Kracht door samenwerking VDL Groep

Presentation VDL Castings

VDL Groep Information

Family owned international company specialized in developing,

producing and sales of semi-finished products, busses, other

end products and assembling cars

Sales mid 2017 : 2.400 MEUR

Result mid 2017: 75 MEUR (after taxes)

Equity: 60% (1.037 MEUR)

Employees mid 2017: 15.581

94 companies, 4 divisions, 19 countries

Website: www.vdlgroep.com

VDL Castings (Former Componenta)

Foundry Heerlen: Moulding Line 850 x 630 x 330/330 » Capacity moulding line : 130 moulds / hr

» Melting : Cupola furnace 20t/hour

» Core making : FCS 60 / H16 / H12 / H 6,5

» Fettling : 15 cabines / 1 automatic grinding machine

Foundry Weert: Moulding Line 1.250 x 850 x 400/400 » Capacity moulding line : 60 moulds / hr

» Melting : Electric induction furnace 10t/hour

» Core making : L130 / L150 / H40 / L16

» Fettling : 18 cabines / 1 automatic grinding machine

VDL – Componenta synergies

Main markets: Heavy trucks, Construction and mining,

Machine building, Agriculture, Wind power

Main customers: Volvo, MAN, Caterpillar, Bomag, Kawasaki,

Scania, Daimler, VCE, Borg Warner, NCB,

Atlas Copco

Products: brackets, hubs, housings, axles, vessels,

hydraulic blocks, turbo housings

Product Range: 20-300 kg in medium size volumes

Materials: ductile cast iron (incl. Simo/ADI/HiSi) and

grey iron

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VDL Castings Heerlen

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VDL Castings Heerlen History

1974/1975: Globon

■ co-operation of De Globe and Oranje Nassau Mijnen

2005: Componenta HWS

■ Finish Stock exchange listed company based in Finland with

production in Finland, Sweden, Netherlands and Turkey

2017: VDL Castings Heerlen

■ Family owned Company based in the Netherlands with production

facilities in 19 countries

Organisation VDL Castings Heerlen

Adjunct Director

Ruud Pisters

Admin / housekeeping

Sales

Frank Kunert, Norbert Müller

Engineering

Adriaan Keppel

Manager operations

Bert Duit

Core Shop Moulding Melting Shop Aftercare Maintenance Shipping

Quality assurance

Paul Hutschemeakers

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VDL Castings Heerlen Plant lay-out

230 m

Core

shop HWS

pouring

Cooling +

shake-out

paintin

g Fettling +

inspection expeditio

n

melting energy Sand

prep.

Tech.serv. offices

Old Furan line

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Heerlen Capacity:

■ 36.000 ton/year in 3 shifts

Materials:

■ 97 % S.G. Iron (incl. Simo, ADI, HiSi)

■ 3 % Grey iron

VDL Castings Heerlen Capabilities

50 100 150 200 250 300 350 400 450 500

GJS, GJL, ADI, SSF

GJS, GJL,

SSF, ADI, SiMo VDL Castings Heerlen

VDL Castings Weert

Component weight

Heavy trucks

62%

Construction

and mining

19%

Machine

building

18%

Agricultural

machinery

1%

Automotive

0%

VDL Castings Heerlen customer segments (2016)

10 30 January 2018

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Main characteristics VDL Castings Heerlen

Melting

■ Hot wind lining-less Cupola , 1250 mm, 20 ton/hour,

oxygen Linde enriched

■ holder furnace (2x) 20 ton

Moulding machine HWS (‘91)

■ 130 moulds/hour

■ 850 x 630 x 330/330 (‘95)

Automated sand plant 70 ton/hour

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Fettling shop

■ 15 booths.

■ 1 Automatic grinding machine (Koyama)

■ heat treatment (normalizing)

■ Inspection (Visual, US, Magnetic particle inspection, certificates)

Painting

■ dipping (only primer)

shipping

■ in- and external storage

Main characteristics VDL Castings Heerlen

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Fettling shop

■ 15 booths.

■ 1 Automatic grinding machine (Koyama)

■ heat treatment (normalizing)

■ Inspection (Visual, US, Magnetic particle inspection, certificates)

Painting

■ dipping (only primer)

shipping

■ in- and external storage

Main characteristics VDL Castings Heerlen

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VDL Castings Heerlen Products

20-120 kg, (complex)

cored

small and medium size

series

brackets, hubs,

housings, axles,

vessels, hydraulic

blocks, turbo housings

axle housing for a truck , EN-GJS-

500, 55 kg

Swing Swing frameframe forfor a mini a mini excavatorexcavator,,

ENEN--GJSGJS--500, 16 kg500, 16 kg

housinghousing forfor hydraulichydraulic motormotor,,

ENEN--GJSGJS--400, 74 kg400, 74 kg

axle housing for a truck , EN-GJS-

500, 55 kg

Swing Swing frameframe forfor a mini a mini excavatorexcavator,,

ENEN--GJSGJS--500, 16 kg500, 16 kg

housinghousing forfor hydraulichydraulic motormotor,,

ENEN--GJSGJS--400, 74 kg400, 74 kghousinghousing forfor hydraulichydraulic motormotor,,

ENEN--GJSGJS--400, 74 kg400, 74 kg

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VDL Castings Weert

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VDL Castings Weert History

Founded in 1963, completely renewed in

different phases from 1987 – 1995

2005: Componenta Weert HWS

■ Finish Stock exchange listed company based in Finland with

production in Finland, Sweden, Netherlands and Turkey

2017: VDL Castings Weert

■ Family owned Company based in the Netherlands with production

facilities in 19 countries

Organisation VDL Castings Weert

Director

Eddy Kremers

Admin / housekeeping

Sales

Jeroen van Dijk, Jan-Philipp Müller

Engineering

Giel Jongen

Manager operations

Paul Stelten

Core Shop Moulding Melting Shop Aftercare Maintenance Shipping

Quality assurance Paul

Hutschemeakers

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Office / Canteen

Melt shop

Grinding

Stock

Shotblasting Moulding / pouring

Core storage Core shop

Sand plant

Maintenance

& Patternshop

CPV

Quality &

Process

Warehouse

CPV & Raw

material

Foundry

Componenta Weert, 51.200 m²

Total buildings: 18.000 m²

Paint

shop

▲ Entrance

VDL Castings Weert Plant lay-out

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VDL Castings Weert Capabilities

50 100 150 200 250 300 350 400 450 500

GJS, GJL, ADI, SSF

GJS, GJL,

SSF, ADI, SiMo VDL Castings Heerlen

VDL Castings Weert

Component weight

Weert Capacity ■ 34.000 ton/year in 3 shifts

Materials:

■ 92 % S.G. Iron (incl. Simo, ADI,

HiSi)

■ 8 % Grey iron

Heavy trucks

12%

Construction

and mining

40%

Machine

building

27%

Agricultural

machinery

17%

Automotive

0%

VDL Castings Weert customer segments (2016)

28 30 January 2018

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Core shop:

4 Core shooting machines

(cold box method)

Automatic core sand preparation (7 mixtures)

3 Core assembly lines

100% water based core coatings

Main characteristics VDL Castings Weert

Moulding line:

HWS Moulding Machine (1987)

Box size: 1250 x 850 x 400/400 (LxWxH/H)

70 moulds/hour (technical capacity)

Green sand moulds (autom. sand preparation)

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Melting Department:

2 x 8 tons MF (8 MW)

induction furnaces Capacity:

9,5 tons/hour.

Temperatures: Tmax-melting =

1580 °C

Main characteristics VDL Castings Weert

Automatic pouring:

Pouring ladle: 1350 kg

In stream inoculation

Registration of pouring

parameters

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Shot blasting: (GF/Disa)

3 Chambers – Hi-speed

Rotation turbines

Removing gating

systems and feeders:

Hydraulic Wedges in

counter balances

Hammers (manual)

Main characteristics VDL Castings Weert

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Fettling shop:

18 cabins for manual grinding,

1 automatic CNC grinding

machine (MAUS)

2nd In progress (ABB Robot Lieber)

Painting (only primers): Paint applied by dipping, several colours

Non water-based primers

Main characteristics VDL Castings Weert

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VDL Castings Weert Products

50-300 kg, (complex)

cored

small and medium size

series (100 – 10.000)

Axles, Housings, hydraulic

motors, carriers, Hubs,

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Hammerbody, ADI

VDL Castings Weert Products

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VDL Castings Weert Products

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VDL Castings Weert Products

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VDL Castings Weert Products

Financing and Investments

Both foundries do have substantial added value for the VDL

group and huge synchronization advantages are expected for

the foundries and the VDL group as well

VDL is accepting a loss making situation in 2017

VDL group is planning to invest in both foundries:

■ Replacement and Maintenance investments

■ Investments to improve quality, productivity and output

(automation)

Investment Planning (Overdue)

Maintenance only

Year 1 Year 2-3 Year 3-5 Total

Weert 1,898 1,183 0,274 3,355

Heerlen 2,702 0,806 3,505 7,013

Total 4,600 1,989 3,779 10,368

Replacement and maintenance investments for period 1-5 year (M€):

The above mentioned investments will secure and improve the performance of

the foundries in production reliability, quality of products and processes and thus

delivery performance and safety.

Investment Plan Weert Foundry 2017-2021

• Investment Planning:

• Year 1:

• Sand process Improvement / Powerfull shotblasting / Special tools hardrunners

• Fettling shop lay out and preparations automation

• Year 2:

• Automatic Grinding (1st stage) / Mouldbox closing

• Year 3:

• Re-position Moulding line, incl. short loop mouldboxes / Hydraulic wedging

• Autom. grinding (2nd stage) / Melt shop increased output

• Year 4-5:

• Upgrading Mould line / New sand plant

• Increase cooling capacity (depending nr of heavy parts)

• Long Term:

• Relocate the dip paint building in combination with shipping docks

Year 1 Year 2 Year 3 Year 4-5

Weert 310 k€ 1.200 k€ 1.700 k€ t.b.d.

Investment Plan Heerlen Foundry 2017-2021

• Investment Planning:

• Year 1:

• Process Data Collection & Management / New Ladle heaters

• Year 2:

• Automatic Grinding / Larger holder furnace / Automated Mould numbering / Dosage Cupola

• Year 3:

• Core storage / Replace H16 core shooters / Residual heat usage

• Autom. grinding next phase.

• Year 4-5:

• Larger mould box / Upgrading Mould line / new Desulf-process

• Next steps automatisation (core shop / fettling)

• New casting cooling process in combination with shot blasting

• Long Term:

• Install a new moulding DISA/HWS line in adjacent (furan) building

Year 1 Year 2 Year 3 Year 4-5

Heerlen 375 k€ 1.200 k€ 2.000 k€ t.b.d.