2 #Roots The Gnutti family The town of Lumezzane, located in the province of Brescia, is universally recognized as the industrial district with the highest success percentage among metal alloys the hot forging of copper, brass and aluminum alloys. machining companies. It even earned an appearance Almag S.p.A. soon became the 2nd largest producer of on the cover of The Economist. The Gnutti family is brass rod in Italy and the 3rd largest in Europe. To get an outstanding example of a trend of entrepreneurial there, the company diversified by turning scrap into success, which through the Holding Umberto Gnutti brass ingots. Another aspect of Brawo s industrial development is the many initiatives it took which allowed the formation of a S.p.A. ( HUG ) fully controls Brawo S.p.A.. The family s industrial roots date back to 1860, when Giacomo Giorgio Gnutti decided to acquire Brawo S.p.A. in synergistic and comprehensive industrial group. Because Gnutti, great-grandfather of the current President and 1976 (active until 1989 under the company name of these initiatives, it was able to operate in complete majority shareholder Mr. Giorgio Gnutti, started his Metalstampati Bonomi ) and transferred all the hot productive autonomy. The group is also geographically personal gunsmith s forge in Lumezzane. forging operations from Almag S.p.A. to Brawo S.p.A.. strategic with Brawo S.p.A., (operating from northern The decision proved to be a successful one. By the mid Italy), Brawo Brassworking Ltd. (operating in Canada as Developing and converting the business, Umberto 90 s, under his counsel and his son s management, Brawo Lofthouse Manufacturing), Brawo USA Inc. in the United Gnutti would later take over the limited company with S.p.A. became what it is today, a worldwide leader in States, Bonfix BV in The Netherlands and Emmebi S.r.l. These companies jointly create BRAWO s world within his sons, founding Almag in 1946, which specialized in the supply of brass, copper and aluminum components. in Italy. the HUG group.
4 BRA U S A O Emmebi BRA O
5 #Mission The Company s key to success is summarized in its mission and strategic policy, which focuses on customer satisfaction. BRAWO pursues this through high levels of service catered to its customers, its reliability, and its commercial, logistic and technological assistance. Likewise, it strives to reduce the final cost of its products while maintaining high quality products and services.
6 #Environmental, health and safety management system BRAWO pays attention to the protection of the environment, assumes responsibility, and adheres to its obligations outlined by existing legislation. The company is always seeking to adopt new practices and policies to reduce its environmental footprint. In connection, BRAWO has planned, implemented and actively managed an Environmental Management System complying with UNI EN ISO reference rule. BRAWO considers its workers health and safety to be priority objectives and integral features of its activity.
7 #Quality management system BRAWO s main objectives have always been customer satisfaction and rigorous high quality standards. To reach and maintain these objectives, our company has been working for more than 20 years with a Quality Management System, certified and complying with the ISO 9001 standard. In 2015, BRAWO achieved the certification for the Quality Management System for the automotive industry, namely ISO/TS Technical Specification. This continuous improvement is ingrained in the company s culture. It is obtained through the study and development of the business processes, the research of innovative solutions, and consideration of market demands. Quality at BRAWO means sharing customer goals and objectives with our employees every day in order to meet those targets.
9 #The advantages of the hot forging process The plastic deformation of metals and in particular the hot forging of Brass and Aluminum are well-established processes. In many cases, they replaced classic foundry processes such as casting, offering improved quality with enhanced component strength while eliminating porosity, an inherent problem associated with casting. BRAWO has adopted and continuously improved the forging process for decades and has achieved unrivalled efficiency and quality. BRAWO actively collaborates with the customer from the early stages of the design phase, introducing elements useful to enable the development of a streamlined and efficient productive process, hence an optimized competitive, high-quality product from inception. Compared to the die casting process, hot forging offers much improved mechanical characteristics and surface appearances with superior efficiency and repeatability of the process. As the forging process reduces porosity, it also ensures less scraps in the successive process of machining and, in general, a better control of the production costs.
11 #Precision #Guidance #Accessibility #Collaboration #The reasons to select BRAWO Sustainability and reliability from five generations. Financial soundness. A vertically integrated group, from the raw material manufacturing to the machined product. An international group with divisions located in various continents. Cooperation and assistance in the project design stage and in the product manufacturing. All the above contribute to optimizing costs, keeping the required technical and functional characteristics of the product. Internal design and manufacturing of forging dies, equipment and tools, based on company know-how and its continuous evolution. Featuring flexible and complementary productive equipment, throughout the entire production process. Capable of machining small and large runs of products with weights ranging from 30 grams to 25 Kilograms, through 50 presses and an equal number of transfer machines and machining cells. Application of Lean manufacturing techniques. Process control through state-of-the art manufacturing software. Maximum attention for the environment through pollution prevention activities and observance of the laws and applicable regulations. Continuous attention to the improvement of human resources skills thanks to a continuous training process. Assistance to the customer through: - Vendor Management Program - Kanban - Just-in-time - Consignment Stock - Warehouse in US - On-line ordering - Personell available 52 weeks per year
12 #Technical department Besides the constant updating of production facilities, a key factor in maintaining BRAWO s current leadership role proved to be the strong attention given to the technical design aspects. The company offers its customers a range of important services as a partner able to support its competitiveness on increasingly demanding international markets.
13 To consolidate and increase its potential, BRAWO chose to concentrate resources and technologies in a structured Technical Department. BRAWO s qualified team offers a real opportunity to those customers that are looking to improve the cost-quality ratio of their products. Here the production process is conceived and planned by the Engineering Process department, based on many years of experience. The service is enhanced further thanks to the Research & Development Department, which is constantly investigating the most recent Technological innovations.
14 #Simulations and software In recent years, BRAWO has acquired innovative software tools, to simulate the various manufacturing processes, such as forging, mechanical machining and dimensional inspection. By analyzing the simulation results, BRAWO s technicians are able to identify and correct potential manufacturing problems before they arise. This results in a quicker, more predictive Time-to-Market. FORGING AND MACHINING In particular the preliminary simulation is an integral part of our process equipment design, having to cope with the increasing demands to manufacture hyper-complex parts. Through the simulation, the significant aspects which might affect the positive outcome of the production process are carefully analyzed. This enables the achievement of an optimal result with costs and times compatible with our customers expectations. FINITE ELEMENT METHOD (FEM) FEM is used in the planning phase of the machining process, to prevent any possible adverse effects caused by deformations due to the positioning and clamping of the component. The mechanical stresses introduced by these deformations, are then simulated and analyzed in order to avoid possible risk situations. MANUFACTURING EXECUTION SYSTEM ( MES ) By using MES software, it is possible to monitor and manage every aspect of production. In particular, through this software, BRAWO supervises in real time the productivity of our manufacturing processes managing the traceability of the product and of the tools and also organizes the maintenance and quality inspections.
16 #Tools manufacturing The need of continuous reduction of Time-to-Market led BRAWO to purchase a modern and effective tool shop (Emmebi S.r.l). Emmebi S.r.l. manufactures tools, forging dies and all the equipment necessary for manufacturing of the products. The use of technologically advanced equipment also allows the execution of the activities in unmanned mode.
19 #Raw material As far as the brass business is concerned, a critical success factor is the complete integration with the subsidiary Almag S.p.A., specialized in the production of this raw material. Almag S.p.A. operates with a Quality Management System, certified in accordance with ISO The raw material is supplied with appropriate certification showing compliance with the specifications and requirements. The aluminum raw material is purchased from ISO 9001 and ISO/TS industry leader certified manufacturers. Testing, controls and additional certifications are carried out, when required, by external specialized laboratories. The following charts provide the regulatory references of the main alloys used.
20 #Brass European reference standard Designation Correspondence with extra-european standards Symbol Alloy number Reference standard Alloy number EN CuZn37 CW 508L EN EN EN CuZn40 CW509L EN EN EN CuZn42 CW510L EN EN EN CuZn38As CW511L EN EN CuZn35Pb2 CW601N ASTM B453 C EN EN CuZn36Pb2As CW602N AS 2345 CW602N EN EN CuZn36Pb3 CW603N ASTM B16M C EN CuZn37Pb2 CW606N ASTM B121M C EN CuZn38Pb1 CW607N ASTM B121M C EN EN EN CuZn38Pb2 CW608N ASTM B124M C EN EN CuZn39Pb0,5 CW610N EN EN EN CuZn39Pb1 CW611N / / EN EN CuZn39Pb2 CW612N ASTM B124M C EN JIS C 3771 EN ASTM B455 C EN CuZn39Pb3 CW614N JIS C 3603 EN EN EN CuZn40Pb2 CW617N JIS C 3771 EN EN CuZn35Pb1,5AlAs CW625N EN CuZn33Pb1,5AlAs CW626N EN CuZn35Ni3Mn2AlPb CW710R EN EN CuZn36Pb2Sn1 CW711R ASTM B124 C EN EN CuZn37Mn3Al2PbSi CW713R SAE J463d C EN EN CuZn39Sn1 CW719R ASTM B124M C EN EN EN CuZn40Mn1Pb1FeSn CW721R EN EN EN CuZn21Si3P CW724R C EN EN CuZn33Pb1AlSiAs CW725R
22 #Aluminium European reference standard Designation Correspondence with extra-european standards Symbol AW EN alloy number Reference standard Alloy number EN AlCu6BiPb 2011 EN AlCu4MgSi 2017A EN AlCu2Mg1,5Ni 2618A EN AlMn EN AlSi12,5MgCuNi 4032 EN AlMg EN AlSiMg(A) 6005A EN AlSi1MgCuMn 6056 EN AlMgSi 6060 EN AlMg1SiCu 6061 EN AlMg0,7Si 6063 EN AlSi1MgMn 6082 ASTM EN AlZn5,5MgCu 7075
23 #Brass and aluminium billets heating and temperatures control The ovens for heating billets connected with the bell and screw presses are of three types: direct gas flame for brass gas forced air for aluminum electric induction for brass and aluminum BILLETS TEMPERATURE CONTROL All ovens at BRAWO are equipped with temperature control of the billets through optical bicolor pyrometers, directly interfaced with the management system, that prevents the forging of billets with a temperature out of the set range. FORGING DIES TEMPERATURE CONTROL At BRAWO, oil-thermoregulated systems are available for the forging equipment, for a constant maintenance of the process parameters.
24 #Forging of brass and aluminium What historically characterized BRAWO, is the hot pressing process. To date, within the Group, there are more than 50 installations of the latest generation, electronically controlled forging presses. Bell presses from 350 to 700 tons, manually and automatically operated, with electronic interlocking. Horizontal drill forging presses, from 250 to 800 tons, continuous or discontinuous, automatically managed with electronic interlocking. Screw presses from 250 to tons, manually and automatically operated tons knee press, manually and automatically operated tons toggle press, manually and automatically operated. Highly efficient Hatebur presses, capable to manufacture up to pieces/hour. Vertical drill presses (forging machine) from 200 to 800 tons, continuous and discontinuous electronically operated, with electronic interlocking. Cross wedge roller automatic equipment. In-line bending billets automatic plants.
26 #Surface and heat treatments BRAWO is equipped with systems for the realization of heat and surface treatments for brass and aluminum. Surface treatments offered by BRAWO include swarf and brass blasting, both with inclined carpet and in step, yellow pickling and vibratory finish. BRAWO offers in house services for stress relieving, annealing, solution heat-treatment and aging. BRAWO outsources other heat or surface treatments required by the customer such as: chemical treatments, physical or galvanic nickel plating, chrome plating, tumbling, lead removal, fire tinning, anodizing, copper plating, polishing, in vacuum and controlled atmosphere heat treatments.
27 #Piece picking system The CAD-CAM process enables BRAWO to design systems to pick various tooling directly from the solid model, which provides the following benefits: maximum repeatability shorting tooling times picking point optimization The use of 5 axis systems enables piece picking systems to be created in a single location with no limits as to shape is concerned.
30 #Toolshop In the Mechanical Machining Department many types of tools are used, including standard and special tools, in order to achieve high quality standards required by the customer. The types of tools vary with the different types of Brass, with and without lead, and the different aluminum alloys required by the market. BRAWO, through its subsidiary Emmebi S.r.l., is able to provide to its machining department all tools needed for manufacturing, supporting it with effective and innovative technical solutions.
31 #Chip removal machining The machining department has access to more than 50 machining centers allowing us to select the most efficient machine specific to the component, ensuring optimal cost and best quality possible for each and every component.
32 #Production machines The wide range of equipment installed in BRAWO departments, enables BRAWO to choose the most optimal system, based on the customers requirements. Using a high level of automation provides consistent quality standards, a high productivity rate and containment of production costs. CNC Machining Centers and Lathes These machines can be easily tooled and are therefore suitable for the production of lower volume, complex products with high quality standards. Four Axis Flexible Cells These machines are particularly suitable for complex products with medium to high production volumes as they provide a higher productivity than provided by the CNC machining centers. Five Axis Flexible Cells Being equipped with the fifth axis and many advanced technological applications, these machines enable machining in a single operation of medium to high volumes and very complex products. Transfer Machines The transfer machines available at BRAWO are equipped with up to 12 stations and 41 tools, empowering the machining with high productivity of significant volumes of complex products. The presence of special devices such as rotating clamps, rotating fixtures, horizontal pivoting units, multiple spindle heads and small machining centers, makes it possible to machine products, whereas competitors would require a secondary set-up/machining operation, which sacrifices capability and cost.
35 #Quality control Product monitoring and measurement To ensure fulfillment of customer s requirements, BRAWO has put in place adequate resources, as far as infrastructure and staff is concerned, to effectively monitor the product and process. In particular: Defining the requirements for the performances and tolerances with reference to drawings, standards, technical specifications, contract terms, and expected requirements for mandatory laws and regulations. Developing control plans and evaluating the strengths and the critical features of the production process.
37 Among the main ones: Executing, monitoring and measuring in the incoming phase and production stage by means of self-inspection performed by the trained production workers and before the shipment is sent to the customer. Zeiss coordinate measuring machines, located in the laboratory room and in the production department Walter and Zeiss optical measurement machines 2 D laser measurement system Roughness tester Profile projectors Hardness measuring equipment (Vickers, Rockwell, Brinell) Utilizing appropriate monitoring and measuring equipment, 3-D optical scanner Infrared pyrometers always on the cutting edge and adequate to the high level of quality expected by BRAWO s customers. Stereo Microscopes and stereo viewers Profilometers Fluorescent penetrating liquids plant Q.Das statistical software BRAWO can realize many types of analysis and technological tests, through the aid of external qualified and accredited laboratories.
38 #Human resources Human resources is an important asset for BRAWO. Today s fundamental economic changes mean that their importance will grow further day by day. For this reason, BRAWO fully involves all staff, with projects designed to enhance their professional abilities and their input. By identifying and coding skills and knowledge in the company, this corporate culture allows managing a more targeted and effective education, providing valuable support to the development plans and personal career. All the people working at BRAWO are aware of their role, and are motivated to achieve the company Mission in mutual interpersonal respect.
39 #Logistics BRAWO s Logistics Department plans and defines with the customer the best options in order to fully satisfy their requirements. CONSIGNMENT STOCK BRAWO is organized for Consignment Stock management, in order to offer the customer an immediate availability of material and at the same time keeping warehouse stock to a minimum. NORTH AMERICA WAREHOUSE BRAWO has a warehouse in the USA, located in Laurens, South Carolina, where product is stored for distribution throughout all North America. The immediate goods availability at this warehouse ensures punctual deliveries and stock management optimization. Thanks to warehouse managing dedicated software, both BRAWO and its customers control the product in transit and in stock.
41 BRAWO S.p.A. Via XXV Aprile, Pian Camuno (Brescia) ITALIA Tel Fax fotografie di Mauro Pini stampa di Intergrafica Verona Edizione 2015 Tailor Made Communication
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