Existing MTI Jobs Corvette/Cadillac XLR Front and Rear Suspension

Our Location
Company History
Metal Technologies, Inc. (MTI) Began In The Early 1990's As A Metal
Fabrication Division of Our Now Sister Company Bedford Machine & Tool
(BMT) Located In Bedford, IN, When Management Decided To Try To Expand
Their Longer Run Production Capabilities.
Summary:
In 1998, MTI Machining of C5 Corvette Front and Rear Suspension
MTI Machining of Safety Cylinder Tubes
In 2000, MTI ISO 9002 Certification – Bedford, IN Location
In 2003, MTI ISO 9001-2000 Certification Upgrade – Bedford, IN Location
In 2003, MTI Awarded Contract For Machining of GMX-215/245 (Cadillac XLR/
C6 Corvette) Front and Rear Suspension
In 2004, MTI Machining of (7) Remy/Allison Transmission Components
Company History
Summary Continued:
In 2005, MTI Purchased Bloomfield, IN Facility and Began Rennovation
In 2005, MTI Began Production of Ryobi Die Casting/Duramax Deisel Engine
Crankcase
In 2006, MTI ISO 9001-2000 Certification - Bloomfield, IN Location
In 2006, MTI Machining Processes All Transferred To Bloomfield, IN Facility
In 2007, MTI Awarded Contract For Machining of Ryobi Die Casting/Ford 6F35
Mid-Case Machining
Sales Percentages by Customer
Other, 5.90%
ABB Youngwood, 9.20%
Ryobi Die
Casting, 9.00%
Diversified
Machine, Inc., 46.3
0%
Remy, Inc, 29.60%
ABB - Youngwood
Diversified Machine, Inc.
Remy, Inc
Ryobi Die Casting
Other
Our Current Plant Located In Bloomfield, IN Offers A
132,000 Sq. Ft. Facility Seated On 53 Acres To Allow Us
An Excellent Opportunity For Expansion and Growth
Excellence in Practice
Metal Technologies Is A Company Committed To The Pursuit of Excellence.
We Strive To Continually Elevate The Standard For A “Job Well Done”
Because We Believe That This Is Only Way We Can Keep Our Customers At
The Top of Their Class In This Very Fluid and Competitive Economic
Environment.
We Believe That Our People and Our Processes Are The Keys To Making Us
and Our Customers Winners. Our Number One Daily Goal Is To Enhance The
Lives and Capabilities of Our People So That They Can Then Implement The
World Class Processes That Will Make Us The Best.
Our Commitments:
• Lean Manufacturing Training For All Employees Including 5s, Kaizen, Value
Stream Mapping, Visual Management and Much More
• Management Training From Vincennes University
• Cross-Training of Employees
• Continuous Improvement
Lean Manufacturing Training
Metal Technologies, Inc. Is Committed To Upgrading Our Employee
Performance Through Training and Education
Existing MTI Jobs
The Following Slides Detail Some of The Projects Metal
Technologies, Inc. Is Currently Involved In As Mentioned Earlier:
• Corvette/Cadillac XLR Crossmember – Diversified Machine, Inc.
• Allison Transmission Housing – Remy, Inc.
• DMAX Crankcase – Ryobi Die Cast
• Corona Rings – ABB Inc.
• Ford Partitions – Huncilman Corporation
Existing MTI Jobs
Corvette/Cadillac XLR Front and Rear Suspension
We Have Been Machining and Assembling The Aluminum Front and
Rear Suspension Components For All Production Corvettes Since 1998.
In Late 2003, This Product Was Introduced As A Dual Platform With The
Cadillac XLR. Accuracy and On-Time Delivery Are Paramount To This
Program Due To The Fact That This Product Begins The Entire Chassis
Build.
Project Features:
• Customer: Diversified Machine, Inc.
• 80,000+ Annual Volume
• Machined On Makino A99 Horizontal
Machining Centers
• External PPM of 5 or Lower
• Cpk of 1.67 or Above On All Key
Point Characteristics
Existing MTI Jobs
Allison Transmission Housing
One of Our Newer and More Complex Projects, This Lower Volume BiMetal Transmission Housing Has Over 1500 Machining Specifications and
Tolerances In The +/- .0003” Range On A 4” Bore. In Addition To
Machining, We Also Perform Other Value Added Services Such As Air and
Water Leak Testing, Washing, and Bore-Scoping Inspections On This
Product.
Project Features:
• Customer: Remy, Inc.
• Machined On A Makino A71 Horizontal
Machining Center
• “State of The Art” Cutting Technology
• Cpk of 1.67 or Above On All Key
Point Characteristics
• Air and Water Leak Testing
Mitutoyo BRTA1220 CMM Measuring A Finished Stator
Housing
Stator Housing Submerged For Water Decay
Process
Existing MTI Jobs
DMAX Crankcase
This Is Our Latest Program Launch and Is Our First Automated Operation
Which Includes Machine Tending and Part Identification. The Casting Is
Machined From A Raw Condition In Which Product Quality Is Imperative
To Meet Our Customer Requirements.
Project Features:
• Customer: Ryobi Die Casting
• 55,000 Annual Volume
• Machined On A Makino A71 Horizontal
Machining Center
• Fully Automated Robotic Loading/Unloading
and Part Identification
• Cpk of 1.67 or Above On All Key
Point Characteristics
Monode
part marker
for
traceability
Rotating
finished
goods
unloading
station
Fanuc
420
Robot
Rotating raw
part loading
station
Overview of Automated DMAX Cell
Cell Layout Designed By Bedford Machine & Tool
An Operator From The Corvette Department Unloads Finished Parts
From The Automated DMAX Cell. MTI Encourages Employees To Cross-Train
Commitment to Quality
Quality Policy
“Committed to Total Customer Satisfaction from a
Customer Point of View”
Every Metal Technologies, Inc. Employee Is Trained and Motivated
To Guarantee That Part Quality Is Their Number One Priority
Metal Technologies, Inc. Has Implemented Several Systems To
Help Us Diagnose and Eliminate Quality and Production
Failures To Ensure That Our Customer Satisfaction Standards
Are Met
SPC Data Control - Quality
Technician Eric Hamer
Analyzing DMAX CMM Data
Unigraphics - Engineer
Michael Parsons Compares The
Actual Part To The CAD Model
Scrap % and First Time Yield
Scrap and Rework Are
Tracked By Data Entry On
A Per Shift Basis. Any
Issues That Arise Causing
An Increase In PPM Values
Are Addressed As Soon
As Possible By Our
Quality Control and
Production Teams
Corvette Department 2006 - 2007
First Time
Yield
MTI
Machine
Scrap
December
97.13%
0.98%
January
96.8%
0.12%
February
97.89%
0.18%
March
98.15%
0.30%
Month
Overall Equipment Effectiveness
(OEE)
MTI Has Recently Implemented OEE On Our Machine Tool
Equipment To Manage and Evaluate Machine Downtime To More
Effectively Plan Maintenance Schedules, Diagnose Potential
Problems and/or Provide Necessary Training To Personnel
Overall Equipment Effectiveness
(OEE)
Corvette Makino 1
90-day Trend
100.00%
Availability
90.00%
Quality
Performance
80.00%
70.00%
Rolling
Average OEE
Why MTI?
•
•
Business Hours: We Currently Machine Aluminum Parts 24 Hours Per Day
Commitment To Automation – To Be Cost Competitive and Fully Understand The
Latest In Technology
•
•
•
Plenty of Open Floor Space In Our Bloomfield, IN Facility
Access To A Hard Working Workforce (Rural Area)
Access To Sister Company Bedford Machine & Tool That Has Designed and Built:
• 6-Speed RWD Dies for GMPT-Bedford
• Pressure Test Units
• Trim Press Machines
•
•
Our Personnel Have Many Years Experience In The Machining Industry, and They
Have A Clear Understanding of Casting Defects and What Causes Them
The MTI staff, Production and Administration, Are Receiving Lean Manufacturing
Training To Help Reduce Costs In Ever Part of The Company
How Have We Done?
DON’T JUST TAKE OUR WORD FOR IT
Included Is The Contact Information of Those Who Can Provide A
Written Letter of Recommendation On Our Behalf
Dan Burkhardt
Program Manager
Alcoa Automotive Castings
(616) 842-3500, Ext. 1027
[email protected]
David Fisher
Purchasing Manager
Ryobi Die Casting, Inc.
(317) 392-8318
[email protected]
Paul Newport
Vice President Global Operations
Remy, Inc.
(765) 778-5960
[email protected]
How Have We Done?
DON’T JUST TAKE OUR WORD FOR IT
The Following People Are References Who Can Speak To You About
Their Experience With Metal Technologies, Inc.
Ray Solimani
C6/XLR Reliability Engineer
GM Corvette Plant
270-745-8499
Paul Allison
Reliability Engineer
GM Corvette Plant
270-745-8229
Our Equipment
Horizontal Mills
Lathes
•
(4) Makino A99, Travels XYZ = 1000mm (39.4) x1000mm
(39.4) x 950mm (37.4), Full 4th Axis, (3) 40 Tool ATC (1)
120 Tool ATC, 12,000 RPM Spindle, CAT 50
•
(1) Mori Seiki CL-203, 6" Dia. Chuck Capacity x 36"
Max Material Length, IEMCA VIP70CNC 3' Advanced
Feeding System
•
(2) Makino A71, Travels XYZ = 730mm (28.7) x 730mm
(28.7) x 800mm (31.5), Full 4th Axis, (1) 60 Tool ATC (1)
137 Tool ATC, 10,000 RPM Spindle, CAT 50
•
(1) Mazak QTN-300, 12" Dia. Chuck Capacity x 26.8"
Max Swing, Spindle Bore Dia. 3.46“
•
(1) Okuma LH35-N, Front 4 Position - Rear 6 Position
Turret, 25" Swing
•
(1) Lodge/Shipley, 16" Swing x 54" Center To Center
•
(1) Hercules LC360A, 6" Dia. Chuck Capacity x 15"
Swing
•
(7) Mori Seiki NH5000/40 DCG, Travels XYZ = 730mm
(28.7) x 730mm (28.7) x 850mm (33.5), Full 4th Axis, 60
Tool ATC, 14,000 RPM Spindle, CAT 40
Vertical Mills
•
•
Mori Seiki MV50-E, XYZ Travels = 508mm (20) x
1000mm (39.4) x 460mm (18.1), 10,000 RPM
Spindle, CAT 40
(1) CNC Bridgeport Mill, Travels = 9" x 42" EZ Trak Plus
CNC, 3 Axis Programmable Control, 3 Axis DRO
•
(3) Bridgeport Knee Mill
•
(1) Cincinnati Mill
CMM
•
•
Automation
•
(1) Fanuc S-420F Robot, 6 Axis, Reach 2405mm
(94.7), Weight Capacity 120kg. (264lb.), R-J1 Control
•
(6) Fanuc R2000iB/165F Robot, 6 Axis, Reach
2650mm (104.3), Weight Capacity 165kg. (363lb.), RJ3iC Control
(1) Brown & Sharp XCEL7-10-7, Travels XYZ = 650mm (25.6) x 1000mm (39.4) x 650mm
(25.6), PCDMIS Software
(1) Mitutoyo BRTA1220, Travels XYZ = 1000mm (39.4) x 2000mm (78.7) x 1000mm (39.4),
GEO Measure Software
Contingency Plan
IN THE EVENT THAT PRODUCTION IS INTERRUPTED
 ELECTRIC POWER OUTAGE (Company: Duke Energy)
1. Has Been Down Less Than 3 Hours In The Last 12 Months
2. Diesel Power Generator For Limited Production
3. Part Bank
4. All Cycle Times Are Based On 20 hours. Make Up Lost
Production 4 Hours Per Day and On Weekends.
5. Air System Outage - Backup Air Compressor Unit
 FIRE PROTECTION/SECURITY
1. Building Has Complete Sprinkler Fire Protection
2. Fire Department Less Than 1 Mile Away
3. Building Has Automated Entry Security System
 MAJOR BREAKAGE
1. Error Proofing of Our PMI System
2. Spare Parts Inventory
3. Bedford Machine & Tool Resources For Repair
How to Contact Us
Metal Technologies, Inc.
RR1 Box 368 SR 54 East
Bloomfield, IN 47424
Phone: (812)384-9800
Fax: (812)384-9600
Website: www.metaltechnologiesinc.com
Randy Lovelace – Project Manager/Sales – Ext 202
Doug Williams – Engineering – Ext 203
Jenny Smith – Purchasing – Ext 204
Jeff Martin – Quality Manager – Ext 207
Michael Parsons – Operations Manager – Ext 208
Brian Pemberton – Controller – Ext 209