KVALITETSKONTROLL I AUTOMATISERTE PROSESSER. Maskineringsforum 2013 Raufoss Grotberg/Andersen/Hemyari

Transcription

1 KVALITETSKONTROLL I AUTOMATISERTE PROSESSER Maskineringsforum 2013 Raufoss Grotberg/Andersen/Hemyari

2 CONTROL IS NOT VALUE-ADD DHe

3 PRESENTATION CONTENT Introduction to Benteler Typical Products BAT and BAS Production Value Chain Zero Defect Approach Examples Program for Plant Tour DHe

4 BENTELER AUTOMOTIVE Worldwide activity Benteler Automotive 2012 Sales: 5,880 million euros 22,760 employees 74 plants, 20 engineering and sales offices in 29 countries (Status 05/2013) Status May

5 BAT WORLDWIDE LOCATIONS Benteler Automotive in Nothern Europe Plant Sales office PG Engineering Status October 2012 DHe

6 PRODUCT GROUP MODULES PORTFOLIO 9 million modules/year Front suspension modules Rear suspension modules Corner modules Pony pack DHe

7 PRODUCT GROUP STRUCTURES PORTFOLIO (1/2) Carrier understructure Doorbeam Roof rail-reinforcement Windowsill-reinforcement Rear bumper B-pillar-reinforcement Rocker panel-reinforcement A-pillar-reinforcement Side member-reinforcement Front bumper Instrumentent panels Front tunnel Mountingplate front wall DHe

8 PRODUCT GROUP STRUCTURES PORTFOLIO (2/2) DHe

9 REGION BAS PORTFOLIO BAS (Benteler Aluminium Systems) supplies light weight solutions in aluminum Front rails and longitudinals Tower strut Stiffeners at tunnel linked to IP-beams Roof cross members Bumper beams rear ROPS Sill A/B-pillar Seat cross member Subframe components and assemblies at front and rear Bumper beams front Front module components DHe

10 PRODUCTION VALUE CHAIN Adding Value from Raw Material to Final Product Casting Extrusion Forming Finishing Casthouse optimised for 7000 alloys Scrap recycling Process optimized for 6000 and 7000 alloys Extrusion tool technology Improved die-life Higher extrusion speed DHe Integrated press- and stretch-forming technology Inline heat-treatment in the forming process at high productivity Punching-trimmingmachining operations linked directly to the forming Robotic deburring Robotic machining Large-bed CNC machining Welding Assembly

11 PRODUCTION VALUE CHAIN Adding Value from Raw Material to Final Product Casting Extrusion Forming Finishing DHe

12 BENTELER OPERATING SYSTEM LEAN ENTERPRISE (BOS LE ) Objectives and Principles Just-in-Time production through systematic reduction of waste by means of continuous improvement Aim: Improvement and stabilisation of the processes within the company Aim: Realisation of the line production through coupling and alignment of processes. Aim: The downstream process collects only the parts it needs. Aim: The achievement of a rhythm by harmonisation of the work contents. DHe

13 ZERO-DEFECT-PRINZIPLE Zero-Deffect-Part Product Quality = + Stable Processes DHe

14 ZERO-DEFECT-PRINCIPLE Product Quality Quality Gates + = + Defect Prevention System + Supplying Process PPS Receiving Process Quality-Cycles PPS Failure Management next Process DHe

15 ZERO-DEFECT-PRINCIPLE Stable Processes 5S + = + Defect Prevention System + TPM + Spare Part Management DHe

16 PROCESS CONTROL DHe

17 EXTRUSION PROCESS Puller Air cooling Puller/ saw Profile Cooling device Butt shear Tool set (Die) Extrusion Press Dummy block Container Billet Ram Run-out table Stretcher Billet Billet Loader Billet heater Profile saw Packing on pallets DHe

18 PROCESS CONTROL DHe

19 PROCESS CONTROL DHe

20 INDUSTRIAL TOOLS CHALLENGES ALU EXTRUSIONS TOLLERANCES Large profile tolerances Dimension variations from heat treatment Material variations due to alloying components Complicated forming tools (mandrel) DHe

21 INDUSTRIAL TOOLS Zero - Defect - Principle Simulation optimalization loops Yield stress distribution Development Design TOOLS Feasibility studies Type of tooling (calibration step) Stability Poka Yoke Trimming Testfasilities DHe

22 PROFILVERKET -PROSESSKONTROLL Ekstrudering av aluminiumsbolt til profiler SFOL Oversikt over prosess steg Dashboard Presser Prosessparametere-Billett Report Die Heater Sag Utherding Lab.- Testing Pakking - Avlevering SPC Verktøy vedlikehold SFOL Profilverket DHe

23 QUALITY ASSURANCE IN CONTINUOUS PROCESSES Do it right in the first place! DHe