ALJO ALUMINIUM-BAU JONUSCHEIT GMBH INNOVATION IN ALUMINIUM PROCESSING
ABOUT ALJO / LOCATION 07.07.2015 2
ABOUT ALJO / FACTS & FIGURES EXPERTS IN ALUMINIUM PROCESSING More than 40 years experience Family owned 300 employees Turnover of 30 million Euros Production area of 11.500 sqm Quality Management System according to aerospace, automotive and marine international standards 07.07.2015 3
ABOUT ALJO / FACTS & FIGURES THREE DIVISIONS UNDER ONE ROOF AEROSPACE MARINE AUTOMOTIVE 07.07.2015 4
ABOUT ALJO / PORTFOLIO CORE COMPETENCIES Type of Production: Prototypes Low and high volume series Small series Component manufacturing Assemblies Complex projects Project Management steps: Design and development Engineering / construction Manufacturing Assembly Delivery logistics After Sales Service / Refits 07.07.2015 5
AEROSPACE DIVISION 07.07.2015 6
AEROSPACE DIVISION / AVIATION AEROSPACE For more than three decades Aljo has been a proven supplier for machined or sheet metal formed aluminium components, assemblies and complex structures with certified aerospace process approvals. As a build to print partner we offer manufacturing solutions for prototypes and single parts as well as small and large series. perfect functionality for you! 07.07.2015 7
AEROSPACE DIVISION / GENERAL CORE COMPETENCIES Material procurement Production planning Tooling Manufacturing Surface treatment Final inspections Delivery logistics Inventory logistics for clients Assembly 07.07.2015 8
ABOUT ALJO / MANUFACTURING PROCESSES MANUFACTURING PROCESSES 2D sheet metal machining 3D milling (five axis) Turning Deep drawing and press forming Bending Heat Treatment Welding Gluing Surface treatment (powder coating, liquid coating) Assembling Quality inspection Our best practices approach to manufacturing is mirrored in our approach to customer service. Build to print (QSF-B) approved for more than 20 years. 07.07.2015 9
ABOUT ALJO / MANUFACTURING PROCESSES 2D-MACHINING 3 PORTATEC PORTAL MILLING MACHINES Control unit: Siemens Sinumerik 840D Working area (xyz): 3.400x1.500x250mm Spindle speed: max. 60.000 rpm & 12KW Toll storage capacity: 24 2D-MACHINING 07.07.2015 10
ABOUT ALJO / MANUFACTURING PROCESSES MILLING 3 AND 5 AXIS MACHINE CENTERS 3D-MACHINING 07.07.2015 11
ABOUT ALJO / MANUFACTURING PROCESSES MOULDING PRESS Size: length 1.000 mm width 800 mm height 400 mm DEEP DRAWING/ PRESS FORMING 07.07.2015 12
ABOUT ALJO / MANUFACTURING PROCESSES BENDING MACHINE Size: length 3.500 mm BENDING 07.07.2015 13
ABOUT ALJO / MANUFACTURING PROCESSES HEAT TREATMENT OVEN Furnace with 2 electrically operated circulating air oven. NADCAP approved SPC controlled handling system Quench basin Time to quench < 10s Automated documentation of process HEAT TREATMENT FACILITY 07.07.2015 14
ABOUT ALJO / MANUFACTURING PROCESSES WELDING SKILLS DIN EN ISO 3834-2 DIN 2303 class Q1, Q2 & Q4 Aluminium constructions SIN 4113-3 EN ISO 9606-2 ISO 24394 B1, C1 & D (chromium-nickel steel, titan and aluminium) EN 287-1 EWE welding engineers & welding specialists acc. DVS-EWF 1173 WELDING 07.07.2015 15
ABOUT ALJO / MANUFACTURING PROCESSES GLUING SKILLS Adhesive specialists acc. DVS 3301 Adhesive bonder acc. DVS 3305 Manually & partly mechanised processing of reactive adhesive systems Separate bonding room with separate area for silicon treatment GLUING 07.07.2015 16
ABOUT ALJO / MANUFACTURING PROCESSES COATING FACILITIES Liquid Coating Drying chamber with for parts up to part size: H/W/L 2.500/3.000/6.000 mm Integrated conveyor systems Powder Coating Max. size 3.200 x 700 x 1.300 mm Pre-treatment with phosphatisation facility Furnace to 220 C COATING 07.07.2015 17
ABOUT ALJO / MANUFACTURING PROCESSES MEASURING EQUIPMENT Air conditioned measurement area Tension testing machine Material testing machine Extensive measurement equipment Zeiss Prismo 10 Navigator Mora-AEH Range 2.400 x 1.400 x 1.800 mm Mobile index arm Faro Type: Quantum (7 axes) QUALITY INSPECTION 07.07.2015 18
AEROSPACE DIVISION / AVIATION AVIATION 07.07.2015 19
AEROSPACE DIVISION / AVIATION PRODUCT SOLUTIONS LOAD MASTER WORK STATION This project for the latest A400M military transporter presents a unique challenge. The Load Master Work Station is a complex assembly which has to be built according to exclusive military specifications and procedures. 07.07.2015 20
AEROSPACE DIVISION / AVIATION PRODUCT SOLUTIONS AIR DISTRIBUTION DUCTS This welded part is made of deep drawn thin sheet metal components for various Airbus types. We set up new production lines to meet the demands of this project. 07.07.2015 21
AEROSPACE DIVISION / AVIATION PRODUCT SOLUTIONS DRAIN-MAST These welded parts are mounted on almost all Airbus Types. Automated production and the latest in welding technology guarantees the ultimate in production efficiency and quality. 07.07.2015 22
AEROSPACE DIVISION / AVIATION PRODUCT SOLUTIONS DIFFUSOR T900 Highly complex forming and welding part made of stainless steel for A380 Airbus aircraft engines. 07.07.2015 23
AEROSPACE DIVISION / AVIATION PRODUCT SOLUTIONS COMPONENTS More than 250.000 single parts and subassemblies per year such as brackets, frames and other sheet metal parts Short lead-times Unique transportation logistic system that guarantees just-intime deliveries to all customer facilities. 07.07.2015 24
AEROSPACE DIVISION / AVIATION PROGRAM PARTICIPATION AIRBUS A319-A321 AIRBUS A400M AIRBUS A350XWB Drain Mast Air Distribution Ducts Sharklet Components Drain Mast FTI Evacuation exit Insert & retainer flapsealings Ramp floor panels Load Master Workstation metal structure Air Distribution Ducts Several interior parts and assemblies 07.07.2015 25
AEROSPACE DIVISION / AVIATION PROGRAM PARTICIPATION AIRBUS A380 Anti Icing Panel, Inlet Outer Barrel Brackets, upper floor crossbeams Exhaust Duct for Flap-Track- Fairings Jettison components for FTF Jettison Pipes Crew rest compartment ladder Ventilation Scoop FTI Evacuation exit FTI Tail bumper For all Airbus Programmes: Detail parts & assemblies 07.07.2015 26
AEROSPACE DIVISION / AVIATION PROGRAM PARTICIPATION VARIOUS Bombardier CRJ lighting frames wings ARJ 21 Air grill retainer Autoflug NH 90 Metal part for seats, Eurofighter Metal parts for seats Lufthansa Technik Metal parts for engine cowlings & aircraft related components 07.07.2015 27
AEROSPACE DIVISION / SPACE SPACE 07.07.2015 28
AEROSPACE DIVISION / SPACE PRODUCT SOLUTIONS THE PHOENIX PROJECT Aljo delivered the test flight unit of a reusable space transport system. The complete set from component manufacturing up to the final assembly was made by aljo. 07.07.2015 29
AEROSPACE DIVISION / SPACE PRODUCT SOLUTIONS MANNED SPACE MISSIONS We delivered experimental equipment, containers and structure parts for several European Spacelabmissions, Space Shuttle flights and the International Space Station ISS. 07.07.2015 30
AEROSPACE DIVISION / SPACE PRODUCT SOLUTIONS LAUNCHERS Aljo is a main supplier of the world's most successful carrier system, -Ariane. 85 sets of complete structures of the 2nd stage and heat shield for Ariane 4 systems were supplied. We are currently involved in the Ariane 5 project with several parts and subassemblies. 07.07.2015 31
AEROSPACE DIVISION / SPACE PRODUCT SOLUTIONS GALILEO PROJECT Aljo has been involved with the manufacturing of components and structures for several satellite programs such as Meteosat, Rosat or Abrixas. Recently we finished the production of structures for the Galileo satellites. 07.07.2015 32
AEROSPACE DIVISION / AVIATION PROGRAM PARTICIPATION VARIOUS Astrium: Ariane 5: Single parts, assemblies & integration devices for ESC-A Phoenix: Fuselage and structure overall Ariane 4: Complete structure of intersection for the 2nd stage Space Shuttle: Integrated Cargo Carrier OHB: Sarlupe: Panels for satellite structures Galileo : Panels, brackets & subassemblies 07.07.2015 33
AEROSPACE DIVISION / REFERENCES CLIENTS - SELECTION 07.07.2015 34
AEROSPACE DIVISION / QUALITY MANAGEMENT QUALITY MANAGEMENT DESCRIPTION EN 9100 NADCAP DIN EN ISO 3834-2 EN ISO 9606-2 EN 287-1 DVS /IIW 1170 DVS /EWF 3301 SCOPE AVIATION HEAT TREATING QUALITY REQUIREMENTS FOR FUSION WELDING OF METALLIC MATERIALS- PART 2: COMPREHENSIVE QUALITY REQUIREMENTS QUALIFICATION TEST OF WELDERS - FUSION WELDING - ALUMINIUM QUALIFICATION TEST OF WELDERS - FUSION WELDING - STEELS INTERNATIONAL WELDING ENGINEER EUROPEAN ADHESIVE SPECIALIST 07.07.2015 35
ALJO PLANT DEVELOPMENT Today Tomorrow 07.07.2015 36
THANK YOU! FOR FURTHER INFORMATION PLEASE CONTACT US! ADDRESS: ALJO ALUMINIUM-BAU JONUSCHEIT GMBH GEWERBESTRASSE 2 27804 BERNE GERMANY CONTACT: MR MATTHIAS SCHÜLER PHONE: +49 (0) 4406 44 210 FAX: +49 (0) 4406 44 299 E-MAIL: matthias.schueler@aljo.de