80 km from Budapest 1975. Start of production activities as a part-time job Car repair, car engineering. machined and metal products Started to supply machined and metal products for food industry Expansion of activites with the production of fasteners and machined components and plastic injection moulding. machined components and plastic injection moulding. Start of a small business manufacturing custom tools Start of a small business manufacturing custom tools as self-employed as self-employed. Established the first factory in the industrial zone Established the first factory in the industrial zone with 6 employees. with 6 employees. (came from FERZOL Ltd. name was founded (came from the two owners named FERenc-ZOLtn) the two owners named FERenc-ZOLtn) The productions plant extended with ; number of employees an additional 2000 m 2 ; number of employees increased to The facility extended with another m 2 headcount expended to 140 employees Facility extension with 2200 m2. Total production area is m Warehouse extension with 5600m Build up new technology, extension of machinery park with new 3D lasercutting machine, grinding machine, panel bending. CNC plant Stamping plant Locksmith section Assembly Powsder Coating Plant Logistics department Quality Management Sales Department Production Support Financial Departmnet Thickness:0,5-4,0 mm Width:3000 mm 1 pc TruLaser 3030 (CO 2 laser) Mild steel: 0,5-20 mm thickness Stainless steel: 0,5-6 mm thickness Aluminium:0,5-5 mm thickness Working range: 1500x3000 mm 1 pc TruLaser 5040 (Fiber laser) Mild Steel: 0,5-20 mm thickness (more economical to 3,5 mm) Stainless steel: 0,5-6 mm thickness (more economical to 3 mm) Aluminium:0,5-5 mm thickness (more economical to 1,5 mm) Copper (copper, brass): 0,5-4 mm thickness Working range : 2000x4000 mm 1 pc TruLaser 5030 (Fiber laser) Working range:1500x3000 Working range:3000x1300x600 Power:3kW Rotary table D=4000mm Material thickness: 0,5 2,5 mm Working range: 1250 x 2500 mm 5 pcs TruPunch 3000 9 pcs Amada bending machine: mm bending length 5 pcs Trumpf bending machine : mm bending length 1 pc Adira 1 pc Simat bending machine : bending length Thickness: depending on lenght 0,5-10 mm 1 db Salvagnini P4Xe panelbending 1 db TruBend Cell 5000 Excenter pressing 7 pcs 1-25 ton 14 pcs ton 14 pcs ton 1 pc315 ton Hydraulic pressing 8 pcs3 ton 1 pc25 ton 2 pcs40 ton 3 pcs ton 1 pc200 ton 1 pc 500ton Fasteners and turned parts insertion 3 pcs PEMSERTER machine. Control unit with 6 cameras for fastener and insert counting Controlled surface: 100% Thread cutting. 4 pcs Tapping machine Automatic tapping machine Working range 1250x1250 mm Threading:M2,5 M8 Max. working width:1350 mm Grinding belt size: 1380 X 1900 mm Grinding brush diameter: 350 mm Working hight 100 mm Speed of grinding tape: 11 m/s Rotating brush speed: 6-17 m/s Press Machine pressforce 315 ton 800 mm width with roll feed Tool making related to the production parts, maintenance of existing tools, sharpening. Wire cutting (EDM): AgiCharmilles CUT 20P EDM Max: 250x350x250 mm Robot arm:1900 mm Electric power:TPS4000 Fronius (400A) Turning diameters:1000x3000 mm Maximum loading 1000 kg 0,5- 4mm mild Steel, stainless Steel, and aluminium sheets. Output: Max. 75 kW 5 machines Manual metal hand welding Advanced pulse welding machine 4pcs REHM MegaPlus 300 2pcs ESAB MG U4000i 2pcs Weldimpex TIG 250 Procedures 2pcs Weldimpex TIG 250 Procedures: MIG / MAG / WIG max.: 400A Drilling, cutting, welding, grinding. Machining after welding. Manual assembly. Rivetting. Screwing. Insulation and gasket adhesives Assembled and semi assembled modules Electrostatic manual powder coating, hand-held spraying, with 3 preparing stages 0,6 m/s track speed Maximum size that can be painted: 450x1200x2500 mm Pre-treatment Phases Approach, entrance section Hot degreasing, acid-film formation18050-60C With Nanotechnology Drained Rinse with cold tap water90ambient temp. Drained Recycled deionized water rinse Recycled deionized water rinse 60 ambient temp. Drained Passivation60 ambient temp. Drained, exit section Advantages compared to the old line. Faster track speed (0,6 m/s up to 1,1 m/s) Pre-treatment improvement in all phases Hot degreasing Rinse with cold tap water Recycled deionized water rinse Recycled deionized water rinse Passivation Automatic powder coating (more even coat of paint) Larger sizes can be painted 450x1500x3500 Sewage treatment is completely environmental friendly technology (There is No wastewater discharge) For raw material, semi- finished and finished products storage on m 2. Finished goods packaging for sea, air and road tranportations according to safety delivery conditions OTD (on-time delivery): 99,7 % Kanban service JIT Delivery of finished products Domestic transport by own lorries, To foreign countries with subcontractors. Ranges: 700x900x1500 mm Main Specifications Distance X - axis 1500 mm longitudinal Distance Y axis 1000 mm transverse Distance Z axis 850 mm vertical Resolution mm Accuracy of measurement in ISO 10360/2 MPEE = 3,0 + L/312 m Maximum speed at 3D measuring 0,52 m/sec Acceleration at 3D measuring 1,73 m/sec 2 ERP System FERZOL is using ERP sytem called Infor:com since It includes full manufacturing documentation, and production data recording. Supplemented with the L-Mobile storage reporting system. PPAP FMEA CP Inspection report New Process Capability studies APQP FAI Machine capability and process capbility measurement cpk 1,33 cmk 1,33 In manufacturing our products we are using median range cards in the SPC process. The manufacturing processes are kept under constant review as time goes on, so they can always be regulated. 2013 ISO Appropriate management system is in operation according to all points in the standard ISO 9001 9 engineers 1 administrator Product development based on customer needs and sketches. Resource lists compilation. Technological preparation instructions For adapting customer documentation, drawings and 3D models we are using CAD systems. Responsibility: -Customer contact -Price calculation -Project management/NPI 9 employees finance and economics A new 2,200 m 2 production plant 1 new TRUMPF CO2 laser cutting machine 2 new AMADA CNC bending machines 315 ton excenter press machine 160 and 200-ton hydraulic press machine paint shop expansion (powder coating machine with nano-ceramic pretreatment, 360 m 2 plant extension) 2 Fiber Trulaser type (5030, 5040) 1 Trubend bending machine 1 Amada bending machine 1 Trupanch S11 servo punching machine New Warehouse m 2 New Warehouse m 2 500 ton excenter press machine 500 ton excenter press machine New 3D Trumph lasercutting machine New 3D Trumph lasercutting machine New Assembly Hall m 2 New Assembly Hall m 2 New welding robot, Yasukawa/Motoman New welding robot, Yasukawa/Motoman New bending robot cell with 4m long New bending robot cell with 4m long Foam gasket sealing robot cell Foam gasket sealing robot cell Grinding machine, TimeSavers Grinding machine, TimeSavers 500t hydraulic pressing machine 500t hydraulic pressing machine New 2.5 m Salvagnini P4Xe panelbending robot New 2.5 m Salvagnini P4Xe panelbending robot