FOCUS ON PRESS HARDENING
that it was functioning properly , tweak the equipment and be able to rectify any problems that might arise ,” Theander cautioned .
Before the first line installation was complete , AP & T received an order for an identical line for GEDIA ’ s Spanish production facility outside Barcelona , Spain .
“ We were able to draw on our experiences from the first line at the very beginning for working on the second line . So , just 17 months later , we were able to deliver a solution optimised for the Spanish facility together with GEDIA ’ s German organisation ,” added Theander .
In January 2020 , GEDIA ordered a third production line of this type . This time , it was for its Dalton , Georgia , factory in the U . S . The line was to be installed in Autumn 2021 . original requirement specification has been practically applied three times over . What does he think of the results ?
“ We now have a user-friendly , spaceefficient solution with a high degree of process reliability and excellent energy efficiency . Aside from TemperBox ® itself , AP & T ’ s servo-hydraulic press , with its considerably lower cooling requirements and energy consumption per stroke compared to conventional hydraulic presses , plays a central role in the result . We are very satisfied ,” he told ISMR .
AP & T SpeedFeeder automation system .
The production lines
GEDIA ’ s complete production lines for manufacturing partially press-hardened components include , for example : -
■ AP & T ’ s servo-hydraulic press .
■ AP & T ’ s Multi-Layer Furnace with TemperBox ®.
■ AP & T ’ s SpeedFeeder automation solutions .
The partnership principle
“ Together with GEDIA , we developed what is probably the world ’ s most advanced production line for manufacturing presshardened components for the automotive industry . By collaborating , we not only solved technological challenges and gained valuable experience , but we also managed to meet high expectations ,” explained Theander .
“ Through professional , trusted and forwardlooking collaboration , we jointly developed and industrialised a new technology , with a business-strategic focus . But it is all about people . They must be dedicated to the task , work well together and understand and trust one another . Not only is this how our relationship with AP & T is characterised , but it is also key to our successful efforts with TemperBox ®,” said Vogt .
So how does the result compare to earlier AP & T press-hardening lines ?
“ First and foremost , the new lines are considerably more energy-efficient mainly because the servo-hydraulic press consumes up to 70 % less energy than conventional hydraulic presses . The latest generation of multi-layer furnaces , consuming 40 % less energy than its predecessors , also makes an important contribution ,” said AP & T . “ In addition , the new lines make it possible to shorten manufacturing cycle times of certain products by up to 20 %, freeing up time for more production .”
In the design process , increased availability and a reduced need for maintenance were key aims . The multi-layer furnaces posed several challenges , which the teams resolved . Further collaboration efforts will continue to try to significantly increase annual production hours .
“ We have also developed a method of verifying the CQI-9 process repeatability of the furnaces so that it is significantly faster than before . This makes room for more valuable production time ,” added Theander .
For Stephan Gante , GEDIA ’ s group director of machine and building management , the
Björn Müller is also pleased . He confirmed that visitors are impressed when they catch their first glimpse of the new , highly automated lines . He also emphasised that the developmental journey with AP & T is continuing .
“ Every phase of this project has given us new experience and insight , which we took with us to the next phase . It is a continuous improvement project that is still ongoing ,” he said .
But perhaps the most important result is the experience gained from this type of collaboration . Or , in the words of Jörgen Theander : “ We usually talk about how we act as One Responsible Partner ® in many of our customer collaborations . But in this joint effort , there have been two responsible partners who jointly created a world-class solution through a clear common goal ; an open , curious approach and a deep sense of dedication .” n
CONTACT
GEDIA was founded over one hundred years ago . It has been manufacturing products for the automotive industry since 1955 . It now has more than 4,200 employees in nine production plants and is also involved in joint ventures and research companies .
With its headquarters in Ulricehamn , Sweden , AP & T develops and manufactures production solutions for the forming of sheet metal and other materials for customers all around the globe . It focuses on sustainable solutions for customers in a wide range of industries . AP & T has sales and service representation all over the world . It has been part of Fairford Holdings since 2009 .
GEDIA specialises in stamped automotive components .