Ulus Metal. 9-Apr-14

Transcription

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2 History : 1970 Production of stamped metal parts for automotive industry 2007 Moved to a new plant in Gebze Industrial zone on a 8000 m 2 closed area First non-automotive business started Total Number of employees : 125 Number of shifts : 1 shift 2

3 Worldwide Customer Portfolio KYB Suspension Europe S.A. Spain TENNECO AUTOMOTIVE Spain, Belgium, Germany, Czech, Poland, USA THYSSENKRUPP BILSTEIN Germany, Romania, USA ZF SACHS Turkey, Germany, Slovakia, Spain MAYSAN MANDO Turkey ISUZU Turkey WABCO Germany, Poland, USA, Brasil, China, India EMERSON Climate Technologies Northern Ireland, Czech Republic, USA, Belgium, China KNORR BREMSE Hasse&Wrede Germany AL-KO Spain KONI Holland, Czech RECORD France MAGNETI MARELLI Poland GABRIEL Europe France BWI (DELPHI) Poland 3

4 Shock Absorber Parts Ulus Metal Overview Product Families Spring Seats Rolled Rings Bracket Assemblies Holders Stabbar Brackets Caps Truck and LCV Chassis brackets Eyering Assemblies Washers 4 4

5 Overview Product Families Brake System Components Cooling Compressor Components Machined Parts 5

6 ZF Sachs Slovakia Ulus Metal Main OEM automotive projects 1/4 Fiat 330 Idea & Lancia & Grande Punto MFA EVO Alfa 955 (Mito) Y413 XC60 ZF Sachs - Germany W212 Magneti Marelli Fiat Fiorino 330 6

7 Main OEM automotive projects 2/4 ZF Sachs - Turkey Fiat Doblo & New Doblo 263 & Fiat Palio & Fiat Albea Renault L38 / Fluence Ford Transit V184/V347 New Transit V36X Ford Connect V227 7

8 Maysan Mando - Turkey Ulus Metal Main OEM automotive projects 3/4 Hyundai MC Hyundai IA Renault Clio Symbol Renault Trafic (X82) Tenneco (Monroe) Germany & Belgium Renault Clio 4 (X98) BR172 SLK 8

9 Main OEM Automotive projects 4/4 ISUZU - Turkey NPR Trucks and NKR Light Duty Trucks Buses Supplier for chassis parts. ThyssenKrupp Bilstein - Romania & Germany X

10 Project Management Experienced Project Management Team In house stamping die design and manufacturing Production flexibility for AM and OEM Projects Fast Prototype sampling Reverse engineering for AM projects 10 10

11 Toolshop CAD systems : Siemens NX, Mastercam, EzCam Capabilities : Wire EDM CNC vertical machining CNC turning Surface grinding Conventional turning and milling machines 11 11

12 Production Shopfloor Transfer lines (600t-250t) Mainly for high volume projects Transfer presses with 3D transfer arms (X-Y-Z axis) 600 Tons 600 Tons 400 Tons 350 Tons 250 Tons 12

13 Production Shopfloor Transfer Press Transfer tool design and manufacture Movie: Spring Seat Movie: Outer Bracket 13

14 Production Shopfloor Progressive lines Progressive tools for higher volume parts Tool capability of on one shot 1 2 or 4 parts production 100 Tons 250 Tons 300 Tons 350 Tons 400 Tons 500 Tons 14

15 Production Shopfloor Progressive Press Progressive tool design and manufacture Progressive tool for stabiliser bracket Movie: Inner Bracket 15 Steel band view of stabiliser bracket 15

16 Production Shopfloor Hydraulic Press - Deep Drawing Movie : Production of deep drawn shell (2nd Operation) Hydraulic presses with hydraulic hole punching machines 600 Tons 250 Tons x Tons Depth : 500 mm Diameter : 275 mm 16

17 Production Shopfloor Manual tandem stamping (400t-30t) Wide range of presses for less volume productions 40 presses from 30 Tons up to 400 Tons 17

18 Production Shopfloor - CNC Machining Movie : Production of muffler plate assembly 18

19 Production Shopfloor Shock Absorber Body Welding Line Machines for producing Shock Absorber Body Assembly (Automated Welding Line, welding fixtures, press-fitting presses, leakage test units, punching presses, control fixtures) Movie: Robot Welding of Bracket Assy 19

20 Mag Welding Line 100% parameter controlled Cloos Welding Machines 500A welding power source Servo controlled rotating movement torch MAG welding on upper mount assemblies Spot Welding Line Projection welding inner&outer knuckle brackets, hose holders, ABS cable holders Welding tools manufactured inhouse Welding power kva Production - Welding Poka Yoke System for Renault Bracket Assy 20

21 Auxiliary Operations IN-HOUSE : Deburring Thread cutting Riveting Chamfering OUTSOURCED : Surface treatment (Zn-Fe coating, Zn-Ni coating, KTL painting) Heat Treatment 21

22 Raw Materials Used MATERIAL TYPES Hot & Cold Rolled Steel (DD11, DD12, DD13, S315MC, S355MC, S420MC, DC01, DC03, DC04) Profile material for rolled rings Stainless Steel AISI 304 (1.4301) MATERIAL THICKNESSES From 0,5 mm up to 6 mm 22

23 Measurement Capabilities Laboratory capabilities CMM DEA with PCDMIS-CAD ++ software with rotating and scaning probe CMM Table Size : 1200x1500x1000 CMM Table Size : 2700x1000x6660 Shadow projector device Pull-out test device (5t capacity) Flatness measurement device Welding strength test and penetration test devices 23

24 Quality system certifications Certified by SGS for ISO TS ISO 9001: 2008 ISO OHSAS

25 New Investments New Investments 800 tons Mechanical Transfer Press (Delivery in August) CNC Milling Machine Spot Welding Machine (750 kva) Coil Feeders 25

26 ULUS METAL Contact information: Company Name : Ulus Metal Sanayi ve Ticaret Limited Şirketi Address Telephone no. : Gebze Organize Sanayi Bölgesi Sokak No Gebze-Kocaeli/ Turkey : lines Fax no. : Web site : [email protected] :

27 ULUS METAL Thank you for your attention 27 27