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Iron casting production
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Transcript of Iron casting production - rustrade.cz casting.pdf · Success factors in detail ... production of...
Iron casting production
2
Business of Autocomponents Division
Chassis and Power Train systems
Steering system
Brake system
Fuel system
Driving and non-driving axles
Suspension modules
Clutch
Wheel discs
Leaf springs
Control systems
Body armature
Stamped parts
Truck beds
Frame
Body
Success factors in detail
Tools and accessories
Dies and press-molds
Fasteners
(JV Bulten-GAZ)
Tooling
Joint ventures
Exhaust system
(JV Bosal-GAZ)
Iron casting
Forging
Aluminum and other
non-ferrous casting
Blanking production
Player №1 in the Russian iron castings market,
produces 8% of the total market volume.
The “iron casting” direction is one of
the Division’s key business lines,
which makes up 20% of the total revenue.
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Product portfolio
1. High competence in design and production of various types of iron
castings
2. Application of Magmasoft automated end-to-end- design and casting
process preparation system 3. Competitive price
4. Up-to-date high-technology efficient equipment
Wide range of castings, the weight of which varies from 0.1 to 150 kg.:
Cast parts for vehicle engines: crankshafts, camshafts, cylinder blocks, cylinder heads,
inlet and outlet manifolds, etc.
Cast parts of vehicle suspension: brake discs, brake calipers, hubs, bearing caps, etc.
Cast parts for railway equipment: anchors, friction wedges, monoblocks, etc.
Cast parts for power-plant industry, manufacturers of special-purpose vehicles,
agricultural equipment, machine-tools, etc.
Competitiveness
Major products
4
Customer portfolio
Breakdown by customers
2012
факт
GAZ; 32%
Motor Plants of GAZ Group; 10%
Russian Railways; 35%
Sollers; 13%
Minsk Motor Plant; 2%
Knorr Bremse; 1% Other customers; 7% (incl. )
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Production capacities and basic manufacturing technologies
Production
capacities
Basic
technologies
Production of a wide range of castings, the weight of which varies from 0.1 to
150 kg. with various sizes:
production of castings from grey cast iron (SCh) – 18, 24 (56 thou. t/y)
production of castings from high-strength iron (VCh)– 50, 60, 70 (56 thou. t/y)
production of castings for repairs from SCh and VCh
production of castings from heat-resistant and oxidation-resisting steels
production of castings from wear-resistant alloys
own production of casting tooling of any complexity
product yield – 108 thou. t/y
Magmasoft automated system of end-to-end- design and process
preparation
Induction melting and duplex-process
Automatic ladling
Equipment for core production according to cold-box and hot-box processes
Investment
projects
Creation of a new shop for production of castings from grey cast iron and
high-strength cast iron with capacity of 30 thou. t/y (under consideration,
planned for implementation)
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thou. t/y
6
Iron casting production location
GAZ JSC
Foundry shop №2
Gray cast iron
Foundry shop №4
Gray cast iron
Foundry shop №7
VCh50, VCh70
Foundry shop №8
VCh50, VCh60, VCh70
Foundry shop №1
VCh50
Foundry shop №3
Gray cast iron
Pattern-shop
Space, m2
Foundry shop №1 35 181
Foundry shop №2 17 499
Foundry shop №3 17 720
Foundry shop №4 22 017
Foundry shop №7 20 525
Foundry shop №8 18 127
Pattern-shop 6 092
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Foundry shop № 1
Casting type High-strength iron
VCh50
Installed
capacity 24 thou. t/y
Product mix
Wide range of castings weighting
from 0.01 to 35.0 kg. Anchor
Rear spring
Rear wheel hub etc.
Melting area Induction melting furnaces with
bath capacity – 31t.
Molding area Automatic molding lines (molding
box size: 1100х800х300/300)
Core-making area
Automatic core-making machines
Hot box & Cold box core-making
machines
Dressing section Rotoblast barrel
Equipment
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Foundry shop № 2
Casting type Gray cast iron
Installed
capacity 22.4 thou. t/y
Product mix
Wide range of castings weighting
from 5 to 122 kg. Cylinder block
Brake drum
Friction wedge etc.
Melting area Cupola furnace
Electric arc furnaces with
bath capacity – 10t.
Molding area Automatic molding lines (molding box
size:1100х700х400/350)
Core-making area Core-making machines, «LAEMPE»
Mixing rubbing mill for “LAEMPE” core-
making machines
Castings’ painting Spray painting
Dressing section Three-turbine rotobalst chamber
Integrated mechanized line for cylinder
block deburring
Equipment
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Foundry shop № 4
Casting type Gray cast iron
Installed
capacity 29 thou. t/y
Product mix
Wide range of castings weighting
from 0.3 to 45.5 kg.
Friction wedge
Manifold
Fly-wheel etc.
Melting area
Cupola furnace
Electric arc furnaces with bath
capacity – 3t.
Molding area Automatic molding lines (molding
box size:700х650х250/230)
Core-making area
Automatic core-making machines
Hot box & Cold box semi-
automatic core-making machines
Dressing section Rotoblast barrel
Equipment
10
Foundry shop № 7
Casting type VCh50, VCh70
Installed
capacity 13.5 thou. t/y
Product mix
Main product – crankshaft castings
with weight from 20 to 35 kg.
Crankshaft
Connecting piece and other
Melting area Induction furnaces with bath
capacity – 12t.
Molding area
Automatic molding lines
(molding box size:
1200х1000х250/250)
Core-making area
Core-making automatic
machines using chemical curable
components (BelNIILIT JSC)
Dressing section Rotoblast barrel
Six-turbine rotobalst chamber
Equipment
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Foundry shop № 8
Casting type VCh50, VCh60, VCh70
Installed
capacity 23.3 thou. t/y
Product mix
Wide range of castings weighting
from 0.2 kg to 150 kg. Satellite gear case
Bearing cap and other
Melting area
Medium frequency crucible
furnaces (bath capacity – 13.5 t),
ladling devices of АВР company
production
Molding area Automatic molding lines (molding
box size: 1100х800х 250/250
Core-making area Hot box & Cold box core-making machines
Dressing section Rotoblast barrel
Equipment
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Pattern-shop
Equipment for making
models
Milling machines
Turning machines
Drilling machines
Grinding machines
Special-purpose machines
Woodworking machines
Machines with numerical control
Wooden casting patterns Core boxes Casting-boxes
Metal casting patterns
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Quality
Certification
Iron Casting Production
ISO-9001
Compliance with international standards
Выполнение требований потребителей достигается за счет приведения процессов производства
Дивизиона Автокомпоненты в соответствие со стандартами ISO 9001 и ISO/TS 16949
Company success at the market
Product competitiveness
Rise of the company prestige and status
Build-up of the personnel motivation
Certification plan
Iron Casting Production 2015
ISO/TS 16949
ISO 14001:2004
BS OHSAS 18001:2007
Certification
GAZ OJSC
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THANK YOU
FOR
ATTENTION! Lenina Avenue 88, Nizhny Novgorod,
Russia 603004, Tel. +7 (831) 299 09 90,
fax: +7 (831) 290 81 89
Epshteyn Kirill – Director of Autocomponents Division
e-mail: [email protected]
Alexey Zaytsev– Director for Development
Autocomponents Division
e-mail: [email protected]
Nikolay Raytsyn - Director for Sales,
Autocomponents Division
e-mail: [email protected]
www.gaz.ru
