Rohrwerk Maxhütte. Quality in seamless AUTOMOTIVE INDUSTRY ENERGY

Transcription

1 Rohrwerk Maxhütte Quality in seamless AUTOMOTIVE INDUSTRY ENERGY

2 AUTOMOTIVE INDUSTRY ENERGY Content Shaping the Future Together The Group of Companies The Steel Business Area Rohrwerk Maxhütte RMH Over 60 years of Competence and Experience Tubes for every Area of Application Automotive Industry Energy Our Process Chain Our Suppliers Products, Sectors, Markets Certifications and Authorisations Delivery Programme Our Values Future

3 Shaping the Future Together Rohrwerk Maxhütte GmbH Seamless quality is the principle of Rohrwerk Maxhütte where hot and cold-finished tubes of highest quality are produced at the production plant in Sulzbach-Rosenberg, Germany.,High-quality tubes is not only a slogan - customised manufacturing is our main focus. The involvement of all Rohrwerk Maxhütte GmbH employees in the implemented quality management system which we stand for is of central importance to us. Who we are and what we do The tube manufacturing company was founded in 1952 by a board decision of the steel mill Maxhütte. At that time, the objective was to expand the real net output ratio. RMH belongs to the Steel & Production business field of the Max Aicher group of companies. Since January 2015, the Max Aicher Group has been spanned by the Max Aicher Foundation. This is one of the largest private foundations in Bavaria and serves in addition to the preservation of the life s work of Max Aicher above all the education and training of more than 3,000 employees and thus the future. With a broad range of dimensions and grades, we supply the automotive, industry and energy sectors with custom-made solutions and components. We are in the position to react to market changes and customer demands with production geared towards seamless steel tubes in different designs and steel qualities and a diversified company structure throughout the value-added chain, both in short-term and on a sustainable basis. At the production site in Sulzbach-Rosenberg, approximately 430 employees produce around 25,000 km of steel tubes with a capacity of 100,000 tonnes per year. For over 60 years, our customers worldwide have been relying on our competence and quality in manufacturing seamless steel tubes. As a reliable partner, we permanently take on responsibility and together with our customers we develop sustainable solutions

4 Canada Group of Companies More than 3000 employees achieve a sales volume of far more than one billion euros. Our business activities in the group of companies have constantly grown in the recent years and thus they have been organised in accordance with positive synergetic effects. The recycling companies supply the steel works with the raw material scrap metal. Therefore, we are the largest recycling company in Bavaria. Steel production is carried out in Bavaria and Hungary. Crude steel is processed by steel works or passed on to the group-owned mills and finishing companies. The steel-processing companies of the group 1 RMH Rohrwerk Maxhütte (Germany, Poland, Croatia) 2 LSW Lech-Stahlwerke (Germany) 3 LSV Lech-Stahl Veredelung (Germany) 4 SAH Stahlwerk Annahütte (Germany) 5 ZAP Železárny Annahütte Prostějov (Czech Republic) 6 OAM Ózdie Acélmuvek (Hungary) 7 MANA Max Aicher North America Inc. (Canada/North America)

5 Steel and Production Business Area in the Max-Aicher Group These days, the Steel and Production division is a significant economic factor and employer with several steel works and mills in the Central European region. The Steel & Production area is the division with the highest sales revenue for the Max-Aicher group of companies. It is divided into the segments quality and high-quality steel and concrete steel. Growth in the area of automotive suppliers is mainly driven by the Bavarian companies. Through the increase of qualities and the expansion in the area of finishing, our group of companies has achieved a market share of about 20% amongst the European automotive manufacturers. Lech-Stahlwerke near Augsburg (LSW) With around 700 employees, LSW generates around 1.1 million tons of high-quality, construction and reinforcing steel per year. Stahlwerk Annahütte in Berchtesgadener Land (SAH) Approximately 500 employees have made Annahütte the global market leader in threaded rod steels. Lech-Stahlveredelung in Landsberg and Oberndorf (LSV) Both at the location Landsberg am Lech and Oberndorf am Lech approximately 150 employees finish the quality steel bars and adapt them according to automotive industry customers requests

6 Rohrwerk Maxhütte RMH We move, connect and hold together Our products are used in many areas and form the basis of daily life. We create durable quality and competitive products, whilst dealing responsibly with the ressources available. Ongoing technical further development and upgrade work on our production facilities are important to fulfil these requirements - and have been for more than 6 decades.

7 Over 60 years of Competence and Experience Foundation Rohrwerk-Maxhütte Start of production of seamless steel tubes World record 16-metre pipe length produced Bearing tubes in the push bench method Stretch-reducing mill with 28 stands Fully automated finishing department and US-inspection Takeover by the Max Aicher Group Laboratory for metallurgical material testing Commissioning rotary hearth furnace New mill control system, flying saw Second finishing line, US-inspection, cooling bed extension Initial operation of big cold pilger mill, Commissioning soft annealing furnace Production of seamless precision steel tubes at various locations (Germany, Poland, Croatia) Commissioning of automatic saw for short pieces Automation finishing line Commissioning 1,000 ton punch press 06 07

8 We Offer More Than Just Tubes Tubes for Every Area of Application In addition to the high-quality standard solutions, individual innovations determine the success of our customers. We help our customers achieve innovations: through our ideas, our know-how and our commitment. This is how we increase the customers` competitiveness through efficient products and processes, new materials, a comprehensive service offer and optimal solutions. Furthermore, our aim is to be one of the best in our business segment. This means that innovations characterise all areas of our company. Together with our customers we analyse their respective needs to develop the best solutions in terms of technology and costs.

9 Automotive - Applications High-quality tubes from Sulzbach-Rosenberg create mobility as the inner and outer ring of countless roller bearings used in machinery, tools, and vehicles of all kinds. On this basis, we are suppliers for many other applications in the automotive areas. The continuous range of the outer diameter and the wall thickness as well as customised delivery lengths enable a production that precisely meets our customers requirements and therefore allow efficient further processing. Furthermore, a special heat treatment during manufacturing ensures low decarburisation depths and therefore provides small machining allowance for the metal cutting of roller bearings. Roller bearing tubes Ball retainer tubes Axel strut tubes Airbag tubes Drive shaft tubes Gear shaft tubes Camshaft tubes Rotor shaft tubes Stabilizer tubes Inner profile tubes 08 09

10 Industry - Applications Our tubes are used in a wide range of applications in diverse segments of the industry. From mechanical engineering to mining as well as in the construction of bridges and buildings, our tubes are provided in light yet strong constructional elements as well as in pre-machined finished components. Low intrinsic weight and a high level of stability even in low temperature range distinguish our steel tubing as a construction element that offers high strength even under torsional and bending loads. Rock Bolt Tubes Drill Pipe Tubes Crane Construction Tubes Grouting Lance Tubes Hydraulic System Tubes Contoured Tubes Rohrwerk Maxhütte s use of innovative production techniques and alternative materials enable a production in exact accordance with cutomer requirements. Tube blanks for cold forging and automated CNC fabrication, as well as internally and externally shaped steel tubes are produced in line with individual specifications.

11 Energy - Applications Boiler tubes from Rohrwerk Maxhütte are used around the world in the construction of containers and conduits in power plants and in the construction of heat exchangers. Boiler tubes are subject to high thermal loads due to their use in areas exposed to high temperatures and pressures. Due to their uniform mechanical and technical properties across the entire tube cross-section, our tubes meet the most demanding requirements for creep strength and leak tightness. As a member of professional associations and working groups involved in the construction of power plant systems, Rohrwerk Maxhütte actively participates in developments and advancement such as the development of high-efficiency power plants. Rohrwerk Maxhütte utilizes new and innovative materials which enable the production of boiler tubes that meet the extreme requirements of power plant engineering. Accessory Tubes Boiler Tubes Membrane Wall Tubes Fitting Tubes Steam Tubes Heat Exchanger Tubes Composite Tubes 10 11

12 Our Path to the Customer Our Process Chain Raw Material Recycling (MAR) Steel Production (LSW) Tube Production (RMH) Tube Conditioning (RMH) Tube Finishing (LSV) Customer

13 Our Suppliers In the Environment & Recycling business area, the Max Aicher group of companies operate numerous treatment plants for recycling scrap metal, as well as by-products of steel production. The Steel & Production division is the largest sector in the group of companies. More than 1.5 million tonnes of steel are produced each year in two steel works in Bavaria and Hungary. One quarter of all European automotive suppliers use steel from the Max Aicher group of companies. For many automotive manufacturers, Max Aicher is the exclusive supplier for special components. Max Aicher is a global market leader in many segments of civil engineering due to its threaded steels. Advantages: Material development, process reliability, traceability, security of supply Range of grades: Over 2,500 different materials The group of companies is one of the largest manufacturers of construction steel, wire and reinforcement meshes in the entire Danube region

14 Figures Data Facts Products Sectors Markets The core competence of RMH lies in the production and preprocessing of seamless tubes. RMH supplies to international customers from the automotive, industry and energy market segments directly from our production sites. An integrated value added chain that covers everything from solution development to steel and tube production, to surface engineering and processing. The customised production of the semi-manufactured goods is one of the factors which determine the properties of our products. The hot-finished tubes and the high quality of the seamless precision steel tubes are suitable for a wide range of challenging applications. The considerable benefits of our products are supplemented by our close cooperation with our customers with customised logistics and services. Products Tubes hot-finished in OD from 21,3 139,7 mm and WT 2,3 13,0 mm Tubes cold-finished in OD from 4,0 120 mm and WT 1,0 11,0 mm Areas of application: Water tubes, boiler tubes, roller bearing tubes, precision steel tubes, special tubes Materials: Case-hardening and quenched and tempered steels, construction steels, engineering steel, high-temperature and fine grained steel, roller bearing steel, customized materials Standards: European standards (EN), international standards (ASTM, ASME), customer-specific standards

15 Sectors RMH supplies customers from the following sectors Distribution Automotive Industry Energy Markets The RMH customer portfolio broken down by region Germany Europe Third countries 20% 10% 40% 42 % 5% 53% 30% 14 15

16 Quality is Our Aspiration Certifications and Authorisations Rohrwerk Maxhütte produces seamless hot-finished and cold-finished steel tubes in a wide range of grades. Product quality is our trademark and therefore, the basis of many years of success. ISO 9001:2015 IATF 16949:2016 ISO 50001:2011 ISO 14001:2015 Our ultimate objective is to fulfil the high expectations of customers with products that are of the highest level of quality. This also includes reliability and the continuous optimisation of quality and technology, as well as targeted customer service. In this context, an extensive quality management system was implemented and certified according to ISO 9001:2008. This quality management system guarantees the highest level of process reliability and the quality of our products. Rohrwerk Maxhütte has been certified and approved in the following national and international acceptance and classification associations: AD-W0/TRD 100 PED 2014/68/EU BauPVo 305/2011 API - 5L Germanischer Lloyd DET Norske Veritas Lloyd s Register EMEA Bureau Veritas DVGW TÜV - CERT TÜV - SÜD

17 Product Range TYPE OF TUBE Seamless carbon, low-alloy and low-temperature steel tubes Black seamless threaded / hot galvanized tubes, plain ends, with thread, with socket DELIVERY STANDARD DIN EN 10255, DIN 2442 galvanized in accordance to DIN EN and DIN-DVGW-directives NR: (1/2-3 ) DIN 2440/2441 ASTM A 53 STEEL GRADE S195T St33/St37.0 Grade A, Grade B Tubes for the conveyance of water and other aqueous liquids Tubes for pressure purposes at room temperature Tubes made of of non-alloy and fine-grain structural steels Tubes for pipelines for combustible fluids - requirement class A Tubes for pipelines for combustible fluids - requirement class B Low-temperature steel tubes Tubes made of fine grained structural steels High-temperature steel tubes Boiler and superheater tubes Cold-finished quality tubes Ball bearing tubes Engineering tubes and mechanical tubing Precision tubes * Other grades on request DIN EN DIN 1629 DIN EN DIN 1629, DIN 1630 DIN EN DIN 17121, DIN 17124, DIN DIN EN ISO 3183 DIN 1629, DIN 1630, DIN 2470 Teil 1 DIN EN ISO 3183 DIN 17172, DIN 2470 Teil 2 DIN EN , ASTM A 333, ASTM A 334 DIN DIN EN DIN DIN EN DIN ASTM A 106, ASTM A 192, ASTM A 209, ASTM A 210, ASTM A 213, ASTM A 335 API 5L, PSL 1 JIS G3461/3462 EN ISO DIN DIN EN /-2/-3 DIN DIN EN ASTM A179 L235, L275, L355 St37.0, St44.0, St52.0 P195, P235, P265 St37.4, St44.4, St52.4 S235, S275, S355 St37-2, St37-3, St44-2, St44-3, St52-3, StE/TStE/EStE-255, 285, 355, 420, 460 L210, L245, L290, L360 St37.0, St44.0, St52.0 L245N, L290N, L360N, L415N StE210.7, StE240.7, StE290.7, StE320.7, StE360.7, StE385.7, StE415.7 P215NL, P265NL, Grade 1, Grade 6 TTSt35N test category 1+2 P275, P355, P460 StE/TStE/EStE-255, 285, 355, 420, 460 P195GH,P235GH, P265GH,16Mo3, 13CrMo4-5, 10CrMo9-10 St35.8, St45.8, 15Mo3, 13CrMo44, 10CrMo9 10 Grade A, Grade B, Grade C, Grade A1, T- and P-Grades such as T11, T12, T22, P1, P11, P22 Grade A, B, X42, X52, X60 STB340, STB410, STB510, STBA12, STBA22, STBA24 Ball bearing steels Case-hardening and heat-treatable steels E235, E275, E

18 Sustainability is a Key Objective Our Values The world wants more: demography, urbanisation and globalisation are the current trends. The global hunger for consumer and industrial goods, infrastructure, energy and raw materials appears to be insatiable. Steel is and will remain the basic material of the industry. It appears in several small and big objects of every day life and our modern existence cannot be imagined without it. Conserving resources and protecting the environment is standard corporate practice for Rohrwerk Maxhütte. We want to make a positive contribution toward a sustainable future by continuously improving environmental performance in every segment and raising awareness among employees, suppliers, and customers. Measures for environmentally appropriate design include the entire product range and all production processes. The complete life cycle of the products is taken into consideration reaching from the use of raw materials to product development, production, and product use all the way to disposal and recycling. Integrated environmental protection is an equal corporate goal in all of Rohrwerk Maxhütte`s activities - on a par with the production of the highest quality and maximum customer satisfaction and the maximum safety for employees.

19 Economically Fair We Take Our Responsibility Seriously We place great emphasis on performance-based compensation and the efficient use of resources. Closed cooling circuits, solvent-free and water-based paint systems as well as the advanced energy management that utilizes waste production heat to simultaneously achieve ecological and economic targets, are standards at Rohrwerk Maxhütte today as well as its advanced energy management that utilizes waste production heat to simultaneously achieve ecological and economic targets. Sustainable and economic management is also used to derive potential improvements in business processes. This includes activities such as heat recovery and the exploitation of residual production materials and by-products. Additional examples are further reduction of noise pollution, reducing the use of solvents in corrosion protection media to minimize ozone-depleting emissions, switching from solvent-based corrosion protection paintwork to product protection media and introducing and further developing advanced furnace feed systems at various heat treatment units

20 People and Nature our most Important Resources Ecologically Fair Environmental Protection is an Integral Part of Our Corporate Culture Environmental protection is an inherent part of our corporate culture. We understand environmentally-conscious actions as corporate responsibility towards our customers, our employees and the entire region. Compliance with relevant laws and regulations is a matter of course for us. We deal responsibly with the resources used, our products and solid waste. Environmental management activities at Rohrwerk Maxhütte focus on preventive measures, as well as the environmental assessment of the products and resources. Environment controlling has enabled the transparent demonstration of company-wide key indicators. This means that measures such as continually reducing the environmental burden with respect to energy, water, oil, gas and waste can be better controlled. We minimise the strain on water, air and soil. Wherever we discover potential for improvement, we carry out operational changes.

21 Socially Fair People as the Focus of Our Actions Our health management programme is an investment in the long-term performance of the company because it helps maintain the health of our workforce. For this purpose we pursue an integrated approach. To recognize accident hazards in the plants, take measures promptly to protect the employees and avoid occupational accidents, employees are trained in regular training courses that target changing attitudes and behaviour in occupational safety. Furthermore, the company integration management programme enables employees to return to daily work gradually after an extended illness. Commitment and sports sponsoring Sport moves people. It creates emotions and awakens enthusiasm. Rohrwerk Maxhütte is one of the biggest employers in the Sulzbach-Rosenberg region. We are aware of our social and corporate responsibility and therefore, we get involved with sports. Many aspects related to sports are also of crucial importance in our company and for our work: commitment to perform, motivation and team spirit

22 Future Focus On Quality and Further Development Quality Rohrwerk Maxhütte is committed to the principles of process-oriented quality management, where the implementation of the quality strategy is considered as one of the company s leadership duties. Each employee stands for the quality of his/her performance. With this integrated approach to the subject of quality we include all relevant leadership, manufacturing and supporting processes from inquiry processing to manufacturing all the way to surveys on customer satisfaction in our quality management system. Synergetic effects which are the result of cooperation with companies within the Aicher group secure an outstanding performance. One of the main objectives of RMH is to invest in the development of new products and to continuously optimise industrial procedures and products. In order to achieve this objective, RMH sets up a detailed programme and annually evaluates the product development plan. Starting with the idea up to the technical solution the central development accompanies the customers from material definition to product design and process integration. In a solution- and customer-oriented approach, the results are custom-made tube solutions where the customer benefits from our high level of technical and methodical competence, our many years of experience and our extensive technological know-how. A significant element is the further development of our high level of expertise with materials. Our steel mill enables us to implement the necessary materials optimisation and target-oriented new developments in-house.

23 RMH invests in research & development in order to supply the markets of tomorrow with competitive, innovative products. The research and development work is not only restricted to new products but is also extended to the process technology used and services offered. Product innovations are developed in close contact to the customers, whether this means improving products which already exist or developing new applications. The production processes are also constantly adjusted and optimised in order to guarantee lower manufacturing costs, procedure reliability and outstanding production results. In addition to supplying standard steel tubes, RMH optimises their range of services to meet the customer s needs

24 Rohrwerk Maxhütte GmbH Franz-Kunze-Straße Sulzbach-Rosenberg Germany Phone: Fax: info@rohrwerk-maxhuette.de