When capacity in the company’s automated three-press line started to become scarce, Esskå Metall went all out. An 800 square metre new addition to the factory is now the home of a fully automated three-press line from AP&T with an automation solution that can handle practically anything.
Esskå Metall’s primary business is the drawing of sheet metal components, supplying the automotive industry and its subcontractors. The company manufactures components such as hubcaps, heat shields, side skirts and various types of brackets for Scania’s heavy vehicles. But, now it has also been commissioned by manufacturers in the ventilation and pump industries. As a subcontractor to the automotive industry, offering a high degree of flexibility and delivery reliability is an obvious must. It is vital to be able to quickly changeover production while maintaining a high degree of availability in the facility.
Additional capacity
In order to meet future needs of its customers’ demands for greater
capacity coupled with great flexibility, the company began planning its
expansion in 2005.
"The automated press line with three hydraulic presses that we purchased
from AP&T in 2001 is now fully booked with assignments in three shifts.
There was no reserve capacity and we quite simply needed more," explains
Lennart Morin, president of Esskå Metalls.
Flexibility is a must
With good experiences from good
collaboration, AP&T once again was awarded the task of drawing up a
production solution that not only had high capacity, but above all had
great flexibility with the possibility of fully automated manufacture of a
large number of different items. Exactly what was unknown.
"We received the order in the spring of 2007 and delivered in the early
part of 2008. Now, production is in full swing," explains Göte Allansson,
AP&T’s key account manager for Esskå Metall.
Advanced line
The new press line consists of three
AP&T 6300 kN ZM presses with third cylinder function and cushion
function. A blank feeder picks the blanks from a pallet before the first of
four SpeedFeeder press robots puts the blank in the press tool. The two
SpeedFeeders located between the presses has four axles, which means it can
even rotate the components. The two others have three axles. A mobile
turning device that makes it possible to turn over the components between
the presses is also included.
"This type of production solution is more advanced and requires greater
investment than a press line built for a specific component. But, the great
flexibility makes it possible to quickly see a return on the investment,"
states Göte Allansson.
Minimal changeover times
One example of a solution that increases flexibility is the tool change
system with automatic tool clamping that AP&T delivered to cut
changeover times maximally.
"Now, we can convert production from one component to another in half the
time compared to the three hours needed in the old press line," says
Lennart Morin. "This streamlines things considerably since one component is
normally produced for one or two shifts before conversion. The entire press
line is monitored via three operator panels with LOGOS – an operator
interface developed by AP&T. AP&T also has responsibility for the
entire press line installation, including training operators for effective
use of the equipment."
Availability with service agreement
In order to
achieve a high level of availability in the press systems, Esskå Metall has
also taken out a service agreement with AP&T.
"We have delivery reliability of 99 percent due to the high level of
availability offered by the press system. For this reason, we work
exclusively with planned preventive maintenance and if anything else should
arise, AP&T technicians are on site in no time," states Lennart Morin.
Huge investment
This is a big investment for Esskå Metall. In addition to the press line,
there is also the cost of expanding the company’s premises to provide more
room for production. And even though a subcontract has no prior guarantees
that production will be at full capacity in the future, Lennart Morin is
calm.
"We have a good partnership with our customers and are often involved from
an early stage, including the designing of components. We make our
investments without knowing exactly what products will be produced, but
with our contacts in the automotive industry, we know relatively well what
demands are placed on us.
And with the new flexibility of the new AP&T press line, Esskå Metall
is ready for the next products – whatever they may be."
