BCC located Aluminium HPDC foundry
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one of the largest foundry in CZ
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> 50 mil € annual sales
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> 12.000 tons Al annual production
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> 1000 employees
All services under one roof
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engineering (design & development)
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tool shop
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aluminium die cast foundry
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mechanical machining
Presentation structure
•
general information
•
production shops description
•
new foundry
•
innovations
•
summary
Presentation structure
•
general information
•
production shops description
•
new foundry
•
innovations
•
summary
History
Long tradition…
1816
foundation (iron works)
1930
first press machines
1945
Al alloy specialization after World War II
1992
privatization - M. Production
1994
KOVOLIS HEDVIKOV Ltd (formation)
1996
KOVOLIS HEDVIKOV, share co. (transformation)
1996
machining shop establishment
2006
2nd tool shop acquisition
2011
new foundry opening
History, since 1816
Long tradition…
1816
founded as ironworks
Mr. Josef Jan Zvěřina
production of 10 - 20 tons of rough iron and alloy
30 employees
1930
steam casting machines, patent purchase
machine production
casting production
History, since 1816
Long tradition…
1945
castings made of aluminium alloys
Mr. Jindřich Valecký – die casting Guru in the Czech Republic
History, since 1816, new history since 1996
Long tradition…
1992
privatization Metal Production spol. s r.o.
1994
Kovolis Hedvikov spol. s r. o. (LTD)
1996
KOVOLIS HEDVIKOV a. s. (stock company)
Company - organization chart
Private ownership
Linear structure,
cross-functional scheme
Company – quality system
Certification
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ISO/TS 16949: 2009
certification since 2003
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ISO 14001 Environmental
Management system since
December 2014
Worldwide services
LCC production, worldwide supplies
Production settled in the Czech Republic – BCC (Best Costs Country)
Worldwide supplies to:
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Europe (90%)
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USA – Honeywell, Krones, Wabco
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Brazil – Wabco, PSA
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Argentina – PSA
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Japan – Honeywell
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Mexico – Honeywell
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India – Honeywell, Wabco
Foot print, production sites
Localized in the middle of the Czech Republic
Pardubice
Prague
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since 2006
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design
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tool shop
Ronov nad Doubravou
Třemošnice
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development
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design
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since 1996
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tool shop
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machining shop
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foundry
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sub-assemblies
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machining shop
Location
Main production plant
Třemošnice, November 2010
Location
Main production plant
Třemošnice, November 2011
new since July 2011
Economy & finance
Sales (mil. EUR)
Production & sales
Casting production (tons)
Employees
Customer‘s portfolio split (Y2014)
With 10 customers achieving 80% of our sales
Customer‘s portfolio split (business plan Y2015)
With 10 customers achieving 80% of our sales
Y2014
Market and products
Brake systems
Compressors
Belt tensioners
Turbos
Compressors
Brackets
Drive systems
Heat exchangers
Telecomunication
Hydromounts
Steering applications
Engine accessories
Textile machines
Wiper systems
Brackets, halters
Compressors
Strategic targets
Continuous, sustainable growth
• Customer satisfaction - exceeding all the requirements of our Customers
• orientation on strategic Customers
• motivated employees, safe environment
• product development strength
• ready to install production
(complexity through machining and sub-assembly)
• innovative products introduction
• continuous quality improvement
• company competitiveness (QCD)
Presentation structure
•
general information
•
production shops description
•
new foundry
•
innovations
•
summary
Services
All under one roof
Development
Design
Tool shop(s)
Foundry
Mechanical machining
Subcontracts / specialists
Design and development
Theory to praxis
Part design, calculations
Part optimalization
CAD - Software
• Unigraphics Software
• Solid Edge
• Solid Works
• Pro-Engineer
• Catia V5
CAE – Software
• Pro Cast - Material flow
simulation
Tooling shop(s)
Majority of the tools made in house
2 tool-shops
• local - KH Třemošnice
• acquired - SH Pardubice (appx. 30 km)
Equipment
• CNC & conventional machines and equipment
• HSC machines (3x Maho Deckel (DMU)), 2x MAS Kovosvit
• EDM (electro erosion machines) 4x
• Wire cut machine (Fanuc)
• spot press
~ more then 100 moulds p. a. produced
Melting shop
Good material is a basis for any next processes
Alloys
• EN AC-46000 / EN AC-AlSi9Cu3(Fe)
• EN AC-43400 / EN AC-AlSi10Mg(Fe)
• EN AC-44300 / EN AC-AlSi12(Fe)
• EN AC-47100 / EN AC-AlSi12Cu1(Fe)
• ADC 12
• AlSi9Cu3 acc. PSA standard
• AlSi9Cu3 acc. GKN - Stenal 460
• ADC 14
• EN AC-42100 / EN AC-AlSiMg0,3
12 melting furnaces
• 3 x Striko Westofen (shaft) [1.000 kg / hod]
• 1 x Marconi (shaft) [1.500 kg / hod]
• 1 x Striko Westofen (shaft) [1.500 kg / hod]
• 2 x Morgan (electro crucible) [250 kg / hod]
• 1 x Morgan (gas crucible) [350 kg / hod]
• 2 x Lac (gas crucible) [350 kg / hod]
• 2x UVP (gas crucible) [400 kg / hod]
Inspection
• 2x spectro analysis / chemical composition inspection
• 2x density index / dross test
Auxiliaries
• degassing (nitrogen)
Casting shop
HPDC technology
Including
• shot control (real time) – all robotized cells
• vacuum assisted die casting
• local squeeze casting
• jet cooling
29 fully automated cells
• metal dosing (ladle or dosing furnace)
• extracting robot (ABB/Reis/Kawasaki)
• sprayer (Wollin)
• trimming
30 press machines
• 1 x RTL 3-250 (automated)
• 2 x RTL 5-400 (automated)
• 2 x RTL 5-500 (automated)
• 5 x Bühler Evo 530 (automated)
• 1 x CLH 630
• 2 x RTL 5-750 (automated)
• 3x Toshiba 650 J-MS (automated)
• 8x Toshiba 800 J-MS (automated) – last installation – 2 sets - 03/2015
• 4 x Bühler Evo 840 (automated) – last installation – 03/2015
• 2 x Bühler Evo 1050 (automated)
• next installations:
Buehler 660: November 2015
Toshiba 800: May 2016
Casting shop
Inspection & control
Equipment
• vibro-deburr (Rössler / Troval)
• shotblasting (Disa, Rössler)
• furnace to treatments as T5, special heat treatment (annealing)
Inspection
• X ray Seifert 160 kV
• 9x 3D - CMM (8 x WENZEL + 1x DEA)
• profile/contour meter
• form tester
• metallurgical microscope
• tensile testing machine
• hardness tests equipment
• UV penetration test
• pressure leakage tests
Machining – Třemošnice and Ronov n. D.
Equipment
41x CNC centers
• Chiron FZ15, Chiron FZ15 Ma, Chiron FZ08W
• Chiron DZ15 (12x)
• FANUC -T21 iFL; AkiraSeiki
• Haas VF2, VF3
25x CNC lathe machines (4x vertical)
• Okuma LVT, LB 250, LB 300
• Takisawa TT200, TC-200
• Index V200
• Haas TL15 / SL20
• Moriseiki NL2000SY
• Famar Pronto 5
special dedicated machines
conventional equipment
pressure leakage tests (air drop evaluation)
assembly
Sub contracting management
Additional possibilities
Electron beam welding
Passivation processes
Impregnation processes
Presentation structure
•
general information
•
production shops description
•
new foundry
•
innovations
•
summary
Increase of capacities, new methods, innovations
Increase of capacities, new methods, innovations
From November 2010 to November 2011
New building
Production area:
External covered area:
Manipulation area:
11 cells installed, 8x
800t, 3x 650t
+ 2x melting furnace
each 2000 kg/hour
5 600 m2
770 m2
6 300 m2
space for additional 2
press machines
(800-1000t)
machining shop
~ 20 CNC machines
central cleaning
Features – target figures, capacities
Target values
General Targets
• increase of production capacities
• progressive technologies application
• lean, complete production flow
(casting –> machining –> assembly –> dispatch)
Equipment
• up to 13 die casting cells (11 on-site nowadays)
total company up to 33 cells, locking force 250t – 1000t
• mechanical machining:
multi-spindle CNC machines
dedicated machines
production cells
Output
• additional 5.000 – 7.000 tons p. a.
company as total 13.000 tons p. a
Employees
• company as a total, appx. 900 employees
Presentation structure
•
general information
•
production shops description
•
new foundry
•
innovations
•
summary
Innovations in order to bring more value to Customer
Our targets
Better internal casting quality
• decreased porosity level
• minimization of porosities and shrinkage
• minimization of cold flows
• leakage avoidance
• dimensional stability
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o
o
o
WFR
JET COOLING
MASTER SQUEEZE
HIGH VACUUM
Better properties / utility values
• mechanical resistance
• strength
• hardness
• elongation
o RHEOCASTING
New methods
o LOST CORES
o LOW SPEED CASTING
o HYPEREUTECTIC ALLOYS
Innovations, running projects
WFR lubrication & Jet cooling
WFR lubrication is a water free release agent (separator).
• no water – gas porosity reduction
• no temperature shock – longer die lifetime
• cycle time reduction
• waste water reduction
Jet cooling
• cooling of very thin cores (diameters of 4 mm)
• combination of water cooling with air flush
Innovations, running projects
Squeeze master
Squeeze master is local squeezing with precise control of
timing, speed and pressure.
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minimization of shrinkage porosity
reduction of gas porosity
high homogeneity in squeezed areas
good pressure tightness in squeezed areas
increased mechanical properties in squeezed areas
Innovations, running projects
High vacuum
Vacuum assisted casting with higher vacuum and better
process check and control.
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gas porosity minimization
possible to precisely fill thin walls and „blind“ shapes
increase of pressure tightness
high structural density
possible to produce weld able casting
possible to perform heat treatment
Innovations, running projects
Rheocasting
Semisolid casting
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almost zero gas porosities
considerably reduced shrinkage porosity
fully heat treatable castings
fine globular structure
mechanical properties at least 50% higher to standard HPDC
tensile strength
elongation
excellent pressure tightness
possible to cast low iron alloys
low casting temperature
low gate speed
much more higher tool lifetime
lower dynamic loading of casting machine
faster machine cycle
Innovations, new methods – road map, next steps
Lost cores
Possible to cast parts with inner shapes
unable to cast by permanent molds.
• sand cores
• salt cores
Low speed casting
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low porosity
thick wall casting
low gate speed
higher tool lifetime
Hypereutectic alloys
• high wear resistance
• low thermal expansion
Presentation structure
•
general information
•
production shops description
•
new foundry
•
innovations
•
summary
Why KOVOLIS HEDVIKOV
Differentiation factors, cost, technology, quality
• privately owned, family company with the industrial background
(lean and flexible management decisions, reinvesting into new technologies)
• core competence – not a conventional, but an innovative supplier of the HPDC castings at a very high technological standard,
combined/supported by:
• all services ‚under one roof‘ concept – development (concurrent engineering activities and part development), tooling design,
tooling production, casting, machining and, assembly and management of the additional added value services (as a surface
treatment)
• footprint: biggest foundry in the Czech Republic, grow potential and capacities
• learning and implementing Japanese style, utilizing Japanese technologies and spreading the innovations
• project management (key accounts) way of project work
• quality mindset - QRQC (quick response quality control) & QR6s quality control systems (problem solving tools) implemented
and deployed
Contact details
KOVOLIS HEDVIKOV a.s.
Hedvikov 1, P.O. BOX 31
538 43 Třemošnice
Czech Republic
telephone:
FAX:
general e-mail :
+420 469 619 111
+420 469 619 103
kovolis@kovolis-hedvikov.cz
your contact person:
Miloslav Pavlas jnr.
sales manager
+420 469 619 320
m.pavlas@kovolis-hedvikov.cz
telephone:
e-mail :
GPS: 49.8693806, 15.5924036
VAT Nr.:
Registration Nr.:
Bank details:
CZ61058041
61058041
Volksbank, 1030002247/6800
www.kovolis-hedvikov.cz