WorkNC-CAD streamlines methods at Sermo

Since it was formed in 1966 at Montaigu in the Vendee, France, the toolmaking business of Sermo has developed to become the leading European manufacturer of mould tools for the automotive industry. At the Montaigu site, which designs and makes moulds for very large components such as bumpers and instrument panels, Jean-Luc Fonteny, CAM Manager of the Production Services Department, which has a staff of 11, explains that the mould design is principally carried out utilising CATIA CAD systems, the majority of which are at the latest version CATIA V5.

<< The person who creates the toolpaths using WorkNC also deals with model preparation using WorkNC-CAD. here is less training needed, and fewer stages to go through. >>
Jean-Luc Fonteny, CAM Manager, Sermo, Montaigu.

Since 1989, Sescoi’s WorkNC CAM software has been used for mould manufacture at Sermo, where its ease of use, and the productivity gains provided by its advanced optimisation functions are appreciated. The outstanding feature, however, is the reliability of WorkNC software, which has helped Sescoi become a market leader in the creation of 3D toolpaths. Sermo has benefited from this throughout its group of companies.

Up until the end of 2001, Jean-Luc Fonteny and his team worked solely in the CAM sector, without being involved in tasks such as design and model creation – these were the responsibility of the Design Department. Since then, a Production Services Department has been created to improve the management of the production line to work towards just-in-time methods. This Production Department took charge of 3D model creation and modification, electrode design, and CAM. The Design Department is now exclusively involved in the modelling of components and tools.

The new Production Department was aware of the need for a CAM system which integrated the functionality of CAD, for 3D model creation and modification (filling holes, moving surfaces, creating protective surfaces), without necessarily having to use CATIA, with its complexity and the need for extensive training. The system needed to be capable of importing CAD data reliably, recovering corrupt surfaces, and to be as integrated as possible with the CAM system. It also had to offer analysis tools in order to simplify preparation for machining, and in addition be easy to learn and use.

At the same time, Sescoi launched WorkNC-CAD, it’s new CAD product, which is integrated into WorkNC Version 15, allowing autonomous methods within the factory. As he was already satisfied with WorkNC, the service provided by Sescoi and their good working relationship, Jean-Luc Fonteny was happy to use both products in the Production Department. The two are now used together for the correction of CAD geometry coming from CATIA V4 and V5, and for the preparation of the component before machining. This means that the same operator can prepare the model then create the toolpath in one integrated system. They currently create electrodes using CATIA, but WorkNC-CAD will soon take over that function, as well.

Because of the use of WorkNCCAD, pre-production processes are now able to be completed by the Production Department alone, resulting in considerable performance gains. Jean-Luc Fonteny explains, “It’s no longer necessary to work with the Design Department – the person who creates the toolpaths using CAM also deals with model preparation. There is less training needed, and fewer stages to go through.”

The Sermo group now has 21 WorkNC licences (9 at Montaigu, 6 at Sermo Sabl, 1 in Brazil and 5 in Poland) and 6 licences for WorkNCCAD (2 at Montaigu and 4 in Poland). They anticipate acquiring more to help achieve their aim of standardising software throughout the group, thereby promoting continued growth. Jean-Luc Fonteny is clear about his aims throughout the company, “Use the same design methods, the same production processes, with the same tools. Wherever the product is designed and made the client will find the same, high, Sermo quality”.