General Electric Machinery Plant / VTG - GE...
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Imagination at work. Introduction 2014 GE Lighting Machinery Plant, Hungary
Transcript of General Electric Machinery Plant / VTG - GE...
Imagination at work.
Introduction 2014
GE Lighting Machinery Plant, Hungary
Introduction
Worldwide solution provider
• Deliver excellence in machine designing & building in multiple automation solutions
• Available machining resources for standard and specialized part manufacturing
• Expertise in mechanical and electrical development, automation and integration
• Customer focused: long-term spare part availability & support
• Managing complex projects
• Highly motivated and focused execution teams
Dedication to Quality
• Meet quality standard of ISO 9001:2009
• Health and Environment committed, EHS: ISO 14001
• Work along Lean & Six Sigma methodologies
• All solutions are CE marked
Concept
Design
Machining
Assembling
Installation Logistics
Support
Your success
L E A N E N T E R P R I S E
Machinery Plant Profile
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Budapest (BP) Hajdúböszörmény (HB)
Management
Solution Sales
Project Man.
Center of
Manufacturing &
Subcontracting
Excellence in
Designing &
Assembling
Complex Development & Service type operation specialist
Design | Machine build | TOW | Install | Customer Service
Our project methodology
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PM in SAP ERP
Capacity management
Project tracking
Process development
Data warehouse
Continuous project tracking with experienced project leaders
Quote Prepare
Concept & Design
Realizing Logistics Support
Install & Debug
Advanced Design Capabilities in…
…Prototyping & benchmarking
…Lighting industry leading portfolio
…Build-to-print
…Complex system improvements
…Re-designing machines, production lines, plants
…Creating best-in class solution
Extensive range of mechanical
designing
• 2-D & 3-D design capabilities
• Applied FEM analysis
Wide experience in electrical
design
• software development
• vision systems
• process-monitoring system
Engineering support
Creation of conceptual solutions
Domain expertise in designing and developing
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Specialized knowledge in digitized process monitoring
• Data collection and analysis
• Reject Analysis
• Batch Tracking / Material Usage / Stock
• Alarm / Event Analysis, Alarm Summary
/ History
• Trend analysis for technological
parameters
• Online SPC Analysis / Histograms
• Online Digital Score-carding of the
Production Line & Sub-systems
• Other specific reporting & data mining
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10+ years of experience with HMI / SCADA / Monitoring systems
Vision Systems & High-end commercial materials
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Professional machining capabilities
CNC machines Significant in-house capacity w/ continuous extension
3D Measuring for multiple industry purposes
Special partners In-house sourcing for materials and for subcontracting
Machining workshop
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Machining workshop capacity
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Machine Group Pieces Capacity (whours/y)
CNC milling machines 15 90.000
CNC turning machines 7 42.000
CNC grinding machine 1 6.000
CNC wire cut machines 4 24.000
CNC water jet machine 1 6.000
CNC engraving machines 2 12.000
Total: 30 180.000
Machine Group Pieces Capacity (whours/y)
NC boring mill / milling m/c’s 2 12.000
NC turning machines 3 18.000
Total: 5 30.000
Possible capacity extensions (in house)
Samples of special parts
Valve Body GE Lighting
50x50x140 Vacuum technical Component
CMHL Gas Burner GE Lighting
50x25x45 with D0,5 holes Burning Unit Critical Component
PGT25+ Diaphragm GE Energy
Gas Turbine Component
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Vibratory Feeder GE Lighting
D220x60 Feeder Unit Critical
Component
Validated subcontracting partners
Part
manufacturers
40+ partners to solve
capacity overloads
professional supply
chain parameters.
Our full capacity can
be doubled.
Special
technology
10+ partners to solve
special machining
needs if parts:
- extremely small
- extremely large
- extremely hard
Surface
treatment
5 partners to apply
various surface
regulations:
- nitriding
- hardening
- coating with oxides
- galvanizing
Service
type
5 partners to assist in
various complex
works:
- gas systems
- process monitoring systems
- assembled units
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Excellence in assembly capabilities
Mechanical & electrical
• Professional assembling and setup in advance and on site
• Cabinet assembling and high performance electrical system wiring
Extensive debugging
• Detailed and long-term dry- & hot-runs
High-tech Vision
• Implement industry-lead process monitoring & vision systems
Complex installing
• Full production line installation
Refurbishment
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Assembling area: 2.200 m2 We can work on up to 3 machines per station with 2,5 m x 2,5 m base concurrently…
6 1 1 8 Mechanical.. Electrical.. Supply.. …assembly stations
Excellence in assembly
Testing room: 880 m2
• Built-in: natural gas, oxygen, water, high
pressure air
• Gases use in bundle: nitrogen, hydrogen,
argon, sulfur, helium
Additional testing room facility: 6.000 m2
Managing concurrent assembling tasks:
• 5 m/c’s | EEH7 line
• 4 m/c’s | DEQ 576 line
• 5 m/c’s | EEH8 line
• 4 m/c’s | DEQ mount
• 2 m/c’s | J304
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Logistics, support
In-house capabilities:
• Jib crane with 12 tons capacity
Packaging and moving capabilities with our
validated GE partners.
Handling shipping and customs.
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Energized assembly team worldwide
Managing multiple projects
40+ automated machines to build, included
3 complete lines in 2014
Global availability
Separated integrator teams on multiple
locations across the world
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Integration teams
2013 2014 Q1 Q2 Q3 Q4 Q1 Q2
GH Hand.Sys. (USA) | 3
3-way WEGO (MEX-HUN) & Apollo (MEX-USA) | 12
EEH lines (HUN) | 6
Ravenna (USA) | 5
Q4
Silver Par (USA) | 6
Mount & Mat. Hand Sys. (USA) | 5
2012 2013 Q1 Q2 Q3 Q4 Q1 Q2
Silver PAR (USA) | 9
NT line move (HUN) | 14
Environment project (HUN) | 4 Molding m/c (India) | 4 H-box mod (HUN) | 4
GH Hand.Sys. (USA) | 3 3-way WEGO I. (MEX-HUN) | 10
EEH lines (HUN) | 6
Ravenna (USA) | 5
Q4
Project (Location) | Team HC
Case study
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Creating concept
Design and manufacture
Support and utilities
Training in Mattoon Drawings Spare parts Manuals
Project Case Study Scope
GE EEH product: New glass halogen capsules using hard glass tube.
Purpose of project
To design and build a High Speed EEH capsule making line to be installed in GE Lighting’s
halogen manufacturing plant in Mattoon, IL.
Project Case Study Schedule
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Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov
PO & Project start
M design
E design
Sourcing
Machining / Cutting
M Assy'
E Assy'
Debug/Test/EVP
Pack/Ship
Install/PVP
Sep 9
Feb 3
Jun 30
Mar 24
Apr 28
May 12
May 12
Sep 15
Jul 28
Nov 10
Quote Prepare
2 Realizing
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Concept Design
4 Install Debug
3
Logistics Support
2
Project Lifetime In months
from Idea to Production
15 months
stretched process…
Project Case Study Overview
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Sa
fety
Electric safety must follow GE & Mattoon LP requirement
Noise level not exceed by 85dB
Ma
jor
fea
ture
s The line output is 1850/hour good capsule
Yield: 95-99%/machine
Shrink rate: max 1%
Drive mode: Independent drives, indexing motion
Parts from unit to unit are fully automated. No manual effort.
Machines are connected with accumulator chains
Op
era
tio
n m
od
e Indexing mode without logic control
Jog mode with logic control
Machines controlled by PLC and has independent control cabinet
Automatic mode
Manual mode (using crank or hand wheel)
Chains: Asynchrony motor drive both ends
Utilities
Electric energy Natural gas
High pressure air Water
Nitrogen Oxygen
Forming gas Vacuum
Customer Project Product # of m/c’s
Procter & Gamble (Hungary)
Mostly built-to-print project with effective simplifications and system upgrades
pantyliner & tampon
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GE Lighting NA (USA)
Build material handling system for process automation by handling lamp components and parts by conveyor system
process development
3
Autonix (India)
Build H4 baking machines for a lamp component manufacturer based on a GE design
baked H4 lamp head
2
GE Power Controls (Poland)
Design an manufacture automated mounting machine for a non lighting GE plant
circuit breaker
1
Project Satisfactions
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