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Tungsram Component Manufacturing 2018 Innovation is our heritage Tungsram Group in Hungary Light Source Factory Light Source Factory • Hard Glass Bulbs • Electromechanical assembly • Precision welding Ceramic Components Factory • Repair Machinery Factory • Tungsten Rod production Kisvárda Metal Component Factory • CNC Sheet metal • Metal stamping Budapest • Welding (HQ) • Plating Hajdúböszörmény • Toolmaking Zalaegerszeg Nagykanizsa Light Source Factory Component Factory • Injection moulding • CNC Machining • Powder painting • Welding • Electromechanical assembly • Wire manufacturing 4000+ qualified employees Tungsram Group Major capabilities and references ➢ Sheet metal – GE Grid, GE Industrial Solutions, GE Power Conversion, Borg Warner ➢ Machining – GE Power, GE Transporation, GE Grid, Knorr-Bremse ➢ Electromechanical assembly and precision welding – GE Power, GE Aviation ➢ Injection moulding – GE Lighting, Current powered by GE ➢ Wire drawing for medical market – Intuitive Surgical (in progress) Integrated supplier of complex projects 3 Tungsram Group Sheet metal and plastic manufacturing (Zalaegerszeg & Nagykanizsa plants) Technologies Pressing & bending Deep-drawing Plastic moulding Bihler (multi-slide) technology Toolmaking (progressive and serial tools) Degreasing, Ni plating Powder coating 5 Sheet metal forming – cutting I. Prima Power E6 Turret Punch Press Prima Power E6 Compact Express Amanda Fiber Laser with MP-Flex loading equimpent 6 Sheet metal forming – bending Amanda HG – 1000 KN (Number of machines: 3) Amanda HFE – 500 KN (Number of machines: 2) Prima Power – 1050 KN (Number of machines: 1) 7 Machines for metal stamping (Nr.) Excenter presses from 1 to 100 tons 50+ Bihler 35, 50, 80 ton multi-slide machines 12 (some with welding and mangling units) Transfer presses 35, 50 tons 54 Stand-alone manual presses (1 – 63 tons) 10 Trowalizing and degreasing equipment 15 Nickel plating line (barrell) 1 8 Product sizes and tolerances - Stamping Material thickness – pressing and bending 0,1 – 3 mm (depends on raw material alloy and technology) Material thickness – deep drawing 0,1- 1,5 mm Tolerance of cutted parameters +/-0,02 mm (depends on material thickness) Tolerance of flatness min. 0,03 mm (depends on component size and geometry) Biggest stamped component 120x120x2 mm (always to be confirmed by technology) Maximum progressive tool size Length: 1 meter Maximum number of steps in transfer tool 9 9 Products and applications Industrial Components 10 Simple Assemblies Electrical Cabinet plate + PEM Electrical Cabinet sheet+ PEM Plate + PEM W: 300 mm, Th: 1,5 mm Steel W: 500 mm, Th: 1,5 mm Steel W: 600 mm, Th: 0,8 mm Steel Reflector holder + PEM BT22 box Holder L: 800 mm, Th: 1 mm Plated Steel W: 450 mm, Th: 0,7 mm Steel L: 500 mm, Th: 1,5 mm Steel Complex Assemblies Housing assy Blade assy Reflector W: 1200 mm, Th: 0,7 mm Steel W: 1000 mm, Th: 0,8 mm steel W: 400 mm, Th: 0,8 mm Reflective Steel Reflector housing Downlighter Assy Box assy W: 600 mm, Th: 0,8 mm Plated Steel D: 300 mm, Th: 1,5 mm Alu W: 200 mm, Th: 2 mm Steel Tooling Design: Progressive tooling Transfer tooling Bihler tooling Special tooling Manufacturing: 300+ tools annually 15+ tool experts 40+ technicians High precision testlab Upgraded machinery 14 Plastic Operation Shopfloor Linear and 6-axis robots Fanuc Arc Mate 100iC 15 250 – 420 t Demag injection molding machine Demag 250T/630-840 Concept top Demag 420T/810-1450 Concept Top Löket térfogat Záróerő csiga átmérő szerszám beépítési magasság max. szerszám beépítési magasság min. szerszám felfogó lapok mérete mm ccm3 Tonna clamping screw diamater mold height max. mold height min. dose volume Tool clamping plates size force d-50 710 mm 330 mm 442(400g) 630x630 250 d-50 820 mm 380 mm 530(480g) 810x710 420 d-60 820 mm 380 mm 760(690g) 810x710 420 16 50 – 100 t Demag injection molding machine Löket térfogat Záróerő csiga átmérő szerszám beépítési magasság max. szerszám beépítési magasság min. szerszám felfogó lapok mérete mm ccm3 Tonna clamping screw diamater mold height max. mold height min. dose volume Tool clamping plates size force d-25 410 mm 200 mm 51(45g) 420x370 50 d-30 430 mm 200 mm 114(101g) 420x420 100 17 3D coordinate measuring / 3 D Sampling 18 Paint Shop Line 1 Line 2 Off-line spray booth Painted parts: Painted parts: • Indoor aluminium • Aluminium alloys Sample painting • Steel • Aluminium sheets Low qty. painting Pretreatment • Steel parts • 4 stage pretreatment Pretreatment Colors • 7 stage • 62 different color Colors Window size • 62 different colors • 1500x600 Window size Speed • 1000x500 • 1,1 m/min Speed • 1,3 m/min 19 Tungsram Group Electromechanical assembly (Nagykanizsa plant) Electromechanical assembly areas Indoor production area: • 2500+ m2 assembly production area • 120+ operators • 2500+ pcs daily LED indoor fixture production capacity • 3 pcs semi-automatic production lines • 8 pcs normal production lines • 4 pcs U shape production lines • 3 pcs production cells Outdoor production area: • 1000+ m2 assembly production area • 60+ operators • 1000+ pcs daily LED outdoor fixture production capacity • 3 pcs semi-automatic – high capacity - production lines • 2 pcs normal production lines 21 Electromechanical assembly production line types 22 Electromechanical assembly – SMT SMT line layout Laser Solder SPI Placement Reflow AOI Marker Printer KY YJLink Panasonic KY Panasonic HB Automation Zenith ALMC 200 SPG 8030 NPM CS-1202N (3D) 23 Electromechanical assembly – SMT Basic PCB dimension • Minimum PCB size: 50x70 • Maximum PCB size: 510x460(Paste printer maximum) • Thickness: 0,3-8 mm • Max warpage: 0,5 mm • Fiducial mark 24 Electromechanical assembly - Cable confection Cable range: Wire crimps: • PVC or silicone seal • F, M, MG, FG types • 0,5-1 mm diameter Cips: • 70-2000 mm lenght • O, OS, S, B types • Optional wire crimps, clips • Pre programmed wire caracterics Equipments: • 2 automatic cutters • 3 semi-automatic cutters • 6 crimping machines 25 Electromechanical assembly – in house synergies Tungsram Group has in Nagykanizsa (& Zalaegerszeg)*: ✓ Automatic Storage System ✓ Powder paining line ✓ Tool shop* ✓ Plastic part production ✓ Paper box production ✓ Sheet metal manufacturing plant* ✓ SMT line ✓ Cable confection area 26 Electromechanical assembly – quality system overview 27 Tungsram Group Machining manufacturing (Hajdúböszörmény plant) Main profile of Production Valve Body Bearing Cap Shaft end GE Lighting GE Transportation LEAX 50 x 50 x 140 D 420 X 50 D 75 x 49 Spare parts Direct material Direct material CMHL Gas Burner Latches Pulling wedge GE Lighting GE Grid Knorr-Bremse 50 x 25 x 45 with D 0,5 holes D 25 x 110 D 72 x 143 Spare parts Direct material Direct material Indexing Cam Liner Stop GE Lighting GE Power D 600 X 300 38 x 42 x 54 Gripper Spare parts Direct material Knorr – Bremse 600 X 600 X 500 Devices 29 Parts manufacturing capabilities /More than 88 cutting equipment including 30 CNCs/ Max mfg size Machine type Accuracy (mm) Machines (mm) CNC turning X: 200-760 0,005-0,02 MAZAK QTN 200, EV 630-01, EEN 400, EEN 320, MAZAK Z: 300-1530 INTEGREX CNC grinding X: 80, 0,005 STUDER S20-4 Z: 400 CNC milling X: 400-1050 0,005 MAZAK VCN 510C, DMU 60T Y: 300-500 0,01 DECKEL FP4CC, DECKEL FP4CC, Mikron WE31D, Mikron VC500, PICOMAX Z: 200-600 0,05 DECKEL FP3CC,, MVI-6, DECKEL FP5NC, FV30/16, FV30/15, FV30/14, FND, FUW250 Traditional 0,01 - 0,1 BFT 90, MIKRON WF3SA, SUI 80, Copymat, 40LN, SWBE, TOS Bua20, KU 250-04 Other CNC X: 280-350 0,005 - 0,05 Agiecut 120, Agiecut Challenge, FIRST FST 250 CZT technology Y: 200-360 Z: 200-300 30 High-tech MAZAK machines QTN 200 MSY II Integrex 300 ST IV VCN 510 C II Size Precision Axis Tool storage Free Capacity Mazak machines [mm] [mm] [pcs] [pcs] [hours/year] QTN 200 MSY II D380 x 575 0,01 5 12 4 000 hr Integrex 300 ST IV D760 x 1530 0,01 – 0,02 11 40 2 000 hr VCN 510 C II 1050 x 510 x 510 0,01 – 0,02 4 30 2 000 hr 31 High pressure Water Jet cutting General properties X, Y : 3050*2050 mm One Z-axis carriage with one cutting head A standard operation system PTV 886 Material palette: ferrous metal, non ferrous metal, glass, marble, plastics 3D coorninate measuring WENZEL LH 1210; 1200mm x 2000mm x 1000mm 32 Professionals In Wire drawing Laser & High speed welding High Temperature Chemical treatment treatment Process Monitoring system 33 New business development From the total Hajdu Plant 89 703 m2 500+ m2 free shop-floor for business development 800 m2 free for additional buildings 34 Tungsram Group Assembly and welding operation (Kisvárda plant) Gas turbines repair and inspection Fuel Nozzle Cap Liner Transition Piece Incoming inspection Combustion space of gas turbines • Visual check for cracks, distortions, missing parts, identification, NDT-penetration Power Nozzle inspection, damages • Measurements: geometrical, thickness of coating • Cosmetic surface grinding, TBC coating strip • Disassembly segments, mount seals, repair with AWI • Taking photos, reporting 36 Generator Control Panel – electrical assembling Operation • Assembling the connections with skilled electricians • Ability to use electrical documentation • Using parts from both the can ban and ordered sources • Adjustments of built-in electrical components • Identification of all parts • Checking connection errors • GCP (Generator Control Panel) to mobile gas turbines • Containing 9’000 parts and 1’500 connections 37 Circuit braker repair and assembly Operations • To get to know the product and process • Material handling • Disassembling parts • Metal part forming • Sorting parts based on many criteria • Semi-skilled workers are capable to be trained 38 New business development 39 Professionals In Automated production line Class forming AWI welding Liquid Grind blasting Resistance welding Penetration test Vacuum technology 40 Certificates ISO 9001:2008 ISO/TS 16949:2009 ISO 14001:2004 41 42.
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