A Global End-to-End Leader, from Steel Mill to Forge. July 2014

Transcription

1 A Global End-to-End Leader, from Steel Mill to Forge. July 2014

2 Index A Global End-to-End Leader, from Steel Mill to Forge. Company Background 2 Health & Safety and Environment 9 Quality 11 Customer Care 13 Manufacturing Process 15 Key Products and Clients 22 Contacts 30 1

3 Company Background Background Group Structure and Shareholders Metalcam Key Figures Management Key Roles 2

4 Background Founded in 1907 in the Northern Italian region of Valle Camonica, Metalcam is today a leading manufacturer of open-die forged steel components Metalcam is one of the few companies with an end-to-end integrated production cycle, from the steel mill to precision forging and finishing, allowing for timely delivery of a wide range of finished products, tailor made based on clients specifications Metalcam Group operates through 4 production sites plus 2 machine shops and employs a total of 380 people Forged components weight between 500 kg and 35 tons and are used for a variety of industrial applications in the Mechanical, Oil & Gas, Energy, Shipbuilding and Extrusion sectors among others. Global presence in over 40 countries, covered directly and through an extensive proprietary network of established agents and sales representative team Longstanding relationships with over 100 key clients worldwide thanks to best in class performance for product quality and customer care / after-sale services 3

5 Group Structure and Shareholders Group Structure Key Shareholders Metalcam S.p.A. (Italy) Medium and Large Forgings 48% Italian financial holding with investments in energy, financial and industrial sectors. Founder of Metalcam S.p.A. 100% Vorlaender (Germany) 100% Adamello Meccanica (Italy) 80% 54,9% Small - Medium Forgings Rolled Rings Valforge (Italy) Small - Medium Forgings Adamello Steel (Italy) 60% Machine Shop Finish Machining B.S. (Italy) Machine Shop Rough Machining 42% LAVORO 3 S.p.A. 10% Italian Private Holding Company Management and employees owned entity Steel Plates 4

6 Metalcam Key Figures 65% 10% 6% 12% 7% Average annual turnover of 110 Mln during last 7 years Highest level in 2008 with 145 Mln of business finalized 5

7 Metalcam Key Figures 2% 12% 16% 2% 7% 15% 2% 10% 1% 6

8 Metalcam Key Figures Power Gen 8% 58% Oil & Gas Raw Material 7% Petrochemical 6% Mechanical Sector 17% Shipbuilding 4% 7

9 Management Key Roles Mario Cocchi CEO Laura Putelli Quality Control Marco Gnaffini Health & Safety Luca Mossoni Quality Assurance Mauro Norini Maintenance Giorgio Polonioli Chief Metallurgist Roberto Rizza Production - Steelmill Lino Cocchi Production - Forge Massimo Cocchi Sales & Marketing Ezio Scalvenzi Administration & Control 8

10 Health & Safety and Environment Health & Safety and Environment 9

11 Health & Safety and Environment Metalcam s number of days lost has halved in the period , despite a rising workforce, from 0.16% to 0.06%; Strong commitment to health and safety: 2 audits to all departments per month 4 medical examinations per year Weekly meetings on production and safety In-house medical center twice per week Key safety features include: Use of individual protective clothing Safety book and internal procedures First AID training Days Lost Workforce First forge in Italy to obtain an environmental certification in compliance with IPPC (Integrated Pollution Prevention and Control) Metalcam performs monthly inspections on equipment emissions Next step ISO Accreditation

12 Quality Quality Control and Assurance 11

13 Quality Control and Assurance Quality Assurance Metalcam is qualified ISO 9001:2008 (Lloyd s Register) Metalcam works with the most important 3rd Party Inspection Bodies such as ABS, TUV, BV, Lloyds Register, DNV, GL and RINA Quality Control Chemical analysis on melted material Non Destructive testing: Ultrasonic, Hardness, Magnetic Particle, Liquid Penetrant, Visual and Dimensional Destructive testing: Tensile, Impact, Bend, Creep tests Micro and macro-graphic examination 12

14 Customer Care Customer Care 13

15 Customer Care Request for Quotation and Offer 8 people fully dedicated from Engineering Department Quick response time: offer to client within 3 days from request for Quotation Sales Department 9 people dedicated to coordinate information flow between Customers and Metalcam for any kind of matter especially from a commercial point of view Expediting 5 people fully dedicated Customer visits and/or conference call Status report by on a bimonthly basis Management of Quality Matters 6 people fully dedicated Always available for all specific questions and ad-hoc meetings/conference call Quality certification submitted by for information only / approval Pre-Production Meeting / Kick-Off Meeting 14

16 Manufacturing Process Manufacturing Process Overview Key Product Features Steel mill Forging Heat Treatment Machining Finish Machining 15

17 Manufacturing Process Overview Metalcam is one of the few companies with an End-to End capability 11) 12) Steel mill Scrap Melting Furnace 1) 10) 9) Refining Furnace Vacuum degassing 2) 8) Bottom pouring Forge Ingot heating Forging 3) 7) Preliminary Heat Treatment Machining (rough and finish) Quality Heat Treatment 4) 6) Final Inspection 5) Packaging & Shipment Metalcam is in constant contact with the client throughout the production process and after the sale through a customer care department 16

18 Steel Mill Equipped with: A 45 tons capacity arc melting furnace A ladle furnace for refining A degassing unit with V.O.D. system Bottom pouring system 17

19 Forging Department Equipped with: n 6 heating furnaces with a total 500 tons capacity n 1 semiautomatic hydraulic tons press n 1 semiautomatic hydraulic tons press n 4 manipulators from 24 to 70 tons capacity 18

20 Heat Treatment Department Equipped with: n 19 methane gas-fired furnaces with 20 to 80 tons load capacities n 1 electric furnaces with tons load capacities n 2 quenching tanks with 130 and 200 m 3 water capacities n 2 quenching tanks with 110 and 200 m 3 polymeric solution capacities 19

21 Rough Machining Workshop Equipped with: n 6 horizontal lathes (3 CNC) n 3 CNC vertical lathes n 7 CNC milling and boring machines 20

22 Finish Machining Workshop Equipped with: Tacchi horizontal lathe Max length: 10 mt Max diameter: 2.8 mt PAMA vertical milling machine Forgings up to 10 tons 21

23 Key Products and Clients Mechanical Oil & Gas and Petrochemical Energy Shipbuilding Extrusion Raw Material 22

24 Major Clients 23

25 Mechanical Key Products Pistons, cylinders, mandrels, columns and crosspieces for presses Coupling boxes, extensions, gaskets and cylinders for rolling mills Segments, mandrels and rolls for coiler tape train of rolling mills Mandrels and cylinders for the production of tubes Rolls and axles for cement factories Bushes and yokes for paper mills Shafts, pinions and wheels for gearboxes Crankshafts Steel Grades 30 CrMoV 9 18 CrNiMo NiCrMo16 40 NiCrMo 7 42 CrMo 4 30 CrNiMo 8 39 NiCrMo 3 Carbon Steel Major Clients David Brown Flender GUSTO MSC KHD Humboldt Metso SMS Group Siemens VAI Tenaris Group Weir Minerals 24

26 Oil & Gas and Petrochemical Key Products Valve bodies for subsea and surface trees BOPs Wellheads Stress joints for riser system Structural parts for tension legs platforms Tube sheets, shells, flanges, gates and other forged equipment for refineries and chemical plants (heat exchangers) Major Clients Aker Solutions BEL VALVES Cameron / OneSubsea Drill Quip FMC Technologies GE Oil & Gas N O V Steel Grades AISI 8630 ASTM A182 F22 AISI 4130 F6 NM AISI 410 ASTM A182 F91/92 F60 / F65 25

27 Power Generation Key Products Turbine discs and shafts for hydro applications Rotor shafts for steam turbine Discs and shafts for gas turbine Generator shafts Wind turbine shafts Compressor discs Thrust shafts Valve and pump bodies Major Clients Alstom Andritz Hydro Ansaldo Energia Flender General Electric MAN Diesel & Turbo Voith Siemens Steel Grades ASTM A182 F6NM 30 CrMoV 9 35 NiCrMo NiCrMo 7 30 CrMoNiV CrMoNiV 4.7 ST462T Carbon Steel Metalcam is equipped to perform internally heat stability test on steam turbine shaft 26

28 Shipbuilding Key Products Propeller shafts Intermediate shafts Gyrofin shafts Thrust bearing stub pipes Rudder shafts Pintles Cylinder and piston heads Connection rods Turbine shafts Piston rods Pinion and gears for reduction units Major Clients ABB Oy Marine Becker Marine Fincantieri IHC Rolls Royce Steel Grades 42 CrMo 4 C 35 ST CrNiMo 6 27

29 Extrusion Key Products Outer-castings Bushes internal Bearing bushes Punches Matrixes and various forgings for extrusion presses Major Clients Battenfeld Extrusions Kind & Co Presezzi Extrusion Schmidt & Clemens Steel Grades W W W W W

30 Raw Material Key Products Polygonal Ingots Round Ingots Round / Square pre-forged blooms Round / Square pre-forged bars Major Clients Forge Fedriga Forgiatura Marcora Forgital Group Manoir Industries Siderforgerossi Steel Grades Carbon Steel Low Alloyed Steel Medium Alloyed Steel High Alloyed Steel Stainless Steel 29

31 Contacts 30

32 Contacts Headquarters Via Leonardo da Vinci, 3 Breno (BS) - Italy Tel: Fax: Contacts Role Telephone Massimo Cocchi Sales Manager massimo.cocchi@metalcam.it Giorgio Polonioli Chief Metallurgist engineering@metalcam.it Laura Putelli Quality Control laura.putelli@metalcam.it Luca Mossoni Quality Assurance luca.mossoni@metalcam.it 31