General Electric Machinery Plant / VTG - GE...

Imagination at work.

Introduction 2014

GE Lighting Machinery Plant, Hungary

Introduction

Worldwide solution provider

• Deliver excellence in machine designing & building in multiple automation solutions

• Available machining resources for standard and specialized part manufacturing

• Expertise in mechanical and electrical development, automation and integration

• Customer focused: long-term spare part availability & support

• Managing complex projects

• Highly motivated and focused execution teams

Dedication to Quality

• Meet quality standard of ISO 9001:2009

• Health and Environment committed, EHS: ISO 14001

• Work along Lean & Six Sigma methodologies

• All solutions are CE marked

Concept

Design

Machining

Assembling

Installation Logistics

Support

Your success

L E A N E N T E R P R I S E

Machinery Plant Profile

3

Budapest (BP) Hajdúböszörmény (HB)

Management

Solution Sales

Project Man.

Center of

Manufacturing &

Subcontracting

Excellence in

Designing &

Assembling

Complex Development & Service type operation specialist

Design | Machine build | TOW | Install | Customer Service

Our project methodology

4

PM in SAP ERP

Capacity management

Project tracking

Process development

Data warehouse

Continuous project tracking with experienced project leaders

Quote Prepare

Concept & Design

Realizing Logistics Support

Install & Debug

Advanced Design Capabilities in…

…Prototyping & benchmarking

…Lighting industry leading portfolio

…Build-to-print

…Complex system improvements

…Re-designing machines, production lines, plants

…Creating best-in class solution

Extensive range of mechanical

designing

• 2-D & 3-D design capabilities

• Applied FEM analysis

Wide experience in electrical

design

• software development

• vision systems

• process-monitoring system

Engineering support

Creation of conceptual solutions

Domain expertise in designing and developing

6

Specialized knowledge in digitized process monitoring

• Data collection and analysis

• Reject Analysis

• Batch Tracking / Material Usage / Stock

• Alarm / Event Analysis, Alarm Summary

/ History

• Trend analysis for technological

parameters

• Online SPC Analysis / Histograms

• Online Digital Score-carding of the

Production Line & Sub-systems

• Other specific reporting & data mining

7

10+ years of experience with HMI / SCADA / Monitoring systems

Vision Systems & High-end commercial materials

8

Professional machining capabilities

CNC machines Significant in-house capacity w/ continuous extension

3D Measuring for multiple industry purposes

Special partners In-house sourcing for materials and for subcontracting

Machining workshop

10

Machining workshop capacity

11

Machine Group Pieces Capacity (whours/y)

CNC milling machines 15 90.000

CNC turning machines 7 42.000

CNC grinding machine 1 6.000

CNC wire cut machines 4 24.000

CNC water jet machine 1 6.000

CNC engraving machines 2 12.000

Total: 30 180.000

Machine Group Pieces Capacity (whours/y)

NC boring mill / milling m/c’s 2 12.000

NC turning machines 3 18.000

Total: 5 30.000

Possible capacity extensions (in house)

Samples of special parts

Valve Body GE Lighting

50x50x140 Vacuum technical Component

CMHL Gas Burner GE Lighting

50x25x45 with D0,5 holes Burning Unit Critical Component

PGT25+ Diaphragm GE Energy

Gas Turbine Component

12

Vibratory Feeder GE Lighting

D220x60 Feeder Unit Critical

Component

Validated subcontracting partners

Part

manufacturers

40+ partners to solve

capacity overloads

professional supply

chain parameters.

Our full capacity can

be doubled.

Special

technology

10+ partners to solve

special machining

needs if parts:

- extremely small

- extremely large

- extremely hard

Surface

treatment

5 partners to apply

various surface

regulations:

- nitriding

- hardening

- coating with oxides

- galvanizing

Service

type

5 partners to assist in

various complex

works:

- gas systems

- process monitoring systems

- assembled units

13

Excellence in assembly capabilities

Mechanical & electrical

• Professional assembling and setup in advance and on site

• Cabinet assembling and high performance electrical system wiring

Extensive debugging

• Detailed and long-term dry- & hot-runs

High-tech Vision

• Implement industry-lead process monitoring & vision systems

Complex installing

• Full production line installation

Refurbishment

15

Assembling area: 2.200 m2 We can work on up to 3 machines per station with 2,5 m x 2,5 m base concurrently…

6 1 1 8 Mechanical.. Electrical.. Supply.. …assembly stations

Excellence in assembly

Testing room: 880 m2

• Built-in: natural gas, oxygen, water, high

pressure air

• Gases use in bundle: nitrogen, hydrogen,

argon, sulfur, helium

Additional testing room facility: 6.000 m2

Managing concurrent assembling tasks:

• 5 m/c’s | EEH7 line

• 4 m/c’s | DEQ 576 line

• 5 m/c’s | EEH8 line

• 4 m/c’s | DEQ mount

• 2 m/c’s | J304

16

Logistics, support

In-house capabilities:

• Jib crane with 12 tons capacity

Packaging and moving capabilities with our

validated GE partners.

Handling shipping and customs.

17

Energized assembly team worldwide

Managing multiple projects

40+ automated machines to build, included

3 complete lines in 2014

Global availability

Separated integrator teams on multiple

locations across the world

18

Integration teams

2013 2014 Q1 Q2 Q3 Q4 Q1 Q2

GH Hand.Sys. (USA) | 3

3-way WEGO (MEX-HUN) & Apollo (MEX-USA) | 12

EEH lines (HUN) | 6

Ravenna (USA) | 5

Q4

Silver Par (USA) | 6

Mount & Mat. Hand Sys. (USA) | 5

2012 2013 Q1 Q2 Q3 Q4 Q1 Q2

Silver PAR (USA) | 9

NT line move (HUN) | 14

Environment project (HUN) | 4 Molding m/c (India) | 4 H-box mod (HUN) | 4

GH Hand.Sys. (USA) | 3 3-way WEGO I. (MEX-HUN) | 10

EEH lines (HUN) | 6

Ravenna (USA) | 5

Q4

Project (Location) | Team HC

Case study

20

Creating concept

Design and manufacture

Support and utilities

Training in Mattoon Drawings Spare parts Manuals

Project Case Study Scope

GE EEH product: New glass halogen capsules using hard glass tube.

Purpose of project

To design and build a High Speed EEH capsule making line to be installed in GE Lighting’s

halogen manufacturing plant in Mattoon, IL.

Project Case Study Schedule

22

Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov

PO & Project start

M design

E design

Sourcing

Machining / Cutting

M Assy'

E Assy'

Debug/Test/EVP

Pack/Ship

Install/PVP

Sep 9

Feb 3

Jun 30

Mar 24

Apr 28

May 12

May 12

Sep 15

Jul 28

Nov 10

Quote Prepare

2 Realizing

7

Concept Design

4 Install Debug

3

Logistics Support

2

Project Lifetime In months

from Idea to Production

15 months

stretched process…

Project Case Study Overview

23

Sa

fety

Electric safety must follow GE & Mattoon LP requirement

Noise level not exceed by 85dB

Ma

jor

fea

ture

s The line output is 1850/hour good capsule

Yield: 95-99%/machine

Shrink rate: max 1%

Drive mode: Independent drives, indexing motion

Parts from unit to unit are fully automated. No manual effort.

Machines are connected with accumulator chains

Op

era

tio

n m

od

e Indexing mode without logic control

Jog mode with logic control

Machines controlled by PLC and has independent control cabinet

Automatic mode

Manual mode (using crank or hand wheel)

Chains: Asynchrony motor drive both ends

Utilities

Electric energy Natural gas

High pressure air Water

Nitrogen Oxygen

Forming gas Vacuum

Customer Project Product # of m/c’s

Procter & Gamble (Hungary)

Mostly built-to-print project with effective simplifications and system upgrades

pantyliner & tampon

7

GE Lighting NA (USA)

Build material handling system for process automation by handling lamp components and parts by conveyor system

process development

3

Autonix (India)

Build H4 baking machines for a lamp component manufacturer based on a GE design

baked H4 lamp head

2

GE Power Controls (Poland)

Design an manufacture automated mounting machine for a non lighting GE plant

circuit breaker

1

Project Satisfactions

24

25

Do you have an Idea? | Contact us: Szabó, István: istvan.szabo5@ge.com