On the basis of the technologies used with us our co-workers are the crucial know-how carriers. Co-workers have large technical knowledge and extensive experience and understand it to develop innovative solutions effectively for our customers.
In teamwork ideas mature and as a result of purposeful pre-development prototyping’s will be realized, agreed with the customer and also with finally in specialized spreading teamwork it comes to the series transfers for the customers. The quality advance planning is using the APQP, which is the basis for the sequences of operations of the projects with the development of products and processes up to the start.
We employ approximately 250 coworkers and have the total production and effective area of approx.11 500 m²with 39 injection moulding machines with closing force from 50t to 2000t.
1. Tier Down Study; Benchmarking
In the product ‘Benchmarking’ the single attributes of a product are measured according to the ‘Benchmark’ as well as compared with the own product port folio. The Benchmark shows the market leader in the product segment. Concerning the comparison the potentials are derived in a potential analysis for the own product to optimise the own position on the market.
2. Product and process development
In our philosophy we understand the process development in its totality, beginning with the concept development up to the component development and the development of technological – and assembly processes as well as the necessary test processes.
CATIA V5: As a direct supplier of the car industry we use the CAD program Catia V5.
Moldflow calculation: For the support of the construction process and for the precise interpretation of the injection moulding tools we use the simulation programme Moldflow.
Pattern and prototype production: As an instrument of the component verification we check the different development stages through the production of patterns, models and prototypes concerning different procedures (e.g., STL, SLS, FTM u.a.m).
3. Project management according to APQP
APQP (Advanced Product Quality Planning; part of the American QS 9000) is a continuous project management for the product- and quality planning and is suitable for all phases of the process development.
The Aim is to have a uniform product-related documentation structure/-hierarchy which deliver the necessary transparency about the production event to the user (manufacturer). Thereby the guidance of production should be simplified. All information relevant for product, project and documents are centrally planned, supervised and administered.
4. Quality Management
Measuring Technology: In the measuring room we are equipped with a 3D co-ordinate measuring machine of the Stieffelmayer company, a 3D measuring arm as well as a measuring microscope of the Mahr company. We provide measuring reports for first pattern check, standard-accompanying measurements for component analyses. In the measuring room the test means supervision also takes place.
Material Test Laboratory: In the material test laboratory we carry out the receipt of goods checked and the release of granulate materials and Batchen for manufacturing and provide material test reports for the first pattern check.
For functional tests warm storage and cold storage as well as endurance and other kinematic functional tests belong to the test dimensions on parts and assemblies.
In the laboratory different testing methods are for disposal/available such as, (for example), for the investigation of assembly-line rate, density, cinder salary or water salary, fuel speed, to mechanical qualities as well as colour measurement and brilliant measurement, custody check and roughness measure.
5. injection mould technology, with the specific features as for example
Gas inside pressure: Special technology in our house is the gas injection technology (GIT). Inspiration places with wall thick accumulations can not be avoided. With the partial filling procedure the fluid gas (nitrogen) takes over the stressful job by creating from hollow cavities. Inspiration places are thereby reduced and also unimportant material will not get saved and therefore bigger form part stability is reached.
2 K hose downpour Hose pouring technology: The technology is primarily used in the plastic processing (e.g., injection moulding). It is a prototype procedure.
In a hose unity a shapeless material (granulate material) is converted by the supply of the warmth in sculptural, homogeneous glazes which are injected by means of pressure into a closed form (hose pouring tools). On solidifying originates a more material cohesion a form part. With this procedure familiar technically high-quality form parts with high exactness in a train are produced. The moulder tools which are required are very complicated to use concerning other form part creation and design freedoms, as well as the integration of additional functions.
The production of form parts concerning different materials or different colours in moulding many parts at the same time serve the improvement of the firmness, the optics (appearance) and the haptics (pavement grip).
6. Assembly, partial-automated as well as fully automated
In our assembly we cover a wide spectrum. We mount assemblies on the account of low numbers of pieces by hand and check this afterwards with a test device. Moreover, we have jobs with assembly devices and servomechanisms as well as jobs with assembly machines. All assembly machines are provided with test stations which mark the good parts and sort out bad parts. Moreover, are used in our assembly ultrasound and heating element sweat machines.