precision turned parts

Transcription

PRECISION TURNED PARTS
MICRODECO S.A. Poligono Urtia S/N Ermua (Vizcaya)
Tlf: 0034 943 170317 Fax 0034943173115 E-mail: [email protected] www.microdeco.com
History – Business Milestones
•
•
Founded in 1963 in Eibar, specialized in manufacturing highly complex turned parts.
Latest turning technology, highly qualified staff and quality are our three pillars.
Business/Organisation Milestones
1963
Foundation of Microdeco
1997
First 5S implementation program
1999
Beginning of the “Mini Companies” management.
Silver “Q” award from the Basque Goverment.
2002
Gold “Q”
Q award form the Basque Goverment.
Goverment
2003
European EFQM quality award for “Social Corporative Responsability”
2006
BAI Award (Basque Automotive Industry).
2008
P t
Partner
and
d foundator
f
d t off AIC-Automotive
AIC A t
ti Intelligence
I t lli
C t
Center.
Beginning of production of Romanian plant MICRODECO Ro
Robert Bosch Preferred Supplier nomination.
2009
Beginning of production in AIC MICRODECO BorP
Beginning of MICRODECO INNOVA, (I+D unit)
2013
Introduction in RVCI (Basque Science and Innovation Net)
2014
50th Anniversary of Microdeco,S.A:
2014“Good practise award” for internacionalization by Basque Goverment
2015
Beginning of MICRODECO MEDICAL
110
History – Technological Millestones
Core technology of our production processes is TURNING with Swiss-art machinery.
Technological millestones
1982
First CNC lathe (elector, TOP, Deco).
1988
SPC (Stadistical Process control ) implementation.
implementation
1990
First Multispindle cam-lathe. SAS 16.6.
1998
First CNC multispindle MULTIDECO.
2001
Extension of MICRODECO headquarters.
2002 Strategical alliance with TORNOS.
2006
production line implementation.
p
Bosch ZME3 First p
2007
First high technology 8 spindle CNC, MULTIALPHA.
2010 First “hard turning technology” machines KUMMER and
MIYANO.
2011 Eddy Current tester implementation.
2012
First high precision multispindle MULTISWISS.
2012Cleanliness control laboratory implementation (gravimetry and
granulometry.)
2014 First multispindle MultiSigma
111
History – Quality Millestones
The reliability of the process is supported by artificial vision unitary controls, statistical
process control ((SPC)) and q
p
quality
y tools as Jidoka or Firewall.
Quality millestones
1993 Certification according to ISO-9002 by AENOR
2003
Environmental certification according to ISO 14001 by AENOR.
2004 Certification according to ISO/TS 16949-2002 by AENOR.
2008 Certification according to ISO EFR (Social
Responsibility Certification)
2009 Certification according to ISO/TS 16949-2002 by AENOR of
Microdeco Ro
112
Business Plan Vision
Business Drivers
‐ Turnover > 20 Mio €
‐ Transformation with Robert Bosch
‐ Improve our position in the turning parts market.(Champions League)
g specialization
p
product p
p
position based in advanced multitechnologies.
g
‐ High
‐ Actitude PRO (Contributing / solver / Interested)
‐Lean mindset
‐ German Productivity
‐ Recovering sustainable profitability.
Organization Structure of Microdeco S.A.
General Manager
Administration and Systems
Sales
Quality
Human Resources management
R&D/ Process and Product
Engineering
MARKET/CUSTO
OMER SERVIC
CE
CULTURE
E/PEOPLE
Management Control
Operations
p
Management
g
Operations
P d ti Plants
Production
Pl t
Production Planning,
Procurement
114
Key figures at Microdeco
‐ErP: 16,5 Mio €
‐BorP: 4 Mio €
‐Ro:
Ro: 2,5 Mio
2,5 Mio €
Tur nover
25
23,00
20,50
19,20 19,30
20
Turnover
T
Éxportation
Investment
K€
15
15,60
9,66
10
7,30
3,78
4,41
17 20 17,20
17,20
17 20
16,66
15,50
12,89
12,00
5
18,50
18,20
4,6
4,48
Year
3 12
3,12
2,41
2,19 1,9122,12 1,68
1,60 2,05 2,05 1,3822,04
1,32
0,924 1,043
0,9141,11 1,34
0,91
0,859
0,826
0,385
11,40
13,00
6,3
5,40
3,48
12,28 12,50
8,73
8,07 8,19
5,11 5,57
14,60
13,50
11,04
18,00
17 00
17,00
3
1,8
2,4
1,35
1,9
2,6
1,2
1,5
2
0
1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015
1.Transformation:
• Internal reorganization
•
Empowerment
2nd. Transformation:
TME ( Minimun efficience
size)
• Local Æ Global
• TurningÆ Industrialization
3th Transformation
•
• New technologiesNew products.
• Cleanliness controls
• Productivity
P d ti it
• Hard Turning
Investments
7,00
0%
7%
12%
12%
6,00
19%
18%
19%
16%
19%
23%
12%
14%
6,30
7%
8%
10%
14%
17%
24%
27%
23%
25%
5,00
4,60
4,48
Yearly ratio of Investment/Sales
38%
8%
20%
36%
30%
40%
4,00
50%
3,00
3 00
3,00
2,60
60%
2,40
1,91
2,00
1,68
1,38
1,00
0,91
0,86
0,83
0,92
2,00
1,90
1,80
1,50
1,35
1,32
70%
1,50
80%
1,04
90%
0,39
0,00
100%
1994
1995
1996
1997
1998
1999
2000
2001
2002
Yearly investment (Mio Euros) 2003
2004
2005
2006
2007
2008
2009
2010
2011
2012
2013
2014
2015
3era
Transformación:
• ...
116
Customer/Market
•
Microdeco is supplier of highly concentrated customer base in automotive industry (93%)
and mainly foreign customers.
customers Export rateÆ (73%)
•
Microdeco participates in a commercial partnership
AUXI with other technologies
enterprises (Gabi,
(Gabi Alfa Group,
Group Saljoar) as Common Commercial Export Dpt.
Dpt
•
Microdeco participates also in DYNAMIK (Technological Alliance of 8 companies.)
Share by sectors
Share by Countries
117
Customer/Market:
118
Productive platform
Microdeco
Medical
Microdeco ErP
Microdeco BorP
Microdeco Ro
Microdeco Inn.
(R&D)
GINA S
S.A.
A
Finesse
Precimontajes
119
Geographical composition of Microdeco group
-Group compositionÆ 169 people
- Microdeco,S.A. (Head-Quarters - Ermua) Æ 110 people
- Microdeco
Mi
d
BorP
B P (Boroa
(B
- AIC)Æ 25 people
l
- Microdeco Ro (Oradea-Romania)Æ 32 people
- Microdeco Innova (Ermua – R&D)Æ 9 people
Finesse Rectificados,
Rectificados S
S.A.
A
Precimontajes, S.A.
- Finesse Æ 14 people
- Precimontajes
j Æ15 p
people
p
Microdeco, S.A.
Microdeco Inn., S.L.U.
Microdeco Medical
Microdeco, BorP.
2 000 m2 in
2.000
i A
Amorebieta
bi t
9500 m2 in Ermua
Microdeco, Ro.
7500 m2 in Oradea (Romania)
120
Microdeco S.A. (Headquarters – Ermua)
•
•
•
General Manager: José Iraolagoitia
Foundation: 1963
Capacities:
–
–
–
–
Precision turning
g and industrialization of high
g volumes
production lines.
Group Management and Headquarters.
Core production and tool shop.
Medical activities.
•
Turnover: 16,5 Mio€
•
p y
: 110
Employees
•
Certifications:
–
–
–
–
ISO 9001
ISO TS 16949
ISO 14001
EFR1000-1
121
Microdeco S.A. (Headquarters – Ermua)
122
Microdeco BorP. (Boroa – AIC-Automotive Intelligence Center)
•
•
Foundation: 2008
•
Capacities:
•
•
–
New technologies development center
–
T ti and
Testing
d industrialization
i d t i li ti off new processes.
–
Technological antenne.
Turnover: 4 Mio€
Employees: 25
123
Microdeco BorP. (Boroa – AIC-Automotive Intelligence Center)
124
Microdeco Ro. (Oradea - Romania)
•
•
•
General Manager: Florenta Loredana Toda
Foundation: 2007
Capacities:
–
–
–
–
–
Strategic production center close to our customers in
east Europe.
W ll located
Well
l
t d Plant
Pl t closed
l
d to
t Hungary.
H
Romanian General Manager.
Romanian Responsibles trained in Ermua Plant during
6 months. All of them speak Romanian, Spanish and
English
Clear facilities, offering total freedom for the Lay-out
design and enlargement possibilities.
•
•
Turnover: 2,5
2 5 Mio€
Employees: 32
•
C tifi ti
Certifications:
–
–
ISO 9001
ISO TS 16949
125
Microdeco Ro. (Oradea - Romania)
126
Microdeco Innova AIE (Ermua – I+D)
•
•
Foundation: 2009
•
Capacities:
–
–
–
–
–
•
R&D Unit for whole group
Product and Process Engineering and quick
prototyping
Scope: Technology, Quality and Organisation
Alliance management
Reinforce of our Business Drivers
Employees: 9
127
Technological capabilities
•
Since the beginnings, Microdeco is preferential customer of Tornos (Swiss company), this
partnership
p
p g
generates feasible solutions for the industrialization of high
g complex.
p
parts.
•
Turning as Core technology Æ Latest machines are Multialpha, Multiswiss, MultiDeco
and give us flexibility to meet requirements of our customers.
•
We have a fleet of 75 machines of multi-spindle lathes and mono-spindles.
•
Complementary technologies Æ Hard turning, Grinding, Flat Grinding, Deburring
(high pressure oil), Trobalization, Heat treatment and Assemblies.
•
Close to customerÆ Use of WebEdi conexion (Supplyon, GXS, Covisint,
128
Annex : Technologies
Columna1
Columna2
R10
NAT-125
TOP-100
Deco 2000-26
Deco 2000-20
Deco 2000-13
Deco 2000-10
Evo Deco
SwissNano
SAS-16
MultiDeco 20.6
MultiDeco 20.8
MultiDeco 26.6
MultiDeco 32.6i
MultiAlpha
p 6.32
MultiAlpha 8.20
MultiAlpha 8.28
MultiSigma
MultiSwiss
Miyano
Kummer LSK250
M hi i ttransfer
Machining
f
Schaublin turning finishing
Grinding centerless+plongee CNC
Grinding centerless+plongee CNC
Flat Grinding
High pressure deburring
Annealing (Heat Treatment)
Hardening
Teflon
Electroless Nickel
Chemical Nickel
Galvanic Coating
AOD (Anodyzing)
Automatic assembly line
Manual assembly line
100% Final Robot control
White room facilities and laboratory
Soap cleaning machine
Monospindle cam
Monospindle cam
Automatic monospindle CNC
Automatic multispindle cam
Automatic multispindle CNC
Automatic multispindle
p
CNC
Hard turning one spindle CNC
Hard turning two spindle CNC
Mi d
Microdeco
own d
design
i (L
(Launik)
ik)
Schaublin TM-100 CNC
Estarta 301 CNC
Estarta 318 CNC (proxi)
XXX (proxi)
Piller
Arrola
BMI (proxi)
Strategic Partnership Berritzen
Strategic Partnership
Microdeco own design
Microdeco own design
(ISV, Visicontrol, Betx, Kokatu, Lazpiur)
Microdeco own design (proxi)
Microdeco own design (Surfat/Milama/Alphaso
Columna3
ERMUA
12
1
2
1
6
5
2
1
2
4
1
4
5
Columna4
ORADEA
4
3
Columna6
Columna7
FINESSE PRECIMONTAJES
1
3
2
1
1
5
1
1
5
2
2
1
Columna5
BOROA
1
1
1
1
1
2
1
2
11
1
1
1
1
1
1
9
1
2
4
3
1
1
1
1
129
Technological capabilities/Value chain
Process machining
•
T i
Turning.
•
Prototyping.
Finishing
•
•
•
•
•
Machining Tests.
Deep hole drilling.
Deep-hole
drilling
CUSTOMER
REQUEST
/BUSINESS
OPPORTUNIT
Y
•
•
•
•
•
•
TURNING
Galvanic (SC)
AOD (SC)
Zinc plating (SC)
Electroless Nickel (SC)
Nickel plating (SC)
Teflon (SC)
•
•
•
•
•
•
PROCESSING
A
Annealing
li
Eddy current test.
Inductive hardening (SC)
Case hardening (SC)
Carbonitriding (SC)
Gasnitriding (SC)
FINISHING
Secondary process
•
Ab
Abrassive
i deburring.
d b i
•
Trobalization
•
High Pressure Oil deburring
CLEANING
100%
CONTROL
Surface Treatment
•
•
•
•
•
•
Fi Turning-Reprise
Fine
T i R i
Grinding (ED) Centerless
through-feed
Grinding (ED) Centerless
plongee
Flat grinding
Honing(SC)
Lapping
Hard Turning (Kummer / Miyano)
Reaming
Roller burnishing
Heat Treatment
Assembly
Cleaning
100% F.Control/Packaging
•
Mechanical pressing.
•
Gravimetry controls
•
Artificial vision controls.
•
Manual- automatic assembly.
•
Granulometry controls.
•
Surface visión controls.
•
White room- In progress
•
Mechanical measuring controls.
•
Mat label/Odette/KLT.
Nuclear Technologies
130
Technological capabilities
Process machining
CUSTOMER
REQUEST
Surface Treatment
Finishing
TURNING
PROCESSING
Heat Treatment
FINISHING
Secondary process
CLEANING
100%
CONTROL
Assembly
Cleaning
Packaging
Nuclear technologies
131
Technological madurity matrix: Technological position
Technological
madurity
Cam Lathes
Old
Go out
Mature
Technological
Transference
Go out
SAS
New applications
Value engineering
Deco
Diversify
Improve MKTG
Quote increase
Estandarization
MultiDeco
Growth
Technological
cooperation
Developments
increase
Open market
Kummer
Embrionic
Colaboration,
subcontractor
Multi Swiss
Consolidate
Knowledge and protect
Develop new
applications and
technologies patents
CORE
Technologie
MultiAlpha
Low
Medium
Strongh
Enterprises
position
132
Range of Products and Materials
Range of Products:
•
•
•
•
Wide range of parts between Ø1 to Ø34 mm with a maximum length up to 700mm.
Tolerance in diameters IT7 and IT11 in lengths.
Our series, ranging from 20k up to 5 Mio parts.
> 250 parts running in serial production with total production of >50Mio parts/year.
Raw materials:
•
Cylindrical bars, hexagonal, etc and raw material refractory high-alloy steels, and ductile steels difficult
chip fragmentation like:
–
–
Stainless steel and hardnenable s.steel (1000Tn), free cutting steel (1000Tn), brass(300Tn), aluminum(40Tn),
titanium and miscellaneous.(ETG100)(200Tn)
High experience in various grades of stainless steels.(1.4305,1.4301,1.4548,1.4841,etc…)
Heat and Surface Treatments:
•
Following specifications of customers, we perform heat treatments and coatings like Nickel-Teflon,
Anodizing, Zinc-Nickel.
133
Products
•
PowertrainÆ Most of our parts are assembled in
Powertrain function of the vehicles (80%).
•
Our most representative products are for:
–
–
–
–
–
–
–
–
Products family turnover in %(2012)
Common Rail components.
Airbag housings.
EGR (Exhaust Gas Recirculation) components.
Proportional solenoid camshaft
Hydraulics
AdBlue (SCR, DNOX),Blue Efficiency
Turbochargers (bushings and pins)
Miscellaneous (H.appliances, office supplies, military equipment, etc..)
134
Customer/Market: Product Position
Market
•
•
•
Focus:Product Driven
Demand (Diversify customers)
Volume
Profit
PLV
PCV
GLP
HPV
25
SHOCK
ABSOR
VERS
EGR
ZME
Blue
Efficiency
HYDRA
ULIC
DNOX
POC EV650
TURB
OO
CHAR
GERS
25
TGV
Airbag
25
75
•
•
•
Technology
Service + Quality
Know-How
Microdeco
Position
135
Products: Common Rail
1. Common Rail (Diesel):
•
Microdeco produces 11 P/N for common rail, divided in 3 groups, ZME, PLV, PCV and VCV:
– VCVÆ Volume Control Valve and Flow pump
(ZME) (Bosch Feuerbach and Kendrion)
– PCV/PLVÆ Pressure Control\Limiting Valves
(Bosch Jihlava)
Microdeco is producing critical elements for this
functions.
136
Products: Injectors
2. Injector (Gasoline) : Microdeco is producing a part for the piezoelectric injector called
“Zentrierbolzen” ((Bosch Turkey).
y)
137
Products: EGR, SCR y Blue Efficiency
3.
EGR, SCR and Blue Efficiency
– EGRÆ Microdeco
Mi d
produces
d
valves,
l
plungers
l
and
d
shaft (Pierburg Group).
– SCRÆ Selective Catalytic Reducer.
Mi d
Microdeco
i producing
is
d i one tube
t b and
d 2 buchses.
b h
(Bosch Aranjuez and Bosch Madrid).
–
Blue Efficiency,
Efficiency Microdeco produces Polkern
Daimler (Kendrion) for the hydraulic circuit and
a family of 6 parts for the EV650 project with
((Bitron Spain).
p )
T
Tecnología
l í EGR
Válvula
Fuente: Grupo Renault
138
Products
4.
Variable Cam Timing solenoid VCT. The references produced by Microdeco are for the
magnetic
g
core (Armature
(
complete)
p
) and housings
g ((Pipe
p y C-Pole).
) Kendrion China.
5. Hydraulics: Microdeco is producing several references for hydraulic components (Rings
and
d Polkerns)
P lk
) Kendrion
K d i CZ.
CZ
6. Airbag: Microdeco is producing a family of parts the airbags. Autoliv France.
7. Turbochargers: We are producing a family of bushings and pins for Turbo application.
(Mitsubishi Nederlands)
139
ProductsÆ EGR components, shaft, plates, guides and valve
discs.
140
ProductsÆ EGR components, shaft, plates, guides and valve
discs.
141
Products: Hydraulics, Polkerns, Valve-seats for EV.
142
Contacts
General Manager
Mr. Jose Iraolagoitia
34 943 17 03 17
34 943 17 31 15
[email protected]
Commercial Manager
Mr. Tony Goffard
34 94 424 30 21
34 94 424 29 86
[email protected]
Customer support (Germany)
Mr Richard Trautnitz
Mr.
+49 917 890800
0049 171 807 807 6
[email protected]
@
Operations Manager
Mr. Patxi Balerdi
34 943 17 03 17
Quality Manager
Mr. Igor Eibar
34 943 17 03 17
34 943 17 31 15
[email protected]
Engineering Manager
Mr. Ina Telleria
34 943 17 03 17
34 943 17 31 15
[email protected]
34 943 17 03 17
34 943 17 31 15
[email protected]
Sales/New Bussiness.Develop.Res. Mr. Enrique Mendia
34 943 17 31 15
[email protected]
Many
y thanks for y
your attention

precision turned parts

Transcription

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