Castings. Proven success...

Transcription

1 Castings Proven success...

2 Proven success... Know-how and Human Capital BUZULUK a.s. IS A MODERN ENGINEERING COMPANY AND MANUFACTURER WITH TWO DIVISIONS. RUBBER AND PLASTIC MACHINERY DIVISION, IS WORLDWIDE SUPPLIER, KNOWN ESPECIALLY FOR SUPERB QUALITY CALENDERING AND MIXING LINES WITH ITS OWN DEVELOPMENT, MANUFACTURING AND SERVICING FACILITY. PISTON RINGS AND SPECIAL CASTINGS DIVISION DEVELOPS, MANUFACTURES AND DELIVERS THE PISTON AND SEALING RINGS, CASTINGS AND MACHINED CASTINGS FOR MAJOR GLOBAL CUSTOMERS NOT ONLY IN THE AUTOMOTIVE INDUSTRY. BUZULUK a.s.

3 3 Castings Machined Castings

4 ABOUT THE COMPANY 4 ABOUT THE COMPANY BUZULUK a.s. BOTH DIVISIONS EXPORT THEIR PRODUCTS AND SERVICES TO ALL CONTINENTS. THE RESEARCH, DEVELOPMENT AND PRODUCTION IS LOCATED IN THE COMPANY HEADQUARTERS IN KOMÁROV TOWNSHIP, LOCATED BETWEEN PRAGUE AND PILSEN, AT THE PICTURESQUE FOOTHILL OF NATURE RESERVE BRDY. BOTH DIVISIONS, EVEN THOUGH OPERATING IN VERY DIFFERENT DISCIPLINES, BUILD ON MORE THAN 500 YEARS FOUNDRY EXPERIENCE IN THE PRODUCTION OF IRON CASTINGS, WHICH IS DOCUMENTED IN THE SEAT OF BUZULUK a.s. BEFORE THE YEAR THIS TRADITION AND SOCIAL IMPORTANCE OF THE REGION COMMITS US TO PROVIDE OUR CUSTOMERS WITH EXCELLENT PRODUCTS AND SERVICES IN THE FUTURE AS WELL. Piston Ring Production Specialist CASTINGS CNC MACHINED CASTINGS PISTON RINGS FOR INTERNAL COMBUSTION ENGINES AND COMPRESSORS SEALING RINGS FROM ALLOYED CAST IRON AND STEEL COMPRESSION RINGS OIL CONTROL RINGS ENGINE AND COMPRESSOR TESTING INDUCTION HARDENING SURFACE TREATMENTS ASSEMBLING

5 5 RESEARCH AND DEVELOPMENT IN-HOUSE RESEARCH AND DEVELOPMENT INCREASING CUSTOMER DEMANDS FOR FUNCTIONAL PARAMETERS OF OUR PRODUCTS CANNOT BE FULFILLED WITHOUT CONTINUOUS PRODUCTS, MATERIAL AND TECHNOLOGIES RESEARCH AND DEVELOPMENT. SO AS TO ENSURE THESE ACTIVITIES WE HAVE NECESSARY RESEARCH AND DESIGN CAPACITY, AS WELL MACHINING AND FOUNDRY PROTOTYPE WORKSHOP, WHICH ARRANGES PRODUCTION OF PROTOTYPES AND SAMPLE EQUIPMENT OF MACHINING PROTOTYPE WORKSHOP SPECIALIZED IN TECHNOLOGIES IDENTICAL WITH MASS PRODUCTION, IT FACILITATES AND ACCELERATES INTRODUCTION OF NEW PRODUCTS INTO THE SERIES PRODUCTION AND ALLOWS FOR TESTING OF NEW PRODUCTION PROCESSES BEFORE IMPLEMENTATION INTO PRODUCTION. FOR TESTING OF NEWLY DEVELOPED PARTS, ESPECIALLY PISTON AND SEALING RINGS, WE USE OUR OWN TEST ENGINE EQUIPPED WITH SPECIAL MOTOR TEST BENCHES FOR TESTING INTERNAL COMBUSTIONS ENGINES AND PISTON COMPRESSORS. NATURALLY, WE CLOSELY COOPERATE WITH OUR CUSTOMERS IN TESTING OF OUR PRODUCTS. AN IMPORTANT FUNCTIONAL FEATURE OF MODERN PISTON RINGS ARE THE NEW MODERN COATINGS, BUZULUK a.s. SETS UP A DEVELOPMENT COATING WORKSHOP, FOCUSING MAINLY ON RESEARCH AND DEVELOPMENT OF SURFACE TREATMENT OF PISTON RINGS WORKING SURFACES. RESEARCH AND DEVELOPMENT COOPERATION USED METHODS: CAD/CAM FEM Analytical calculations (BUZULUK software) Practical - testing methods, measuring (samples production) Testing (ICE, piston compressors, gearboxes) DUE TO VERY RAPID AND CONTINUOUS GROWTH OF ADVANCED TECHNOLOGIES ACROSS THE SPECTRUM OF ENGINEERING, WE ALSO COOPERATE WITH EXTERNAL COMPANIES, RESEARCH INSTITUTES, UNIVERSITIES AND SPECIALIZED COMPANIES. THANKS TO THE COOPERATION, IT IS POSSIBLE TO PARTICIPATE IN DEVELOPMENT OF OUR PRODUCTS AND TECHNOLOGIES FOR ADVANCED AND HIGHLY SPECIALIZED FACILITIES THAT EXCEED SEVERAL TIMES THE BUDGET ANNUALLY ALLOCATED FOR RESEARCH AND DEVELOPMENT IN OUR DIVISION. OUR CURRENTLY LARGEST EXTERNAL PROJECTS - RESEARCH OF FRICTIONAL LOSSES IN THE ENGINE AND OPTIMIZING THE DESIGN OF PISTON RINGS AND DEVELOPMENT OF SURFACE TREATMENT.

6 QUALITY MANAGEMENT 6 QUALITY MANAGEMENT THE COMPANY BUZULUK a.s. HAS ESTABLISHED AND CERTIFIED SYSTEM OF QUALITY MANAGEMENT ACCORDING TO ISO 9001 STANDARDS. THE COMPANY WAS ONE OF THE FIRST COMPANIES IN THE CZECH REPUBLIC TO OBTAIN THIS CERTIFICATE AS EARLY AS IN JANUARY THE QUALITY MANAGEMENT SYSTEM WAS ESTABLISHED AND CERTIFIED ACCORDING TO THE VDA 6.1 STANDARDS IN DURING PREPARATIONS FOR DELIVERIES TO THE AUTOMOTIVE COMPANY VOLKSWAGEN. SUBSEQUENTLY, THE CERTIFICATE ACCORDING TO THE ISO TS/16949: 2009 STANDARDS FOR AUTOMOTIVE INDUSTRY WORLDWIDE WAS ESTABLISHED IN ON REQUEST OF THE NATIONAL INSTITUTE OF METROLOGY, NORMALIZATION AND INDUSTRIAL QUALITY OF BRAZIL, THE COMPANY BUZULUK a.s. ESTABLISHED AND HAS BEEN THE HOLDER OF THE CERTIFICATE ACCORDING TO HE INMETRO STANDARDS SINCE JANUARY THE CERTIFICATE IS A PRECONDITION FOR THE POSSIBILITY OF COMPONENTS DELIVERIES TO THE BRAZILIAN AUTOMOTIVE MARKET. WITHIN THE ESTABLISHED QUALITY MANAGEMENT SYSTEM, THE COMPANY FOCUSES ON TEAM ORGANIZATION WITH THE AIM OF CONTINUOUS IMPROVEMENT OF QUALITY, PRODUCTIVITY AND REDUCTION OF THE DELIVERY TERMS, AND IT OFFERS INNOVATIVE TECHNICAL SOLUTIONS TO THEIR CUSTOMERS. Quality Certificates: ISO 9001:2008, ISO/TS 16949:2009 Inmetro Certificate: KSPG Automative Brazil Ltda Appreciation for quality of deliveries from Škoda Auto year 1999 Process audit VW according Formel Q Fähigkeit Appreciation of quality from STIHL during Volvo Cars Quality Excellence Award 2014

7 7 PERSONNEL POLICY PERSONNEL POLICY BUZULUK PERSONNEL STRATEGY REPRESENTS ONE OF THE KEY PILLARS OF THE COMPANY S STRATEGY. WITHOUT TRUST TO OUR EMPLOYEES, WITHOUT THEIR MOTIVATION AND RESPONSIBILITY WE CANNOT BE ONE OF THE BIG PLAYERS IN THE MARKET. DURING THE WHOLE PRODUCTION PROCESS OUR PRODUCTS GO THROUGH MANY TEAMS. WE WOULD NOT HAVE ANY FUTURE WITHOUT THEIR MUTUAL SYNERGY. 555 years of tradition... Proven success.

8 STRATEGY 8 STRATEGY OUR PERMANENT STRATEGY IS TO BE A RELIABLE AND FLEXIBLE PARTNER FOR A WIDE PORTFOLIO OF CUSTOMERS. OUR PHILOSOPHY IS TO UNDERSTAND CUSTOMERS NEEDS AND BASED ON CLOSE COOPERATION TO SUPPLY PRODUCTS AND SERVICES SUPPORTING CUSTOMERS SUCCESS AND EASIER LIFE. BUZULUK KNOW-HOW IN THE FIELD OF PISTON RINGS, SEALING RINGS, MACHINED CASTINGS AND SUBSYSTEMS DESIGN, DEVELOPMENT, PRODUCTION AND LOGISTIC IS BASED ON LONG TERM EXPERIENCE AND COOPERATION WITH CUSTOMERS WHO ARE TECHNICAL AND COMMERCIAL MARKET LEADERS. ON THE OTHER HAND, IT IS A PLEASURE FOR US TO COOPERATE WITH SMALLER CUSTOMERS WITH SPECIFIC AND INTERESTING APPLICATIONS AND PRODUCTS. WE CONTINUOUSLY INVEST INTO R&D TO BE ABLE TO OFFER THE BEST VALUE/PERFORMANCE RATIO FOR OUR CUSTOMERS. OUR TARGET FOR THE FUTURE IS TO EXPAND OUR PRODUCT AND SERVICE PORTFOLIO IN THE AREA OF HIGH TECH SPECIALIZED PISTON RINGS, SEALING RINGS AND SMALL MACHINED CASTINGS FROM CUSTOMIZED CAST IRON MATERIALS. WE WOULD LIKE TO EXPAND IN SUPPLY OF ASSEMBLED SUBSYSTEMS HELPING TO REDUCE EVEN CUSTOMERS LOGISTICS AND PRODUCTION COSTS. WE TAKE CARE ABOUT INTERPERSONAL CONTACTS WITH CUSTOMERS AND PARTNERS ON ALL LEVELS BECAUSE WE BELIEVE THAT PERSONAL RELATIONSHIPS AND TRUST ARE A NECESSARY BASE FOR LONG TERM SUCCESSFUL BUSINESS. WE KNOW HOW... This is the advantage for our customers and partners.

9 9 STRATEGY SOMETIMES IS BETTER NOT to cooperate with the biggest one. 555 years of tradition... Proven success.

10 PRODUCTS 10 CASTINGS OUR CASTINGS ARE VERY POPULAR AND HIGHLY COMPETITIVE

11 555 years of tradition... Proven success.

12 PRODUCTS 12 CASTINGS BUZULUK foundry production program focuses mainly on small cast iron castings (up to 1kg) due to very productive semi-automatic production line. Given that this device mainly casts individual blank rings the manufacturing is specialized in the production of smaller castings in larger series. With high productivity and fine surface quality (fine foundry sand) are our castings very popular and highly competitive. The surface quality can be increased by surface treatments, chemical plating (e.g. zinc). The individual melts are separated in the process and we can provide our customers with the attest of tests for each melt. Because of the long tradition in foundry industry (over 555 years), we are able to develop own kinds of cast iron. This allows us to optimize the properties of the material according to customer requirements.

13 13 USE: Semi-products for the final machining Inlet and exhaust valve seat castings for gasoline and diesel engines Semi-produced valve guides Rocker arms of pin stands for gasoline and diesel engines Pulleys for belting of engines Car water pump propellers Hose couplings (compressed air, hydraulic) Rope cramps Clamps for crating Couplings el. and other rails, pipes (railway, building industry,..) Automotive door hinges NVH solutions (anti-vibration use for engines, gearboxes) Castings for mining systems Others 555 years of tradition... Proven success.

14 MARKET 14 MARKET CASTINGS / MACHINED CASTINGS THE ENGINEERING INDUSTRY AUTOMOTIVE INDUSTRY MINING INDUSTRY FARMING, AGRICULTURAL INDUSTRY

15 15 MARKET RAILWAY INDUSTRY ROAD INDUSTRY PRODUCTION INDUSTRY CONSTRUCTION INDUSTRY

16 TECHNOLOGY AND PRODUCTION 16 TECHNOLOGY AND PRODUCTION PROCESS CONTROL THE TECHNOLOGY USED IS THE CASTING INTO HIGH-PRESSURE-FORMED SAND MOULDS, STOCKED INTO COLUMNS. MOULDING TECHNOLOGIES: SEMI-AUTOMATIC FRAME LINE: SEMI-AUTOMATIC - CASTINGS UP TO 1,0 KG INDIVIDUAL FRAME MOULDING: MOULDING MACHINES - CASTINGS UP TO 1,5 KG PATTERN EQUIPMENT: BUZULUK a.s. USE IN ITS PRODUCTION PROCESS THE SYSTEM OF METAL PATTERNS INSTALLED ONTO THE PATTERN PLATE. PRODUCTION OF THE PATTERN EQUIPMENT, ASSEMBLY ON TO THE PATTERN PLATE INCLUDING THE GATING SYSTEM IS DONE BY BUZULUK IN ITS PREMISES. WHEN AGREED WITH CUSTOMER, DELIVERED PATTERN EQUIPMENT CAN BE USED IN CERTAIN CASES. OTHER FORMING TECHNOLOGIES ARE NOT USED IN BUZULUK a.s. MELTING: IS DONE IN 1 AND 2 TON INDUCTIVE MELTING FURNACES. THE PROCESS OF MELTING IS CONTROLLED BY COMPUTER, WHICH ANALYSES THE RESULTS OF QUANTOMETRICAL ANALYSIS AND GIVES INSTRUCTIONS DIRECTLY TO THE FURNACE PLATFORM FOR PROCESSING OF MELTED METAL. CORE PRODUCTION (IN HOUSE): TECHNOLOGY USED - CRÖNING

17 17 TECHNOLOGY AND PRODUCTION MATERIALS: GREY CAST IRON ALLOYED CAST IRON DUCTILE CAST IRON STEEL CAST IRON CASTINGS OF DIFFERENT MATERIAL MODIFICATIONS IN ACCORDANCE WITH VALID CZECH AND FOREIGN STANDARDS AND ACCORDING TO THE CUSTOMERS REQUESTS. THE INITIAL MATERIALS IN THE AREA OF SPECIAL CASTINGS AND ALSO PISTON RINGS ARE IN ACCORDANCE WITH THE CS STANDARD ISO , CLASSES 10,20 AND 50,60. TRACEABILITY: THE FOUNDRY IS CONNECTED WITH A METALLOGRAPHICAL, MECHANICAL, SAND AND CHEMICAL LABORATORIES, WHICH FOLLOWS THE FOUNDRY OPERATION. THE INDIVIDUAL MELTS ARE SEPARATED IN THE PROCESS AND WE CAN PROVIDE OUR CUSTOMERS WITH THE ATTEST OF TESTS FOR EACH MELT. CASTINGS DIMENSIONAL LIMITS: MOULDING SYSTEMS SEMI-AUTOMATIC FRAME LINE INDIVIDUAL FRAME MOULDING FRAMELESS LINE (DISAMATIC PLANNED) CASTING WEIGHT up to 1Kg up to 1,5Kg up to 15Kg CASTING DIMENSIONS up to 300mm height 2x25mm up to 350mm height 2x35mm up to 450mm height 280mm 555 years of tradition... SURFACE ROUGHNESS Ra 16-25, Rz Ra 16-25, Rz Ra 16-25, Rz Proven success.

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19 19 PRODUCTS MACHINED CASTINGS WITH OUR PRODUCTS WE ARE CURRENTLY THE MOST SUCCESSFUL IN THE AUTOMOTIVE INDUSTRY 555 years of tradition... Proven success.

20 PRODUCTS 20 MACHINED CASTINGS The production program of the company BUZULUK a.s. is also focused on CNC machining of castings. Not only own castings but also eventually purchased. (large castings, i. e. another material. aluminum, steel,...). With this technology, our company can offer the completely finished product, from its casting after finishing to packaging. We offer to our customers even more machined parts of any assemblies which we are willing to assembly and eventually test and send in a place according to Customer requirements. With our products we are currently the most successful in the automotive industry. These are the parts for mechanical and automatic transmissions.

21 21 PRODUCTS USE: Internal combustion engines Car body parts Car chassis Gearboxes (shifting forks, gear holders,...) Different industrial parts Parts for building and construction machines Others 555 years of tradition... Proven success.

22 PRODUCTION TECHNOLOGY 22 PRODUCTION TECHNOLOGY CASTING: CASTED BY BUZULUK FOUNDRY (SEE CASTINGS), STEEL AND ALUMINIUM CASTINGS DELIVERED FROM SUB-SUPPLIER MACHINING: 10 PCS ROBUST VERTICAL CNC MILLING MACHINES DIMENSIONS: TABLE SIZE x 550 mm. MAX. DIMENSION OF CASTING: 1000 x 600 x 550 mm

23 23 PRODUCTION TECHNOLOGY MATERIALS: BUZULUK MATERIALS: GREY CAST IRON ALLOYED CAST IRON DUCTILE CAST IRON STEEL CAST IRON CASTINGS OF DIFFERENT MATERIAL MODIFICATIONS IN ACCORDANCE WITH VALID CZECH AND FOREIGN STANDARDS AND ACCORDING TO THE CUSTOMERS REQUESTS. THE INITIAL MATERIALS IN THE AREA OF SPECIAL CASTINGS AND ALSO PISTON RINGS ARE IN ACCORDANCE WITH THE CS STANDARD ISO , CLASSES 10,20 AND 50,60. PURCHASED MATERIAL: ACCORDING TO CUSTOMER REQUIREMENTS 555 years of tradition... Proven success.

24 References 24 AMERICA USA MEXICO BRAZIL EUROPE BELGIUM CZECH REPUBLIC GERMANY FRANCE GREAT BRITAIN SLOVAKIA SWEDEN ESTONIA LATVIA LITHUANIA BELARUS POLAND UKRAINE SERBIA BULGARIA HUNGARY ITALY AFRICA EGYPT SAR ASIA RUSSIA GEORGIA TURKEY INDIA CHINA NORTH KOREA AUSTRALIA

25 25 Environment Environmental Policy ENVIRONMENTAL MANAGEMENT IN COMPLIANCE WITH THE STRATEGY OF A PROMINENT WORLD MANUFACTURER OF PISTON RINGS AND RUBBER MACHINERY WITH CLOSE RELATIONSHIPS WITH CITY AND REGION THE COMPANY BUZULUK a.s. DECIDED TO INTRODUCE THE ENVIRONMENTAL MANAGEMENT SYSTEM IN 2001 AND SINCE 2002 THE COMPANY IS THE HOLDER OF THE INTERNATIONAL CERTIFICATE ACCORDING TO ČSN EN ISO IT DEFINES THE METHODS OF COMPANY MANAGEMENT REFLECTING PREVENTION AND CONTINUOUS IMPROVEMENT OF THE ENVIRONMENT. CONSUMPTION OF NATURAL RESOURCES WASTE MANAGEMENT CHEMICAL SUBSTANCES; REACH AIR PROTECTION PROTECTION OF WATERS 555 years of tradition... Proven success.

26 26 THANKS TO US THE THINGS ARE MOVING THANKS TO SEVERAL HUNDRED YEARS OF EXPERIENCE IN THE FOUNDRY INDUSTRY, WE ARE ABLE TO OFFER TO OUR CUSTOMERS THE WORLD S BEST IRON CASTINGS LEVEL. THIS PERFECT KNOWLEDGE OF METALLURGY IS THE BASIS OF THE FACT THAT WE ARE ABLE TO PRODUCE ANY CUSTOM-MADE CAST IRON MATERIAL. ON THE BASIS OF KNOWN TECHNICAL ADVANTAGES OF SPECIAL CAST IRON, THIS MATERIAL IS STILL HIGHLY ACTUAL AND REQUIRED IN MANY MODERN INDUSTRIES.

27 LET THERE BE MOVE... WE OFFER: INDUCTION HARDENING Generators Custom development and production hardening Control of microstructure and hardening process CHROME PLATING (hard chrome plated, porous chromium, chromium-ceramic, chrome diamond) NITRIDING (including stainless steel) SPRAYING MOLYBDENUM (Mo wire flame spraying) HEAT TREATMENT (hardening in a vacuum furnace, annealing, tempering) USE OF ENGINE TEST BENCHES Engine test bench (eddy current max rpm and 150 kw) Engine test bench (Super flow max rpm and 300 kw) Compressor test bench (Wabco + Buzuluk + KS Kolbenschmidt) Foundry castings of the company BUZULUK a.s. are supplied to automotive industry as well as beyond it. From automotive transmissions up to door hinges. Strong industrial segment are the railways, where the castings are primarily used mainly for rails and electrification. Other important sectors are the glass industry, textile and building industry. Moreover, we keep and continue the production of artistic castings. 555 years of tradition... Proven success.

28 CONTACTS Buzuluk a.s. Buzulucká 108, Komárov Telephone: Division Piston Rings Sales & Logistic Telephone: Telephone: G016/15 Our web site: Environmental Policy 02/2016