 60 4-axis machining center. However, at the beginning of 2016 management decided to modernize their range of machines. Only one thing was certain at that point of time - production was to be switched over to 5-axis machining. At first, the people in charge were thinking about purchasing the PICOMAX 75, including the dividing unit ATS 200 and an ERC robot by Erowa. Why PICOMAX 75? Because this would fully integrate 5 axes in the control unit and because this combination guarantees perfect accessibility and machining precision in 5,4 and 3 axes.
Furthermore, the machine can be run with 3-axis only, with retrofitting of the fourth and fifth axis possible at any time later on. In the course of those talks, however, entirely new perspectives opened up for Managing Director Klaus Schön: „First of all, I have to admit that one of my employees and I have been tip-toeing around the VERSA for years, dreaming of having one for our production. Still, FEHLMANN needed a lot of persuasive power to finally convince us. When FEHLMANN explained to us the capabilities offered by the 5-axis simultaneous machining center VERSA 825, we went to Switzerland to see the machine for ourselves directly on site. That finally convinced us, also as the automation could easily be retrofitted at any time later on.“

An investment in the future
It is true, in Korschenbroich prototype production and very small series are the core competences, but Klaus Schön apparently had always had a penchant for automation. Notwithstanding the above, two older machines were to be replaced by the new purchase and an employee who was about to retire was to be compensated for. This is why intensive benchmarking was conducted prior to the investment. G. & K Schön GmbH had their mind almost firmly set on the VERSA, based on the good experiences with Fehlmann in the past. The main advantage of 5-axis machining (3+2 axes) lies in the fact that re-clamping roller burnishing tools for complete machining had consumed a lot of time in the past. In addition to this technology, however, numerous other reasons spoke in favor of Fehlmann, said Klaus Schöne - among other things, reliability, attention to detail, compact footprint, excellent service and high precision. In Korschenbroich, microns are not “split” - normally we are talking about a few hundredths of a millimeter. Currently, however, components are being manufactured with high accuracy within just a few µms. Therefore, the benchmarking process focused not so much on the machining center itself, but rather on the overall package, including the automation offered.  Whereas similar machining centers with automation did not really generate a great deal of enthusiasm, the concept including the Erowa robot Leonardo, which is able to accommodate up to 24 320 x 320 mm UPC pallets in the standard version, impressed immediately. In addition, a loading/unloading drawer on the robot allows for setting up jobs during production time. As Peter Potjans, Technical Consulting and Sales at Fehlmann AG, puts it: „For their automation, Fehlmann uses almost exclusively Erowa systems, as we are familiar with the interfaces, allowing problems to be avoided right from the start. Moreover, this robot also offers a compact combination thanks to the multi-level system, intuitive operation and an excellent price-performance ratio. Operating the Leonardo is simple, intuitive and fast and done via touchpanel controls. Therefore, this machine solution is almost tailor-made for our range of workpieces."

Employee motivation through increasing demands
Not only roller burnishing tools are being manufactured at G. & K. Schön. The company also offers job order production services. Occasionally, these workpieces may be quite complex. This is one more argument why the responsible people at G. & K. Schön prefer the VERSA 825, as it allows for dynamic HSC milling, as well as the machining of difficult to machine materials. Equipped with an HSK-A63 motor spindle with 18,000 rpm, 120 Nm torque and a tool changer with a capacity for 44 tools, the VERSA seems to be the perfect basis for future tasks. However, Klaus Schön cautions: „We do not know yet which way to go. The reason is that the machine with robot is currently not yet fully utilized. Already at this point, however, bottlenecks in programming are beginning to show. Of course, this is a welcome development in principle. However, in our region, good qualified skilled workers are rare.“
On the one hand, the VERSA has only been put into operation in October 2016 and in view of such automation, it is a well-known fact that such bottlenecks may occur. On the other hand, however, the employees have been involved in the concept right from the beginning, have accepted it well and are fully motivated. What is more - the employees are really keen on being challenged and thus regard the automation solution for the production of roller burnishing tools, which are mainly repeat parts, as 100% positive. Nothing is standing in the way of the company's intention to process jobs during unmanned operation into the night using the automation.

G. & K. Schön at a glance
The company was founded in 1984 and mainly focuses on the manufacture of high-quality roller burnishing tools for the automobile and hydraulics industry. In this sector, G. & K. Schön rank among the leading specialist providers in Germany. Due to the continuously increasing demand, the sales network has been expanded for years and the company meanwhile exports its products to 14 countries across the globe. In addition, the company also offers job order production services (prototype construction, single-part construction).

By the way ...
Klaus Schön about the subject of 'service' at Fehlmann: „The service inspires me because we always communicate at eye level. Apart from that, the attention to detail, the compact footprint of the machine, as well as the high precision of Fehlmann has convinced us.“

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