Creating maximum value

Transcription

1 Creating maximum value

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3 contents This is Howshun Our business areas Meet Yao, our CEO Quality supplying partner How do we work? Hard work today yields profitability tomorrow What we believe Our values and policy Casting process Forging process Machining process & Quality control Time line, project sample flow 2

4 this is howshun casting forging machining Howshun is a manufacturing engineering company producing customer-specific products and components while securing quality efficiently. Over the years, the company has refined its technology and increased its knowledge in casting, forging and machining for the industry. The company invests substantial amounts in development and operations to meet market demands. Operations Annual growth Ÿ Sand and precision casting parts in 23% low-alloy steel and ductile iron and grey iron materials. Employees 252 Ÿ Forging of products in low-alloy Establishment steels. Year 2004 Quality system Ÿ Delivery of precision and advanced machined products from casting and forging. ISO TS 16949/ISO 9001 Ownership Private family global business U.S.A China 35% 5% Brazil 15% 45% Europe european head office 3 Headquarters & plants

5 our business areas Sustainable manufacturing Howshun's Sustainable Manufacturing concept is the heart of the company. It stabilizes and secures quality for manufacturing of any high volume products. rail and mining Howshun's Rail and Mining aims to ensure the quality and durability for heavily strained products developed for high-speed trains, railway transportation and the mining industry. Examples: wheels, brake brackets and bogie components. Construction and mining Howshun's Construction Equipment handles products and components for heavy machines and the construction industry. These products and components often suffer more strains than specified in drawings. Example: couplings, shafts, link arms and excavator components. hydraulics Howshun's Hydraulics specializes in securing hydraulic components where failure jeopardizes safety. The products processes are strictly controlled and nothing is left to chance. Examples: cylinder end, rod eye and heads. Project Howshun's Project team develops solutions for the most challenging tasks. Problematic parts or time consuming parts will be engineered to reduce costs and create stability. Conversions from casting to forging, welding to casting and reconstructions and re-designing for manufacturing are being engineered. 4

6 Meet yao, ourceo W ith a passion for engineering, a mind-set to solve problems and a belief that there is always room for improvement, we at our company commit ourselves to fulfil our customers' dreams by realizing their constructions. Years of practice and research has forged us into a dependable partner. A partner delivering not only products but also stability and quality. We always have the ambition to generate value through our services and to act as a strong supplying partner. To our long-term business partners who has supported us in our journey and to our new partners entrusting us with their constructions; we are grateful for the confidence given to our team. YaoRongping Rong ping Yao, Chief Executive Officer 5

7 your quality & supplyingpartner P roduction line stoppages are nightmares for any manufacturing company. A strong supply chain is often a key factor for the success of a company. By securing and selecting the right supplying partner, a company's hidden costs can be reduced dramatically. In our business we cannot leave anything to chance. Every risk is a cost that can be a very expensive lesson to learn. We at Howshun secure and rationalize the manufacturing process to ensure the quality and capability of the production. We thoroughly customize and develop every production process for each product to create a reliable and efficient supply chain for all deliveries. 6

8 how do we work? Sustainable manufacturing I n work, as in life, there is a virtuous circle between what we do and the manner in which we do it. Manufacturing products that fit and work well are essential but being a reliable business partner requires that we do more than that. Howshun's approach is to create a balance between quality, cost and delivery by understanding every product's requirements, reducing costs and increasing efficiency. Increase quality, cost efficiency and delivery precision are expressions that define our goal to offer reliable products and services. In all aspects of our operations, from new development to handling of expired parts, our focus is process stability, continuous improvement and 'Just-in-time' for our customers. phase 1. technical review In the early stage our engineering department uses a comprehensive planning before manufacturing any parts. With the latest simulation technology we are able to identify and predict problematic zones. By thoroughly engineering the process a sustainable and stable supply chain is created. phase 2. samples Part-samples will be sent to you for verification along with required certificate documents, guaranteeing the parts fit the given technical specifications. 7

9 phase 3. process capability Our process capability statistics will ensure stability and efficiency of the process. If possible, there will also be rationalizing to further reduce the costs and increase cost-efficiency. phase 4. mass production Our services do not stop when the parts fit the given technical specifications. To handle different order volumes, safety stocks and 'Justin-time' throughout the parts' lifecycle we can customize every delivery with required logistic solution. phase 5. after sales When parts expire we will continue to deliver the needed volumes for customer's maintenance and warranties. The process will be well preserved with stocking options for the parts remaining lifetime. 8

10 hard work today yields profitability tomorrow O ur engineering and development activities are crucial for ensuring our company's competitiveness and long-term growth, and are often conducted in close collaboration with customers. Our sales team consists of experienced project leaders, engineers and multi-cultural and international staff members who manage and solve the complexity, cultural differences and obstacles that customers may experience. casting simulation process capability test With the latest casting simulation technology we are able to start optimizing our production and identify problematic zones before we start production. It is often required to compare the output of a stable process with process specifications and to make a statement about how well the process meets customers' specification limits. Simulations are key tools in comprehensive quality assurance; they enable us to discover valuable information about the manufacturability of products, components and parts early in the process. By studying the process we can guarantee the quality, and continuously improve and implement CAPA (Corrective and Preventive Actions) to further stabilize and reduce production costs. From an environmental perspective it also eliminates sources of wasted energy and material, which leads to lower manufacturing costs and lessen impact on our environment. 9

11 Design for manufacturing Designing engineers and Constructors are often well aware of the requirements for the end-product demanded by the market, but they often lack understanding of the actual manufacturing process for the parts. Our engineering team consists of experts from manufacturing with rich experience in casting, forging and machining. Our experts from different fields are able to suggest design modifications to reduce manufacturing costs without affecting the function of the parts. Apart from designing modifications, we can also assist your engineers in conversion, between forging, casting and welding. Ÿ Forged parts can be converted to casting to reduce manufacturing costs. Ÿ Casted parts can be converted to forging for better mechanical properties. Ÿ Welded products can be converted into casting to reduce risks, cost and time of welding. key activities Ÿ Casting simulation Ÿ Process capability tests Ÿ Rationalize production Ÿ Part and product conversions Ÿ Design for manufacturing 10

12 what we believe We are dedicated to secure quality and offer cost-efficient solutions. Our vision To become world leader in securing quality and develop sustainable manufacturing by; Working with safety, environment and personnel motivation. Creating value for our customers Driving quality and manufacturing to benefit our customers We listen to our customers and partners, to fulfil their current needs, to help them solve their problems and to foresee their future demands, but more importantly, to create a stable and safe supply chain. We will continue to improve ourselves so you can rely on our services, quality and effciency. 11

13 Our values and policies At Howshun we believe in and operate on a few clear values. These values are the foundation and basis of all of our businesses. quality We continuously deliver parts and products that fit customer specifications with minimum variation. Diligence We give full attention to every customers and task, knowing that we always do our outmost. Innovation We believe that there is always a better way to do things The Howshun way Quality requires precision, products need development, management demands efficiency and customers expect satisfaction." 12

14 casting process raw material melting Our materials are sourced at the lowest prices available due to our purchase volumes and longterm relationships with our suppliers. The specified material is melted and composed in our furnaces at temperatures ranging from 1400 C to 1600 C with computerized systems constantly monitoring the temperature. With a customized mix of metals, recycled iron and scrap iron we blend the specified material standard required for the parts. The material will be tested and verified before and after pouring. vertical mold and core making Moulded and shaped sand works perfect as a holder for molten iron and steel due to its high melting temperature at 1700 C. Vertical moulding is beneficial due to the speed, quality, versatility and safety of the process. In this process, two mould sides are made from the tool pattern. One side has the front pattern of the casting and the other side the back of the casting. The two mould sides join and form the entire casting piece. wax making cleaning For more precise casting parts we use lost-wax casting. In this process, a wax model of the casting part is created. The wax model is then coated with sand to form a shell around the wax model. The wax model is then removed, leaving only the shell. Before pouring the iron/steel into the shell, the shell must be heated up to avoid shattering of the shell due to high temperature differences. When the castings are below 60 C, they are ready to be cleaned. Remaining residual sand and moulding media is removed from the surface of the casting. Excess materials left from the moulding process are removed and at last blasted, ready for inspection to be delivered to machining or customer. After pouring, the filled shells are allowed to cool and finally the shell is split revealing the casted part. 13

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16 Forging process raw material die impression All materials are sourced directly from well-established and international recognized steel mills with proper certificates for our incoming inspection. Tool patterns are manufactured together with our long-term specialist partner to ensure quality, stability and life time. Open and Closed die forging Open and closed die forging is the process of deforming a piece of metal. Approximately 1230 C carbon steel is warmed up for deformation into customers' specifications. Depending on the shape and complexity different steps are required. In the open die forge process, the steel is hammered or stamped into the desired shape and form through multiple dies that do not completely enclose the part. In the closed die forge process, or impression die forging, the process uses pressure to compress the steel to fill the enclosed die impression. Multiple die impressions may also be used to modify the material into the final desired shape and form. Advanced controlled cooling cleaning After forging the parts are glowing hot. Depending on the material specification given by the customer the desired mechanical properties can be achieved by controlling the cooling process. Through this process, we are able to save the heat treatment costs and reduce the total production costs for our customers. When the forged parts have cooled down, they are cleaned. Burr and excess materials left from the forging process are removed and at last blasted, ready for inspection to be delivered to machining or customer. 15

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18 Machining process Innovative machining solutions Our methods and systems help us strengthen the production with newly developed processes and approaches that can significantly increase flexibility, lower costs and improve manufacturing accuracy. Together with our customers we need to face the market pressure for manufactured products. We need to manufacture with the lowest possible cost and uphold high quality while being agile to adapt our production for changing volumes and new parts. Our production benefits our customers with highly effective machining centres, innovative machining solutions and turnkey engineering services, all to reduce costs and cycle times. milling to its maximum Our control technology, machine stability and spindle performance enables us to satisfy most requirements and fulfil our customers' part features and quality requests. Fixtures are thoroughly designed for maximum efficiency and stability performance. innovatve turing lathe With a complete turning facility and the ability to construct specialized cutting tools for complex parts we guarantee high efficiency and short cycle times. 17

19 quality control inspection center We deliver quality by meeting our customers' specifications continuously with minimum variation. Therefore, a well-equipped inspection centre is required. Our inspection centre is suited with modern Computerized Measuring Machines (CMM), mechanical properties testing equipment, ultrasonic inspection machines, magnetic particle detectors and hydraulic pressure testing machines. A strong inspection department ensures us that our deliveries fit customer demands and requirements. Our main production is stationed in China due to the low labour costs offered. This enables us to verify the capacity of our processes with 100 % inspection without substantially increasing the costs. Delivery reports All deliveries include the following reports certificates. Material certificate Chemical report Mechanical properties report Heat treatment report Measuring report Other requested reports Ultrasonic test reports, for inclination detection Ÿ Magnetic particle report, for crack detection Ÿ Pressure reports, for leakage detection Ÿ Ÿ Ÿ Ÿ Ÿ Ÿ Ÿ 18

20 project sample flow Review of all technical requirements and documents. Design and construction of production process, mould, tooling, fixtures and inspection gauge tools Week 3 Week 1 Week 2 Week 4 Manufacturing of mould, tooling, gauges and fixtures Manufacturing of blank raw piece samples 19

21 Verifying blank raw piece and start machining for samples Customer verification and approval for serial production Week 5 Week 7 Week 6 Packing and delivery to customer 20

22 head quarters Howshun Innovated Manufacture Co., Ltd Meichi Industrial Zone, Yunlong, Yinzhou Ningbo China Phone: Website: Europe head office Howshun Sweden AB Gustav Adolfs Torg 10A Malmoe Sweden Phone: