From Enquiry to Series Production

• 1.

  Customer Enquiry

  • initial assessment by engineering and sales
  • indicative manufacturability analysis
  • Cost Estimator
  • budget quotation

• 2.

  Concept and Feasibility

  • Simulation
  • feasibility study
  • supporting product development
  • indicative tooling concept
  • Simultaneous Engineering

• 3.

  Sales and Technical Management

  • contract review
  • prototype construction, rapid prototyping
  • testing at customer site

• 4.

  Binding Quotation

  • binding prices incl. delivery and payment terms
  • final legal coordination of all contract documents
  • order by the customer

• 5.

  Kick-off Series Production

  • production, capacity and schedule planning
  • tooling design
  • final coordination of series drawings and gauge concept with customers
  • tool manufacturing

• 6.

  Sampling and Approval

  • production of first sample parts (FOT)
  • creation of PPAP and initial sampling
  • Run@Rate
  • approval by the customer
  • handover to series production

Delivering Consistent Quality at Every Scale

• 

• Buckle Housing Assy

  Dimensions: 70x34x10 mm

  Material: C45 in t = 1.1 mm

  Fully automatic production using a linked stamping and bending machine, in which the components are bent to completion and riveted together.

• ETZ Diffusor outlet

  Dimensions: Ø57 x 50mm

  Material: 1.4306 in t = 1.2 mm

  The components are deep-drawn, formed and then tumble-finished.

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• 

• Cup

  Dimensions: Ø74 x 90 mm

  Material: 1.4301 in t = 1.5 mm

  The components are deep-drawn, formed and then degreased.

• Assembly Hinge Reinforcement

  Dimensions: 669 x 533 x 384 mm

  Material: CR3 GI40/40-U in t = 1.0 mm

  The hinge reinforcement consists of three individual parts. These are spot-welded and then e-coated (KTL).

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• Assembly Reinforcement Frame

  Dimensions: 760 x 1,000 mm

  Material: DC04+ZE75/75 in t = 0.7 mm

  The reinforcement frame consists of four individual parts that are joined by spot welding to form the complete frame.

Manufacturing

• 

  Prototyping/Small Batch Series

  • 2D/3D laser system and laser welding
  • Hydraulic presses/CNC press brake
  • 3D printer
• 

  Tool Making

  • progressive and transfer dies
  • max. tool length: 4,600 mm
  • try-out presses up to 500 tons
  • various joining processes in the tool
  • fully equipped machine park
• 

  Stamping/Forming Technology

  • stamping presses from 50 up to 1,000 tons
  • max. strip width: 1,000 mm
  • max. strip thickness: 5 mm
  • steel, stainless steel, aluminium, high-strength steel
  • high-performance straightening machines with 21 rolls
• 

  Welding/Assembly Technology

  • various joining processes
  • automated welding robot systems
  • MAG/MIG/laser welding and brazing
  • spot and projection welding
  • drawn arc/tip ignition welding
  • TOX presses up to 100 tons
  • integrated control systems
• 

  Surface Treatment

  • degreasing/washing systems (PCE/ modified alcohol)
  • ultrasonic cleaning and preservation
  • vibratory finishing system
  • surface coating through partners
• 

  Quality

  • optical and tactile 3D measuring machines
  • roughness measurements, hardness tests, tensile/compression tests, salt spray tests, visual inspections
  • certified according to IATF 16949, ISO 9001, ISO 14001, ISO 50001, TISAX

• 

• Precise Tool Cost Calculation with AutoForm CostEstimator

  With the AutoForm CostEstimator, we calculate tool costs for sheet metal forming parts at an early development stage – realistically, based on well-founded forming simulations. The determined manufacturing hours feed directly into our capacity planning and enable reliable schedule and resource pre-planning in tool making.

• Forming Simulation – Safety from the Start

  With state-of-the-art simulation software such as AutoForm, we analyse and optimise forming processes close to application – even before the first prototype. We realistically simulate complex manufacturing steps such as deep drawing, bending and springback and identify potential sources of error such as wrinkles, cracks or insufficient material utilisation at an early stage.

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• Digital Efficiency with Operations1

  With Operations1, we digitalise our manufacturing processes – connected, mobile and error-free. The platform enables the easy creation, management and execution of digital work instructions, checklists and inspection protocols in real time. Instead of paper, we use an intuitive solution that guides employees safely through processes and increases transparency and quality.

• Digital Invoice Verification – Fast and Transparent

  With digital invoice verification, we optimise our entire approval and review process. Incoming invoices are automatically captured, validated and digitally forwarded to the responsible departments for review. Clearly defined workflows and transparent approval processes reduce manual effort, avoid errors and ensure timely procedures.

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