FIR COMPANY FORM-PLAST S.A. INTRODUCTION BYDGOSZCZ, POLAND
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1 FIR COMPANY FORM-PLAST S.A. INTRODUCTION BYDGOSZCZ, POLAND
2 LOCATION Bydgoszcz Poznań 130 km Bydgoszcz Warszawa 270 km Bydgoszcz Gdańsk km FORM-PLAST S.A Bydgoszcz, ul. Torunska 143 tel.: , fax: form-plast@form-plast.com.pl
3 BIRD FLIGHT VIEW Our factory occupies an area of sqm, including production facility area of sqm, warehouse with pallettes capacity and office space of sqm total.
4 Office
5 CORE ACTIVITIES INJECTION MOULDING MOULD MANUFACTURING PAINTING
6 VISION to integrate different technologies painting surface treatment CUSTOMER R&D prototype moulds testing Injection moulding ultrasonic welding assembly Prototype Tools CNC Mill
7 COMPANY STATUS LAW STATUS: Joint-Stock Company since 2008 Established in 1978 Employement: peoples MAIN MARKETS: Automotive TV/LCD/LED Logistic - Packaging System Main customer in plastic products: Faurecia, Toyota Boshoku, Olsa, Delphi, BMW, Volvo Truck, Volvo Car, Magna, TYCO Electronics, Loewe, Sharp, LGE, TPV, 3M. Main customers in moulds manufacturing: Toyota Boshoku, Faurecia, TRW, Olsa, Shapersgroup, Volvo 3P, Volvo Truck, Thule, Delphi, Magna, Valeo, Loewe, LG, Sharp, Samsung, Electrolux, 3M, Lear
8 REFERENCES
9 DIVISIONS INJECTION MOULDING TECHNOLOGIES: One component parts up to 33 kg Two-component parts Gas assisted moulding RHTC Moulding Overmoulding with inserts 75 INJECTION MACHINES:
10 INJECTION MACHINES REVIEW LP Injection machine Producer Screw diameter Screw type Pillar distance Injection Pressure Shot weight [g] Tool height Flange diameter [mm] 1 Arburg 220E Arburg 22 Azot. 220 x Arburg 220E Arburg 22 Azot. 220 x HRV 30 Huarong 18 Azot. 310x SM 50 Asian Plastic 25 Azot. 310x KM 50 E Kraus Mafei 25 Azot. 340x HRV 60 Huarong 22 Azot. 320x VE 70 E Negri Bossi 28 Bi-m. 360x WH 80 Metalchem 40 Azot. 340 x HRV 80 Huarong 28 Azot. 370x KM 80 E Kraus Mafei 30 Azot. 425x JSW 110 E JSW 40 Bimet 404x VE 90 E Negri Bossi 35 Bi-m. 400x SM 90 Asian Plastic 36 Azot. 360x UT 90 Żywiec 35 Azot. 355x HRV 100 Huarong 32 Azot. 420x KM 110 E Kraus Mafei 40 Azot. 490x SM 120 Asian Plastic 41 Azot. 410x SM 120 Asian Plastic 41 Bi-m. 410x VE 120 E Negri Bossi 40 Bi-m. 450x LF 137 H LienFa 35 Azot. 452x VE 160 E Negri Bossi 45 Azot. 510x UT 175 Żywiec 50 Azot. 480x SM 210 Asian Plastic 60 Azot. 500x VE 210 E Negri Bossi 52 Azot. 570x KR 250 Krupp Azot. 505 x 505
11 INJECTION MACHINES REVIEW LP Injection machine Producer Screw diameter Screw type Pillar distance Injection Pressure Shot weight [g] Tool height Flange diameter [mm] 26 SM 250 Asian Plastic 67 Azot. 560x BSKM 800 Battenfeld 60 Azot. 560 x VE 300 E Negri Bossi 60 Azot. 630x LF 320 H LienFa 55 Bi-m. 610x LF 320 H LienFa 65 Bi-m. 610x UT 340 Żywiec 65 Azot. 692x SM 350 Asian Plastic 75 Azot. 695x SM 350 H Asian Plastic 60 Azot. 720x SM 350 H Asian Plastic 60 Azot. 720x SM 450 Asian Plastic 75 Azot. 780x SM 450 H Asian Plastic 67 Azot. 820x SM 450 H Asian Plastic 67 Azot. 820x LF 507 H LienFa 65 Bi-m. 710x LF 507 H LienFa 70 Bi-m. 710x LF 507 H LienFa 75 Bi-m. 710x SM 550 Asian Plastic 90 Azot. 845x BSKM 2000 Battenfeld 80 Azot. 795 x SM 600 Asian Plastic 93 Azot. 860x LF 707 H LienFa 75 Bi-m. 860x LF 707 H LienFa 80 Bi-m. 860x LF 707 H LienFa 85 Bi-m. 860x SM 850 Asian Plastic 100 Azot x LF 837 H LienFa 90 Azot. 1005x LF 837 H LienFa 100 Azot. 1005x Sandretto 800 Sandretto 90 Azot. 920 x SM 900 Asian Plastic 110 Azot. 1060x
12 INJECTION MACHINES REVIEW LP Injection machine Producer Screw diameter Screw type Pillar distance Injection Pressure Shot weight [g] Tool height Flange diameter [mm] 52 SM 1100 Asian Plastic 120 Azot. 1250x SM 1200 Asian Plastic 110 Azot. 1220x SM 1200 Asian Plastic 130 Azot. 1220x LF 1270 H LienFa 100 Azot. 1210x LF 1270 H LienFa 110 Azot. 1210x SM 1500 Asian Plastic 130 Azot. 1520x LF 1670 H LienFa 120 Azot. 1520x LF 1670 H LienFa 150 Azot. 1520x SM 1800 Asian Plastic 145 Azot. 1820x LF 2070 H LienFa 180 Azot. 1805x SM 2500 Asian Plastic 160 Azot. 2020x LF 2570 H LienFa 180 Azot. 1905x LF 3070 H LienFa 220 Azot. 2005x ES80H /25 Engel 18 Azot. 66 BSKN 700 H Battenfeld 38 Azot. fi F85 Feromat Klockner 2x 30 Azot. 380 x ES 2F 60/100 Engel 25, 28 Azot. 510 x HDC 160 B Huarong 2x34 Azot. 640x x SM 250 Asian Plastic 36, 46 Azot. 970 x HDC 300 Huarong 2x44 Azot. 910x x HDC 500 Huarong 2x55 Azot. 1100x x
13 DIVISIONS Subcomponents assembly into complex modules: ASSEMBLY sealings glue tapes screwing/riveting ultrasonic welding decorating assembly of purchased parts
14 INJECTION MACHINES REVIEW
15 H&C TECHNOLOGY HEAT & COOL The technology HEAT & COOL enables to achieve high quality of visible surfaces.
16 DIVISIONS PAINTING 3 FULLY AUTOMATIC PAINTING LINES, EACH EQUIPPED WITH: preparation stands 6-axis painting robots (FANUC) IR or hot drying tunnels cleaning/reworks stands quality inspection tampo printing silk screen paint Maximum part size: Maximum size of part: x 800mm Maximum height: 280 mm
17 DIVISIONS PAINTING
18 ASSEMBLY PAINTING Our painting technology is fully automatic the further works will be effected on next montage stages.
19 AUTOMOTIVE PARTS Housing
20 AUTOMOTIVE PARTS Sealing Box Canister Control Panel
21 Cable Channel AUTOMOTIVE PARTS
22 AUTOMOTIVE PARTS Clamp Heater Clamp(Thule) Air conditioning lever
23 Front door cover AUTOMOTIVE PARTS
24 Cover wheels AUTOMOTIVE PARTS
25 AUTOMOTIVE PARTS Foot step lower GrillDV & MV
26 Sealing Collar AUTOMOTIVE PARTS
27 PROJEKT MGMT TV / LCD / LED PARTS
28 PACKAGING SYSTEM
29 TOOLSHOP includes: MOULD MANUFACTURING DEPARTMENTS: Design and Developement Office Planning and management team Plastic flow simulation unit Technologists and programmists office Spark erosion unit Toolsmith unit Quality unit Injection mould warehouse
30 Design and development : TOOLSHOP includes: COMPUTER SOFTWARE
31 TOOLSHOP includes: MOULD MANUFACTURING PROJECT MANAGEMENT Each project is managed by one project leader Planning in Microsoft Project System
32 DIVISIONS MOULD MANUFACTURING Manufacturing of the moulds with maximum weight up to 30 Tons Machines in toolshop: 3-Axis CNC Milling machines 5-Axis CNC High precision milling machines Turning machines Grinding machines EDM + Electrods making (11 pcs.)
33 Design and development : TOOLSHOP includes: 3-AXIS MILLING MACHINES: 1. HARTFORD HEP-3150 SG 3250x1500x1040 mm 2. HARTFORD HV x780x500 mm 3. FADAL VMC x750x650 mm 4. FADAL VMC x500x500 mm 5. HASS VM x660x635 mm 6. DECKEL MAHO 103V 1000x600x600 mm 7. HARTFORD VMC x510x510 mm 8. MAZAK FJV x980x500 mm 9. HASS/MIKRON VCE x300x250 mm MILLING MACHINES 5-AXIS MILLING MACHINES: 1. MAHO DECKEL DMU 70 EVOLUTION 790x600x520 mm 2. MAHO DECKEL DUO BLOCK 100P 125T 1000x1000x1000 mm 3. FIDIA K x1250x1400 mm 4 4-AXIS MILLING MACHINES: 1. CME FS2 2000x1000x1000 mm 2. MAHO DECKEL DMU 125T 1250x880x800 mm 3. MAZAK VTC-20B 1120x510x510 mm INTEGRATED MILLING CENTER: 1. Mazak Integrex 200 IV S fi 660x1045 LONG CHANNELS DRILLING MACHINE: IXION TLF AXIS (2000 x 2000 x 800 mm)
34 Design and development : TOOLSHOP includes: SPARK EROSION MACHINES DEPTH EROSION MACHINES (EDM): 1. SURE FIRST 1080EDM 970x800x505 mm 2. CHARMILLES ROBOFORM 900x600x450 mm 3. SODICK AQ 75L 700x500x350 mm 4. SURE FIRST CNC x300x300 mm 5. CHARMILLES D x250x150 mm 6. EDEC 40 EROMEX 400x250x150 mm 7. EDE x250x150 mm 8. SODICK AM 3L 300x200x250 mm WIRE EROSION MACHINES: 1. JAPAX LDM x600x300 mm 2. JAPAX LDM x600x300 mm 3. FANUC ROBOCUT OC-1C 500x500x395 mm 4. SURE FIRST DW x300x200 mm Milling Electrodes: 1. HAAS MINI MILL 400x300x250 mm 2. SURE FIRST MG x400x600mm 3. MAZAK IMPULS 300x200x250 mm
35 Design and development : TOOLSHOP includes: SIMULATION ON INJECTION PROCESS
36 Design and development : TOOLSHOP includes: Making of programs for milling in CNC machines (3 - Axis, 4 - Axis, 5 - Axis) TECHNOLOGIES Making of program for engraving in CNC milling machine Simulation programs for Multi- Tasking Machines
37 Design and development : TOOLSHOP includes: TECHNOLOGIES Design and making of electrode for spark erosion Making of program for wire erosion Design of device for milling machine for serial production.
38 Design and development : TOOLSHOP includes: MILLING MACHINES 3-Axis 5- Axis Multi-Tasking Machines
39 R&D FROM CONCEPT TO REALISATION Project Car lamp 1) Technical design concept 2) 3D file of the injected part 3) Plastic flow simulation 4) 3D file of injection mould 5) Timing schedule 6) Injection mould book 7) Manufacturing of the mould 8) Measuring of the mould 9) Testing
40 R&D 3D files of the parts Plastic flow simulation 3D of injection mould
41 R&D Injection mould book Manufacturing of the mould
42 R&D Measurements Samples
43 QUALITY CERTIFICATES Q1 AWARD since 2007 ISO/TS 16949:2009 ISO 14001:2004 PN-N-18001:2004
44 QUALITY FACTORS KEY PERFORMANCE INDICATORS for 2014: quality performance PPM = 19 delivery performance 99,92%
45 QUALITY EQUIPMENT EQUIPMENT: FORM-PLAST S.A. is equiped with 250 quality assurance devices that guarantee effective measurings for automotive industry: - 3D-Measuring machine Mitutoyo - Slide caliper - Micrometer - Microscope - Highmeter - Glossmeter - Dynamometer - Digital weight - Special tools for securing special factors or part functioning areas - other devices used in injection, painting, assembly and toolshop departments
46 New CNC CMM with laser scanning Ranges in axis: X1200*Y3000*Z1000mm QUALITY EQUIPMENT
47 Design and development : TOOLSHOP includes: QUALITY EQUIPMENT Manual CMM Mitutoyo M7106
48 QUALITY EQUIPMENT Measurement arm with digital handheld laser scanners
49 QUALITY EQUIPMENT Microscope dimension and angle measurement
50 QUALITY EQUIPMENT Roughness measurement
51 QUALITY EQUIPMENT Colour inspection Spectrophotometr 2500c with 45/0 geometry, is a portable, hand-held equipment designed to measure, match and control the colour of small, irregular surfaces as well as substrates with grain and texture. Conformity with Volkswagen standards. Software Spectra Magic Pro
52 QUALITY EQUIPMENT Gloss inspection Microgloss Elcometer Dynamomether Push pull test
53 We have computer system for monitoring of measuring devices as follows: - tracking of control dates of standard measuring devices - indentification of measuring devices with internal register - the program includes all measuring devices used in FORM-PLAST. QUALITY EQUIPMENT
54 Design and development : TOOLSHOP includes: QUALITY AUDITS Quality audits in : Date Company Audit scope Result Johnson Controls Quality System Audit Green Volvo 3P Process Audit Positive Skoda / VW Audit VDA % (class A) PZL Mielec Quality System Audit Positive Scania Quality System Audit Positive Tensho Poland Corp. Process Audit 86% (Green) FIAT Quality System Audit 89% (Green) Johnson Controls Quality System Audit 88,00% Tyco Electronics Quality System Audit 84% (class B) LG Electronics Process Audit 85,3% (class A) PAS Process Audit 92% (class A)
55 QUALITY AUDITS Quality audits in : Date Company Audit scope Result Delphi Thermal Process Audit 94,7% (Green) Magna Quality System Audit 91% (Green) Scania Quality System Audit Positive Husqvarna Quality System Audit 98% (class A) Peguform Quality System Audit Positive LG Electronics Quality System Audit 80% (class B) LG Electronics Technical Audit 85% (class B) BMW Quality System Audit Positive M OHSAS audit 97,6% (class A) Faurecia Quality System Audit 80% (class B) Boshoku Quality System Audit 90% (class A) M Quality System Audit Positive SRG Global Quality System Audit 95% (class A) Boshoku Process Audit 95% (class A) Loewe Process Audit 80,5% (class A) Diehl Controls Proces and System Audit 91% (class A) M Argentina Proces Audit Positive Delta Tech Proces audit 80% (class AB) Delphi Audit MCA 93% (Green) OLSA Audit procesu 97% (class B) FIAT Audit procesu 81% (Green) TÜV Rheinland Audit ISO/TS Positive
56 SALES - MAIN CUSTOMERS
57 SALES - MAIN CUSTOMERS
58 CONTACT We hope that this presentation will encourage you to enter into cooperation with Form-Plast S.A. Tel:
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