GE Lighting
Machinery Plant, Hungary
Introduction
2014
Imagination at work.
Introduction
Worldwide solution provider
•
Deliver excellence in machine designing & building in multiple
automation solutions
•
Available machining resources for standard and specialized
part manufacturing
•
Expertise in mechanical and electrical development,
automation and integration
•
Customer focused: long-term spare part availability & support
•
Managing complex projects
•
Highly motivated and focused execution teams
Design
Concept
Machining
Your success
Assembling
Support
Logistics
Dedication to Quality
•
Meet quality standard of ISO 9001:2009
•
Health and Environment committed, EHS: ISO 14001
•
Work along Lean & Six Sigma methodologies
•
All solutions are CE marked
L E A N
ENTERPRISE
Installation
Machinery Plant Profile
Complex Development & Service type operation specialist
Design | Machine build | TOW | Install | Customer Service
Budapest (BP)
Management
Solution Sales
Project Man.
Hajdúböszörmény (HB)
Center of
Manufacturing &
Subcontracting
Excellence in
Designing &
Assembling
3
Our project methodology
Quote
Prepare
Concept &
Design
Realizing
Install &
Debug
Logistics
Support
Continuous project tracking with experienced project leaders
Data
warehouse
Process
development
Project
tracking
Capacity
management
PM in SAP
ERP
4
Advanced Design Capabilities in…
…Prototyping & benchmarking
…Lighting industry leading portfolio
…Build-to-print
…Complex system improvements
…Re-designing machines, production lines, plants
…Creating best-in class solution
Domain expertise in
designing and developing
Extensive range of mechanical
designing
• 2-D & 3-D design capabilities
• Applied FEM analysis
Wide experience in electrical
design
• software development
• vision systems
• process-monitoring system
Engineering support
Creation of conceptual solutions
6
Specialized knowledge in
digitized process monitoring
• Data collection and analysis
• Reject Analysis
• Batch Tracking / Material Usage / Stock
• Alarm / Event Analysis, Alarm Summary
/ History
• Trend analysis for technological
parameters
• Online SPC Analysis / Histograms
• Online Digital Score-carding of the
Production Line & Sub-systems
10+ years of experience with HMI / SCADA /
Monitoring systems
• Other specific reporting & data mining
7
Vision Systems & High-end commercial materials
8
Professional machining capabilities
CNC machines
Significant in-house capacity w/ continuous extension
3D Measuring
for multiple industry purposes
Special partners
In-house sourcing for materials and for subcontracting
Machining workshop
10
Machining workshop capacity
Machine Group
CNC milling machines
CNC turning machines
CNC grinding machine
CNC wire cut machines
CNC water jet machine
CNC engraving machines
Total:
Pieces
Capacity (whours/y)
15
7
1
4
1
2
30
90.000
42.000
6.000
24.000
6.000
12.000
180.000
Possible capacity extensions (in house)
Machine Group
Pieces
Capacity (whours/y)
NC boring mill / milling m/c’s
2
12.000
NC turning machines
3
18.000
5
30.000
Total:
11
Samples of special parts
Vibratory Feeder
GE Lighting
D220x60
Feeder Unit Critical
Component
Valve Body
GE Lighting
50x50x140
Vacuum technical
Component
CMHL Gas Burner
PGT25+ Diaphragm
GE Lighting
GE Energy
50x25x45 with D0,5 holes
Burning Unit Critical Component
Gas Turbine Component
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Validated subcontracting partners
Part
manufacturers
Special
technology
Surface
treatment
Service
type
40+ partners to solve
10+ partners to solve
5 partners to apply
5 partners to assist in
capacity overloads
special machining
various surface
various complex
professional supply
needs if parts:
- extremely small
regulations:
- nitriding
works:
- gas systems
-
extremely large
-
hardening
-
-
extremely hard
-
coating with
oxides
process
monitoring
systems
-
galvanizing
-
assembled units
chain parameters.
Our full capacity can
be doubled.
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Excellence in assembly capabilities
Mechanical & electrical
• Professional assembling and setup in
advance and on site
• Cabinet assembling and high performance
electrical system wiring
Extensive debugging
• Detailed and long-term dry- & hot-runs
High-tech Vision
• Implement industry-lead process
monitoring & vision systems
Complex installing
• Full production line installation
Refurbishment
6
1
Mechanical..
1
Electrical..
8
Supply..
…assembly stations
Assembling area: 2.200 m2
We can work on up to 3 machines per station with 2,5 m x 2,5 m base concurrently…
15
Excellence in assembly
Testing room: 880 m 2
•
Built-in: natural gas, oxygen, water, high
pressure air
•
Gases use in bundle: nitrogen, hydrogen,
argon, sulfur, helium
Additional testing room facility: 6.000 m2
Managing concurrent assembling tasks:
•
5 m/c’s | EEH7 line
•
4 m/c’s | DEQ 576 line
•
5 m/c’s | EEH8 line
•
4 m/c’s | DEQ mount
•
2 m/c’s | J304
16
Logistics, support
In-house capabilities:
•
Jib crane with 12 tons capacity
Packaging and moving capabilities with our
validated GE partners.
Handling shipping and customs.
17
Energized assembly team worldwide
Managing multiple projects
40+ automated machines to build, included
3 complete lines in 2014
Global availability
Separated integrator teams on multiple
locations across the world
18
Project (Location) | Team HC
Integration teams
Q4
2012
Q2
Q1
Silver PAR (USA) | 9
Environment project (HUN) | 4
Molding m/c (India) | 4
Q4
Q3
2013
EEH lines (HUN) | 6
GH Hand.Sys. (USA) | 3
Ravenna (USA) | 5
2013
Q1
Q2
3-way WEGO I. (MEX-HUN) | 10
Mount & Mat. Hand Sys. (USA) | 5
EEH lines (HUN) | 6
Silver Par (USA) | 6
3-way WEGO (MEX-HUN) & Apollo (MEX-USA) | 12
Q4
Q2
Ravenna (USA) | 5
H-box mod (HUN) | 4
NT line move (HUN) | 14
GH Hand.Sys. (USA) | 3
Q1
Q3
Q4
2014
Q1
Q2
Case study
20
Project Case Study
Scope
Purpose of project
To design and build a High Speed EEH capsule making line to be installed in GE Lighting’s
halogen manufacturing plant in Mattoon, IL.
Creating
concept
Design and
manufacture
Support and
utilities
Training in
Mattoon
GE EEH product: New glass halogen capsules using hard glass tube.
Drawings
Spare parts
Manuals
Project Case Study
Schedule
Sep
PO & Project start
Oct
Nov
Dec
Jan
Feb
Mar
Apr
May
Jun
Jul
Aug
Sep
Oct
Nov
Sep 9
Feb 3
M design
Jun 30
E design
Sourcing
Mar 24
Machining / Cutting
Apr 28
M Assy'
May 12
E Assy'
May 12
Debug/Test/EVP
Jul 28
Pack/Ship
Sep 15
Install/PVP
Project
Lifetime
In months
Quote
Prepare
Concept
Design
2
4
stretched process…
Nov 10
Realizing
7
Install
Debug
3
Logistics
Support
2
15 months
from Idea to Production
22
Project Case Study
Safety
Overview
Electric safety must follow GE & Mattoon LP requirement
Noise level not exceed by 85dB
Major features
The line output is 1850/hour good capsule
Yield: 95-99%/machine
Shrink rate: max 1%
Drive mode: Independent drives, indexing motion
Parts from unit to unit are fully automated. No manual effort.
Operation mode
Machines are connected with accumulator chains
Indexing mode without logic control
Utilities
Jog mode with logic control
Electric energy
Natural gas
High pressure air
Water
Nitrogen
Oxygen
Forming gas
Vacuum
Machines controlled by PLC and has independent control cabinet
Automatic mode
Manual mode (using crank or hand wheel)
Chains: Asynchrony motor drive both ends
23
Project Satisfactions
# of m/c’s
Customer
Project
Product
Procter &
Gamble
Mostly built-to-print
project with effective
simplifications and
system upgrades
pantyliner &
tampon
7
Build material handling
system for process
automation by handling
lamp components and
parts by conveyor
system
process
development
3
Build H4 baking
machines for a lamp
component
manufacturer based on
a GE design
baked H4
lamp head
2
Design an manufacture
automated mounting
machine for a non
lighting GE plant
circuit
breaker
1
(Hungary)
GE Lighting NA
(USA)
Autonix
(India)
GE Power
Controls
(Poland)
24
Do you have an Idea? | Contact us:
Szabó, István: istvan.szabo5@ge.com
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