OUR EXPERTISE FOR YOUR SUCCESS WITH

OUR EXPERTISE FOR YOUR SUCCESS WITH
CONTRACT MANUFACTURING
1
INDEX
2
OPERATIONAL ORGANIZATION
30
ABOUT PALFINGER
4
Vision & Mission
5
PALFINGER Europe GmbH - Lengau
32
The PALFINGER brand
6
Steel Construction Batch Production
36
Strategy & Goals
7
Steel Construction Custom Manufacturing
37
Company Profile
8
Hydraulic Cylinder Batch Production
38
9
Hydraulic Cylinder Custom Manufacturing
39
Electroplating
40
History
Organization
10
Management
11
REFERENCES
COMPETENCIES
41
12
Steel Construction
14
Hydraulic Cylinders
15
Electroplating
18
Surface Treatment - CED
19
Pre-Assembly Of Modules
20
TECHNOLOGY & PROCESSES
22
Quality Management
24
Quality Assurance Process
25
Classification Societies
26
RAP! Rapid Processing
27
Internal Fixture Construction
28
Adaptive Welding
28
Laser Hybrid Welding
29
3
ABOUT PALFINGER
4
VISION & MISSION
Worldwide, PALFINGER stands for the most
innovative, reliable and cost-effective lifting
solutions for use on commercial vehicles and
in the maritime field.
With our technological expertise and experienced staff, we set quality benchmarks
in the industries in which we operate. High
flexibility and competence in production
plus a global sales and services network give
us a crucial competitive edge and ensure our
customers LIFETIME EXCELLENCE.
5
THE PALFINGER BRAND
We promise LIFETIME EXCELLENCE. Our core
message. The essence of our brand. For our customers, this means: Top-quality performance with
no compromises. The most economical, reliable,
and innovative lifting solutions in a global network
of competent service partners - for the life of a
product.
BRAND VALUES:
6
≥
PROFITABILITY
≥
RELIABILITY
≥
INNOVATION
STRATEGY & GOALS
PALFINGER continuously strives for profitable
≥
growth with maximum shareholder value. The
the continuous improvement of products, trends through rapid adaptation of our
consideration of economic, ecological, and
processes, and organization.
resources and capacities and thus to ensure
Innovation is the result of our passion for societal aspects is viewed as fundamental for
the company’s success.
≥
Flexibility enables us to handle any market our business success.
≥
Internationalization guarantees our customers market-compliant products on PALFINGER has defined three strategic pillars
every continent and our company maximum for achieving the primary goals:
independence from regional economic
fluctuations.
Innovation
Innovation
Internationalization
Flexibility
Innovaattion
Innovation
Internationalization
Flexibility
7
COMPANY PROFILE
As a multinational company group with its
innovative and customized marine, offshore
headquarters in Salzburg, Austria, PALFINGER and wind cranes as well as launch and recovery
has manufacturing and assembly sites in
systems.
Europe, in North and South America, and
in Asia.
Around 65 percent of the PALFINGER Group
is owned by the Palfinger family and around
The core product is the truck-mounted
34 percent is in diversified holdings. 1 percent
knuckle boom crane. The company is the
of the shares are owned by PALFINGER AG.
world market leader in this segment, with a
market share of more than 30%. PALFINGER In 2013 the company generated a total sales
is also the world’s largest manufacturer of
revenue of 981 million EUR with a current
timber and recycling cranes and container
workforce of ca. 6900 employees.
handling systems. Over the years the product
range has been steadily expanded with
products such as truck-mounted forklifts,
tail lifts, and truck-mounted access platforms. With high-tech railroad systems and
bridge inspection units, PALFINGER is the
European technology and market leader in
this sector. Farm cranes as well as truck
bodies and pick-up tail lifts round out the
product range. PALFINGER MARINE is one
8
of the world’s leading manufacturers of
HISTORY
FROM A FITTER’S WORKSHOP
The company was founded in 1932 and is now
The pioneering phase, the era of the crane, and
TO A GLOBAL PLAYER
one of the world’s leading and most innovative
the period of expansion define the company’s
manufacturers of hydraulic lifting systems for
history. Today PALFINGER is a worldwide group.
commercial vehicles and in the maritime sector. Always close to the customer.
1932
1964
1989
1999
1992 - 2013
FUTURE
Richard Palfinger establishes
a metal working and repairs
workshop.
Specialization in hydraulic,
truck-mounted loading
cranes.
Export ratio over 90
percent for the first time,
presence in more than
70 countries.
Stock market launch in
June 1999.
Continuous diversification
and internationalization with
products at the cutting edges
of the transport chain.
PALFINGER is going to
consolidate its position as
technology leader.
9
ORGANIZATION
The PALFINGER organizational structure has
been regionally oriented since 2010. The Euro-
≥
Global distribution and service network
(more than 200 general importers/dealers ≥
28 distribution subsidiaries in more than
130 countries worldwide
pean business units as well as the areas outside and 4,500 distribution and service centers ≥
Europe have a large degree of autonomy so that worldwide)
(33 production and assembly sites)
they can best fulfill the demands of the respective markets.
PALFINGER DEALER NETWORK
Corporate locations
Headquarters
Dealers
As at 31. December 2013
10
Global sourcing, production, and assembly MANAGEMENT
BOARD OF DIRECTORS
Wolfgang Pilz
Christoph Kaml
Herbert Ortner
Martin Zehnder
Marketing Director
Chief Financial Officer
Chairman of the Board
MBA, Chief Operations Officer
11
COMPETENCIES
12
CONTRACT MANUFACTURING
We promise LIFETIME EXCELLENCE. Our core
The economic benefits are obvious. The wage
≥
Steel construction
message. The essence of our brand.
level of Eastern European sites in combination
≥
Hydraulic cylinders
with the high level of quality make PALFINGER
≥
Electroplating (chromium and nickel-
The core competencies of PALFINGER lie
a competitive and reliable system partner in the chromium plating)
chiefly in the production of safety-related
following areas:
≥
CED coating and spray painting
welded constructions (especially of high
≥
Assembly and pre-assembly of subsystems
strength fine-grained steels) and hydraulic
or modules
cylinders, and also in durable surface coating
technologies (CED) and module assembly.
STEEL
CONSTRUCTION
HYDRAULIC
CYLINDERS
ELECTROPLATING
CED
COATING
ASSEMBLY
OF MODULES
13
STEEL CONSTRUCTION
In the steel machining and processing sector,
≥
PALFINGER’s production sites are equipped
up to 10 tons
with state-of-the-art cutting, bending, and
≥
welding technologies. Thanks to automated
high-strength steels
manufacturing technologies, high-strength
≥
Real net output ratio
fine-grained steels can be machined and
≥
From trimming to coating and assembly
processed with utmost precision.
Welded modules with a total weight of
Years of experience in processing
of modules
≥
High-precision and fully-automated
manufacturing technologies
14
HYDRAULIC CYLINDERS
With well over 150,000 cylinders leaving the
Specific features include our long cylinder
Tenevo plant annually, PALFINGER is one of the center, where we manufacture cylinders up to
world’s largest manufacturers of hydraulic cyl-
12 m in length. Furthermore, thanks to a special
inders. We have concentrated engineering and
process PALFINGER has the capacity to supply
construction know-how in a skill center devoted
CED coated cylinders.
to hydraulic cylinders. When the need arises,
we thus have the capacity to design cylinders
and perform calculations according to customer
specifications. Our manufacturing capacities
cover the entire vertical range of cylinder production, from the sawing of raw materials and
the hard chromium plating of piston rods to the
testing of finished cylinders.
15
CYLINDER SKILL CENTER
≥ Innovation
in new materials (light-weight
construction, special piston rod coatings,
sealing techniques)
≥ Design
of hydraulic cylinders in CREO
≥ Calculation
of cylinder specifications by means of Mathcad 15 (e.g., according to EN12999 or EN280)
≥ Standardization
of cylinders across different PALFINGER products
16
≥ Design
to cost/cost calculations for cylinders
≥ Project
execution
STANDARD CYLINDERS
PRODUCT CYLINDERS
CONSTRUCTION CYLINDERS
≥ Assembly
≥ Customer
≥ No
≥ Little
drawing is available
engineering effort on PALFINGER’s part
≥ Large
to medium quantities
≥ Manufacturing
takes place chiefly at our
Romanian partner’s facilities
≥ Material
provides all drawings
specifications are known as much
≥ Speed
≥ Rapid
≥ Short
cylinder is designed at PALFINGER
as possible
≥ Structural
≥ No
≥ Cylinder
engineering effort whatsoever required
strength verified by PALFINGER
sent to the cylinder skill center, on PALFINGER’S part
where it is machined
≥ Cylinder
≥ Manufacturing
request forwarded directly to
Tenevo, where it is processed
Advantages:
drawings of the cylinder are available
≥ The
≥ Large
takes place chiefly at our Tenevo production plant
quantities can be designed
- Size - Surprise
Advantages:
processing of requests
delivery times are achievable
Advantages:
≥ Manufacturing
≥ Cylinders
≥ Many
process optimally structured
can be produced with the existing equipment
≥ Cost
benefit can be passed on to customers
years of experience, which can be fully exploited by the skill center or in welding
≥ Thanks
to an outstanding network of
suppliers, materials can be obtained at
low cost
≥ The
customer’s specific wishes are taken
into account
17
ELECTROPLATING
Jointly with our Romanian partner Nimet, we
offer chromium or nickel-chromium electroplating.
In the chromium process, we have the
capacity to manufacture piston rods up
to 12,000 mm in length with maximum
diameters of 200 mm. We can also do the
grinding and polishing work for these sizes
with no problem.
Short runtimes, high flexibility, and high
quality make PALFINGER your ideal partner
for manufacturing piston rods. Coating is
possible in the continuous flow process and
in a bath process.
We also have the capacity to perform
continuous induction hardening (bars).
18
SURFACE TREATMENT - CED
INNOVATIVE PROCESS TECHNOLOGY
In the individual dip tanks, the components are
Upon request, robots can be used to topcoat the
FOR DURABLE SURFACE PROTECTION
degreased, rinsed, activated, zinc phosphate-
surfaces in the color specified by the customer.
coated, rinsed again, passivated, and after
Proper surface treatment is the foundation for
rinsing with ultra-pure water, the CED coating is
Maximum dimensions of the parts: 2 x 2 x 3 m;
durable and long-lasting surface protection. In
applied.
maximum weight: 750 kg
the cathodic electrodeposition facilities at the
Marburg and Lengau production plants, compo- Salt spray test for stratification - CED: 700 hours
nents run through the individual process steps
Salt spray test for stratification - CED with spray
of CED coating in a fully automated manner.
painting: 1000 hours
19
PRE-ASSEMBLY OF MODULES
Upon request, PALFINGER will deliver fully painted,
tested, ready-to-install system modules or finished
products.
20
„We have been working successfully with PALFINGER for
years in the parts and components supply area. The professional execution of projects in combination with reliable
delivery, the high-quality products, and the competitive
pricing policy clearly speak for this cooperation.“
Herbert Empl
CEO of EMPL Austria Fahrzeugtechnik GmbH
21
TECHNOLOGY & PROCESSES
22
GUIDING PRINCIPLES
Innovative logistical processes make us a
flexible and reliable partner.
Following the guiding principle of “Reserving
resources - producing flexibly”, we work
according to the concept of order-related
production.
23
QUALITY MANAGEMENT
The PALFINGER production sites have ISO
Other established tools include:
9001:2008 system certifications, are certified
≥ Analysis
of errors from internal complaints and warranties
and licensed by the DNV and GL classification
≥ CIP
societies as self-testers of marine components,
1. Welding audit once a quarter by the capability of plants and equipment
and have EN3834 welding licenses. All systems
PALFINGER AG welding technology center
≥ Measures
through audits:
are inspected at least once a year in the scope
2. 5S audits
of external audits. Monthly quality indicators
3. Process analyses by the triple-M method
are used for continuous monitoring.
24
≥ Preventive
maintenance to ensure the process
are implemented according to the
PDCA cycle
QUALITY ASSURANCE PROCESS
A comprehensive prototype process ensures
PALFINGER also has an analysis center in
that the customer’s production requirements
Lengau for raw materials and a test center
are compliant with the PALFINGER production
in Köstendorf with the capacity to perform
procedures under industrial conditions. Even
diverse tests, including load tests.
during the order checking stage by the specialist department, potential problem points as well
as potentials are identified and solutions are
proposed in coordination with the customer.
Numerous process instructions, checklists,
work instructions, and test procedures have
been created for this purpose, such as:
≥ Nondestructive
testing: ultrasonic testing, magnetic particle inspection, radiographic
testing
≥ Destructive
testing with grinding and hardness
profile, corrosion testing such as NSS tests or
ESS tests
≥ Measurement
protocols
25
CLASSIFICATION SOCIETIES
As the top priority of ISO 9001, our sites stand
production of acceptance parts (compliant to
What classification societies are:
for maximum customer orientation and the
DNV, LRS, BV, RHINA) emphasize our process
Institutions for shipowners, which have the
continuous improvement of our processes and
skills, even for special requirements such as
necessary expertise to assess ships (incl.
products. Certification by German Lloyd and the those arising in the offshore sector.
certain add-on components). Insurance companies then draw up policies for these ships on the
basis of these assessments.
Tasks of classification societies:
≥ Creation
of technical directives for the design, engineering, and construction of ships
≥ Monitoring
and documentation of compliance with these directives during construction
≥ Surveyors
monitor the condition of the ships in their charge
26
RAP! RAPID PROCESSING
RAPID PROCESSING refers to an order-based production process with
an established cycle time and variable capacity with a guaranteed
Order-based, costum
production processes
Every production
order is based on
end customer use
Upstream production is optimized
in terms of setup costs
delivery date.
Reduced storage
PROCESSING OF REQUESTS
Customer request (request,
specifications)
Batch order
Feasibility
Study
Joint
acceptance
Flexible working
time model
QUICK RESPONSE CENTER
Kick-off meeting
Internal processing
with the customer
(assembling the
(customer requirements, project team, data materials, welding preparation,
specifications)
calculation)
Prototype
production
The cycle times for
assembly, upstream
production, and
procurement
are fixed
within 24 hours
Customer drawings/
NC contours
Submission of tenders
(prices, project plan)
Feasibility
testing
Materials testing
10 working days from order
Delivery
Production
Pricing
27
INTERNAL FIXTURE CONSTRUCTION
ADAPTIVE WELDING
Fixtures are designed and constructed in
When welding with robots, it is crucial to ensure
the plant:
that the components are in the programmed
position in the welding device. Any deviations
≥ Materials
can be purchased at optimum accordingly.
prices
≥ Capacities
must be detected beforehand and corrected
can be exploited directly in
the plant
Before the actual welding process, a laser
≥ No
system and the corresponding software are
external interfaces needed
≥ The
manufacturing process is continuously optimized
used to determine the position of the weld
joint and to adjust welding parameters such as
welding speed, welding power, and pendulum
parameters to the actual joint shape.
28
LASER HYBRID WELDING
≥ The
laser hybrid welding process is a
combination of the laser and MIG (metal
inert gas) welding techniques.
≥ The
laser beam guarantees a root welding
with high process reliability.
≥ The
MIG process compensates an uneven
gap situation and fills the weld seam opening
angle of 16°.
≥ Compliance
with the specifications is only
possible through the combination of both Criterion
Limit
Value [mm]
Component length
Min.
1200
Max.
3600
Component height
Min.
140
Max.
770
Component width
Min.
100
Max.
530
Min.
3
Max.
7
Material thickness
techniques and the adjustment parameters
that are possible as a result.
Possible profile shapes:
29
OPERATIONAL ORGANIZATION
30
SITES
“Organizational amalgamation of the European
production facilities into an independent
business unit also opens up the possibility
of providing production capacities for external customers. This is based on the strategic
consideration of benchmarking and further
optimizing the productivity of PALFINGER’s own
facilities in the medium and long term through
competition on the free market.”
Martin Zehnder, COO PALFINGER AG
31
PALFINGER EUROPE GMBH - LENGAU
PALFINGER Europe GmbH in Lengau is the largest production site of
PALFINGER AG and it went into operation in 1984. The focus is on the
production and assembly of cranes with lifting power ranging from 13 m
to 78 m. As a combination plant (i.e., a production and assembly plant),
it has the latest technology of the PALFINGER Group at its disposal.
The CED coating facility for the special surface treatment of cranes and
the hexagonal component production facility for knuckle booms and
telescopic profiles have been part of the company since 2002 and
2007, respectively. One of the two spare parts centers is integrated
at the Lengau site for carrying out spare parts deliveries.
STEEL
CONSTRUCTION
32
HYDRAULIC
CYLINDERS
CED
COATING
ELECTROPLATING
ASSEMBLY
OF MODULES
PALFINGER PROIZVODNJA D.O.O. - MARBURG
PALFINGER proizvodnja d.o.o. was founded in 1193 and is headquartered in Marburg. The processing and machining of steel components is
the main area of activity, in particular the coating and pre-assembly of
crane columns for PALFINGER knuckle boom cranes. The plant is also
the most important production and assembly plant for marine and wind
cranes. PALFINGER MARINE offers an extensive product range of
knuckle boom, stiff boom, and telescopic cranes for diverse
applications.
YouTube Playlist Batch Production
and Custom Manufacturing
STEEL
CONSTRUCTION
HYDRAULIC
CYLINDERS
CED
COATING
ELECTROPLATING
ASSEMBLY
OF MODULES
33
PALFINGER PRODUKTIONSTECHNIK
BULGARIA EOOD - TENEVO
PALFINGER Produktionstechnik EOOD in Tenevo has served as the
central production site for the cylinders and hydraulic components of
PALFINGER cranes since 2003. The plant now covers nearly all of the
hydraulic component needs for the entire PALFINGER Group
YouTube Playlist Batch Production
and Custom Manufacturing
STEEL
CONSTRUCTION
34
HYDRAULIC
CYLINDERS
CED
COATING
ELECTROPLATING
ASSEMBLY
OF MODULES
PALFINGER PRODUKTIONSTECHNIK BULGARIA
EOOD – CHERVEN BRYAG
PALFINGER Produktionstechnik Bulgaria EOOD is headquartered in
Cherven Bryag and has been part of the PALFINGER Group since 2000.
The main focus is on the production of thrust cylinder components for
the various types of cranes as well as on the manufacturing of diverse
welding components for the individual assembly plants.
STEEL
CONSTRUCTION
HYDRAULIC
CYLINDERS
CED
COATING
ELECTROPLATING
ASSEMBLY
OF MODULES
35
STEEL CONSTRUCTION BATCH PRODUCTION
BASED ON THE EXAMPLE OF PALFINGER PROIZVODNJA D.O.O.
36
YouTube Playlist Steel
Construction Batch Production
STEEL CONSTRUCTION CUSTOM MANUFACTURING
BASED ON THE EXAMPLE OF PALFINGER PROIZVODNJA D.O.O.
YouTube Playlist Steel
Construction Custom Manufacturing
37
HYDRAULIC CYLINDER BATCH PRODUCTION
BASED ON THE EXAMPLE OF PALFINGER PRODUKTIONSTECHNIK BULGARIA EOOD
38
YouTube Playlist Hydraulic
Cylinder Batch Production
HYDRAULIC CYLINDER CUSTOM MANUFACTURING
BASED ON THE EXAMPLE OF PALFINGER PRODUKTIONSTECHNIK BULGARIA EOOD
YouTube Playlist Hydraulic
Cylinder Custom Manufacturing
39
ELECTROPLATING
BASED ON THE EXAMPLE OF NIMET SRL
YouTube Playlist Electroplating
40
REFERENCES
41
41
Sennebogen
Putzmeister
Putzmeister designs, produces, sells and serves its customers
worldwide with technically high-quality and service-oriented
machines in the areas of concrete transport, truck-mounted and
As an internationally operating
stationary concrete pumps, placing booms and accessories,
company, SENNEBOGEN designs
industrial technology, pipe delivery of industrial solids, concrete
and produces complete model
placement and removal of excavated material
series for cable excavators and
in tunnels and underground, robotics and
caterpillar, telescopic, and
handling technology, mortar machines,
harbor cranes, material handling
plastering machines, screed conveying,
machines, multiloaders, and
injection, and special applications.
carrier equipment.
42
EMPL Fahrzeugtechnik
Metz Aerials
EMPL Fahrzeugtechnik is the leading European manufacturer of
Metz Aerials is the expert center
individually built, custom-made truck bodies and trailers.
for aerial rescue equipment in
the Rosenbauer Group and with
a staff of ca. 300, produces turntable ladders and elevating rescue
platforms for fire departments.
43
PALFINGER AG
F.-W.-Scherer-Straße 24
5020 Salzburg
Austria
T +43 662 4684 - 2220
[email protected]
www.palfinger.com
44
KP-FERTIGM2+E, E09/14, K 09/14, D 09/14
WWW.PALFINGER.COM