Wednesday, 02 August 2017 09:43

Order for Four Forging Lines

chuler delivers multi-station mechanical presses with a press force between 8,000 and 20,000 kilonewtons to China

Automotive supplier Chongqing Lianhao Technology from China has ordered four mechanical forging lines from Schuler. The multi-station mechanical presses with link drive have a press force between 8,000 and 20,000 kilonewtons.

"We have to thank our sales department in Weingarten for the acquisition of this order," says Markus Bieg, head of the Industry Division in Weingarten. "Our colleagues here will also be responsible for the technical aspects of the product and design of the system. This demonstrates how important this site is for the Schuler Group." Manufacturing and assembly will take place at the Göppingen and Erfurt sites. The delivery of the four forging lines is planned to take place in the course of first half-year of 2018.

2017 08 02 094300Automotive supplier Chongqing Lianhao Technology from China has ordered four mechanical forging lines from Schuler. Photo: Schuler

Due to the large stroke range from 250 to 800 millimeters, presses of the type MML2 with link drive, which are optionally available with ServoDirect technology, are suitable for the mass production of drive and chassis components in a large variety of sizes – from bevel gears to transmission shafts. The link kinematics reduce the forming speed, thereby increasing both the quality of the parts and the formability of the material. The link drive system of the MML2 developed by Schuler can be optimally adapted to the respective component requirements during the design of the press and permits a use for both cold and warm forging.

"Economical manufacturing of parts in large volumes is only possible by optimal coordination of the equipment, process technology know-how, and tool technology," Markus Bieg says. "At Schuler, this knowledge is combined with years of experience. The result: the particular expertise for implementing efficient, complete solutions – like the MML2 press series."

About the Schuler Group – www.schulergroup.com

Schuler is the technology and world market leader in forming technology. The company offers presses, automation solutions, tools, process expertise and service for the entire metalworking industry and lightweight automobile construction. Customers include automobile manufacturers and automotive suppliers as well as companies from the forging, household appliance, packaging, energy and electronics industries. Schuler is a leader in coin minting presses and implements system solutions for the aerospace, rail transport and large-dimension pipe manufacturing sectors. In the 2016 fiscal year, Schuler generated sales of 1,174.2 million euros. After acquiring toolmaker AWEBA and the majority stake of Chinese press manufacturer Yadon, Schuler is present in 40 countries with about 6,600 employees. Schuler is majority-owned by the Austrian ANDRITZ Group.

Published inMachinery
Wednesday, 02 August 2017 09:38

Automated forging lines for Mongolia

At Darkhan Metallurgical Plant, Schuler installs induction heaters, short stroke die forging hammers and robots for the production of steel balls

Mongolia, a landlocked country in Central Asia, is renowned for its vast mineral resources of coal, copper, gold and iron ore. In the last years, especially consumption of grinding media has increased. The Darkhan Metallurgical Plant (DMP), established in 1990 and located around 200 kilometers North of the capital Ulaanbaatar, has now installed two automated Schuler forging lines featuring short stroke die forging hammers KGH 5.0B for the manufacture of steel balls with diameters of 100 to 140 millimeters.

2017 08 02 093753The forged steel balls are removed by an employee from a discharge chute integrated into the die area. photo:Schuler

In the first step of the production process, round steel bars are cut into pieces by a circular saw and heated by induction. Next, a robot arm takes the red-hot parts from the conveyor belt and inserts them into the Schuler hammer. The forged steel balls are then removed by an employee from a discharge chute integrated into the die area. After their quenching and hardening, as well as the subsequent tempering process and quality control, the grinding balls are ready for use.

As a system supplier, Schuler has provided the whole line including the dies and lubrication within seven months. The assembly began in November 2016, configuration and testing of the machinery was completed on December 14th, 2016. In the meantime, DMP has commissioned the lines. A new steel ball is produced by each line every eight seconds; the annual capacity of both lines is up 25,000 tons per year.

2017 08 02 093727Schuler provided two lines featuring short stroke die forging hammers KGH 5.0b to the Darkhan Metallurgical Plant in Mongolia. Photo: Schuler

“Our customer had no experience in forging, so we introduced him to this new technology step by step and provided operator, maintenance and security training”, says Markus Bieg, head of Schuler’s “Industry” division in Weingarten, Germany. “Via Remote Service, we can assist DMP 24/7.” This is Schuler’s first project in Mongolia. With the help of the customer, visualization as well as documentation have been translated into local language.

According to DMP, the project will open new opportunities to the development of metallurgical industry in Mongolia.

About the Schuler Groupwww.schulergroup.com

Schuler is the world market leader in metal forming technology. The company supplies presses, automation solutions, dies, process know-how, and services for the entire metalworking industry and lightweight automotive design. Customers include automobile manufacturers and suppliers as well as companies from the forging, household appliances, packaging, energy, and electronics industries. Schuler is the market leader in minting presses and supplies systems solutions for the aerospace, railway and large pipe industries. In 2016, Schuler achieved a turnover of 1,174.2 million Euros. Following the acquisition of die manufacturing company AWEBA and with a majority holding in Chinese press manufacturing company Yadon, Schuler employs around 6,600 members of staff in 40 countries. The Austrian ANDRITZ Group holds a majority share in Schuler.

Published inMachinery

With a flexible and highly productive 630 ton system, Feinwerktechnik hago GmbH is optimally set up at the site in Mississippi

A planned expansion abroad is a Herculean task for an SME. Nonetheless, automotive supplier Feinwerktechnik hago GmbH has taken the plunge, and just a few weeks ago the company opened a new site, hago Automotive Corp., in the southern USA. The key production system at the plant in Iuka, Mississippi is a 630 ton servo press from Schuler.

“As an SME with little experience in internationalization, it was extremely important to eliminate as many risks as possible“, explains Marcel Wegmann, authorized representative at Feinwerktechnik hago GmbH. “A Schuler press is a dependable, robust competitive premium product which guarantees reliability in the machinery pool.”

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“A Schuler press guarantees reliability in the machinery pool“, says Marcel Wegmann (second from the right). Photo Schuler

For Hago Automotive Corp., it is extremely important that the system can be used in a wide range of applications and is highly productive. As of 2017 it will be used to produce innovative sheet metal parts for body shells, gear boxes and exhaust gas systems for a new off-road vehicle from a premium German manufacturer.

“We see the Schuler press as a type of all-purpose weapon, which covers a very large part of our product portfolio”, says Marcel Wegmann. “It enables us to economically produce large parts in transfer operation as well as smaller parts using progressive dies with maximal stroke rate and accuracy.”

And that is not the only advantage: an identical system is located at hago’s headquarters in Küssaberg, Germany, on the border with Switzerland. “This means that we can also fully break-in and optimize complex dies that we have developed and constructed in Germany at the site in Küssaberg”, explains Marcel Wegmann. As a result, there is no need to run them in at the site in the USA.

“We have had a positive experience with our Schuler presses in Küssaberg in terms of service and product quality, and this tipped the scales decisively when it came to the investment decision in the USA“, adds Marcel Wegmann. “We hope that the new system will now provide us with a considerable competitive edge which we can also build upon over the long term.”

About the Schuler Group – www.schulergroup.com

Schuler is the world market leader in metal forming technology. The company supplies presses, automation solutions, dies, process know-how, and services for the entire metalworking industry and lightweight automotive design. Customers include automobile manufacturers and suppliers as well as companies from the forging, household appliances, packaging, energy, and electronics industries. Schuler is the market leader in minting presses and supplies systems solutions for the aerospace, railway and large pipe industries. In 2015, Schuler achieved a turnover of 1.2 billion euros. Following the acquisition of die manufacturing company AWEBA and with a majority holding in Chinese press manufacturing company Yadon, Schuler employs around 6,800 members of staff in 40 countries. The Austrian ANDRITZ Group holds a majority share in Schuler.

About Feinwerktechnik hago - www.hago-ft.de

Since it was founded in 1970, Feinwerktechnik hago GmbH has grown from a mere tool making and die shop to a generalist in sheet metal forming with more than 700 employees. The spectrum of the state-of-the-art production facilities with Schuler presses ranges from parts of the size of a paper clip to body panels for buses with batch sizes from 1 to several million parts per year. As the company also encompasses a design and construction department as well as a tool-making department, hago is able to offer fast, efficient and individual one-stop solutions. In addition to the automotive industry, customers also include manufacturers of electric motor laminations, furniture and medical technology. In mid-2016, hago Automotive opened a site in Iuka, Mississippi (USA).

Published inProduction
Monday, 01 August 2016 07:23

Metal packaging production at top speed

With up to 200 pieces per minute, Schuler’s impact extrusion press X-250S accelerates M/s Alumatic Cans’ manufacturing process.

For more than half a year now, a Schuler impact extrusion press has been at the very heart of a new production line at M/s Alumatic Cans Private Limited. With the help of the X-250S, the company  located in Pune manufactures in between 180 and 200 aerosol cans per minute. The metal packaging press was delivered by Schuler including slug feeder and tools, the rest of the line by M/s PacksysGlobal Thailand.

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“None of the production lines we have already operated before is as fast as the one with the X-250S at its center”, states M/s Alumatic Cans’ Managing Director Danesh  Sayani: “Schuler has not only installed the press on-site, but also ensured that it fits into the production process. The Service experts are always available in case of any problems.”

M/s Alumatic Cans, established in 2011, started manufacturing one year later and supplies monobloc aluminum aerosol cans, aluminum rigid cans and aluminum vitamin containers both internationally and locally. With an annual capacity of more than 70 million units, it is one of India’s leading manufacturers today. “We are dedicated to provide 100% customer satisfaction with a strong commitment to quality, service and product innovation,” Managing Director Danesh  Sayani says.
 
The most important feature of Schuler’s XS series is the motion characteristic of the knuckle-joint. This design provides a slide motion that permits higher production speeds. At the same time, it improves part quality and broadens the spectrum of possible parts that can be made on the press. Other performance enhancing design features complement the motion characteristics.

Innovative knuckle-joint drive
The XS series has four articulated joints in the design of its knuckle-joint drive as compared to conventional impact extrusion presses with three. This creates slide motion characteristics that are especially favorable for both speed and part quality with very long nominal forming travel. The slower impact speed on the slugs provides protection for the punches and ensures longer tool lifetime.

Thanks to the longer nominal force stroke, more material can be formed and therefore thicker slugs. The forming stroke of the X250S is 20 mm, which is about three times that of conventional presses. Thus, the XS presses are much more flexible in their range of applications. Significantly larger and more complex parts can be produced on this series.

Compared to a conventional impact extrusion press, the forward motion of the slide on the XS press is faster. Towards front dead center it becomes slower than on a press with conventional drive. Thanks to the slower slide speed, the impact is softer than on a conventional press with the same stroke rate. After impact, the slide motion is more constant and guarantees very uniform speed forming. The slide return stroke of the XS starts earlier and has the same speed as a conventional press.

Very stiff wear-free slide guiding guarantees utmost precision in slide movement. This is essential to assure the quality of the parts and provide long tool life, while achieving high production rates. Tool changeovers can be performed in a matter of a few minutes. The tool holders are self-centering by means of specially shaped receptacles, eliminating the need to adjust the die relative to the punch.

A precise indexing sequence is essential for production at high speeds. The systems gain flexibility and can be controlled independently due to the uncoupling of the slug feeding and finished part transfer functions. The NC servo drive controls the dial feed plate that provides both slug feed and part transfer. This way the slugs can be guided smoothly in front of the die without vibration.

The finished part removal function is driven by a second servo motor. Here too, the motion has been optimized. It consists of three phases: the part is picked up slowly, quickly transferred out of the punch area and gently deposited onto the exit conveyor.

About the Schuler Groupwww.schulergroup.com
Schuler is the technological and global market leader in forming equipment. The company offers cutting edge presses, automation, dies, process know-how and services for the entire metal forming industry and lightweight vehicle construction. Its clients include car manufacturers and their suppliers, as well as companies in the forging, household equipment, packaging, energy and electrical industries. Schuler is the market leader in coin minting presses and supplies systems solutions for the aerospace, railway and large pipe industries. In fiscal year 2015, Schuler posted sales of € 1.2 billion. With around 5,200 employees, Schuler is represented in 40 countries and is a member of the Austrian ANDRITZ Group.

Published inProcessing
Wednesday, 15 June 2016 07:57

Innovative products, satisfied customers

König Metall in Gaggenau, Germany achieves its business objectives at its Croatian site with two 400-ton HPX presses from Schuler

Highly satisfied customers, innovative products, and optimal production processes: these are the objectives set by Hans-Jörg Leuze, Managing Director of König Metall in Gaggenau, Germany. Help achieving these objectives came in the form of two recently acquired hydraulic Schuler HPX presses, each with a press force of 400 tons, at the Croatian site of Pisarovina.

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"For us, as an automobile supplier, Schuler Presses delivers exactly what we need", says Hans-Jörg Leuze. "Our customers expect us to develop and manufacture parts of the utmost quality, and to do so, we need appropriate machines." In 2014, König Metall had founded the facility in Pisarovina, located about 30 kilometers south of Zagreb. As of today, 200 people work at the location which has shown a rapid growth in the last two years; the first production hall was followed by a second one very quickly.

The machine park now includes a total of 22 presses, most of which have been delivered by the Schuler Group. Among other things, the two latest Schuler lines produce parts for trucks and exhaust systems for various vehicles. HPX presses are ideal for small and medium batches of components with high forming paths, thereby making them the perfect solution for König Metall. Thanks to the standardized machine concept, not only do they offer an attractive price/performance ratio, they can also be supplied in just seven to eight months and installed and commissioned at the customer’s site in just a few more weeks.

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With further plants in Germany, Italy, Poland, Canada and Russia, and 950 employees worldwide, König Metall is a global company today which specializes in sheet metal and pipe processing. The company, which was founded in 1901, is being run by the fourth generation. Until 2013, the late Dr. Otmar Zwiebelhofer was the sole owner and manager, former managing director of the Employers' Association Südwestmetall.

About the Schuler Groupwww.schulergroup.com
Schuler is the world market leader in metal forming technology. Schuler offers presses, automation solutions, dies, process technology and service for the entire metalworking industry and lightweight automotive design. Our clients consist of automotive manufacturers and suppliers, as well as companies from other industries, such as foundries, household devices, packaging, power and electronics. Schuler is the market leader in minting presses and supplies systems solutions for the aerospace, railway and large pipe industries. In the 2014 fiscal year, Schuler achieved a turnover of 1.18 billion euros. With approximately 5,400 employees, Schuler is represented in 40 nations around the world. The Austrian ANDRITZ Group holds a majority share in Schuler.

Published inSheet Metal

Schuler AG, the market leader in forming equipment, is to take over the die construction specialist AWEBA and thus greatly expand its activities in this business field. Based in Aue, Germany, the AWEBA Group is one of the world’s leading full-service providers of dies and fixtures. Under the terms of the purchase agreement, Schuler will acquire a 100 percent stake in AWEBA Werkzeugbau GmbH Aue.

The transaction is still subject to the approval of the relevant anti-trust authorities. AWEBA Werkzeugbau GmbH was previously held by private and institutional investors. The parties have agreed not to disclose any details about the purchase agreement.

AWEBA was founded in 1882 as “Bernhard Hiltmann Spezialfabrik für Schnitt und Stanzwerkzeug”. The company today supplies international customers in the automotive and electrical industries, as well as machine and plant manufacturers. The product portfolio includes forming, cutting, hydroforming, and die-casting dies, as well as fixtures and a comprehensive range of services.
In fiscal year 2015, the AWEBA Group generated sales revenue of around € 60 million.

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Schuler CEO Stefan Klebert commented: “We are delighted to add a successfully managed company like AWEBA to our Group. With its high level of expertise in research and development and excellent engineering know-how, the company is a perfect fit for Schuler. The acquisition is part of our growth strategy. AWEBA complements our product portfolio in forming technology in line with market requirements and will expand and strengthen our existing activities in die construction.”

The AWEBA Group employs around 600 people, including almost 200 highly skilled engineers and toolmakers. The company owns 40 valuable patents in the field of die manufacturing.

AWEBA CEO Udo Binder stated: “Becoming a member of the Schuler Group opens up tremendous opportunities for the further expansion of AWEBA. Schuler’s global market standing will enable us to quickly grow our international presence and enhance our profile as a global system supplier. This gives AWEBA growth opportunities which would not have been achievable without Schuler.”

The AWEBA takeover is Schuler’s second major acquisition in the last twelve months. Last year, the company acquired a majority stake in the Chinese press manufacturer Yadon with annual sales of around € 110 million.

About the Schuler Groupwww.schulergroup.com
Schuler is the technological and global market leader in forming equipment. The company offers cutting edge presses, automation, dies, process know-how and services for the entire metal forming industry and lightweight vehicle construction. Its clients include car manufacturers and their suppliers, as well as companies in the forging, household equipment, packaging, energy and electrical industries. Schuler is the market leader in coin minting presses and supplies systems solutions for the aerospace, railway and large pipe industries. In fiscal year 2015 (ending Dec. 31), Schuler posted sales of € 1.20 billion. With around 5,200 employees, Schuler is represented in 40 countries and is a member of the Austrian ANDRITZ Group.

Published inProcessing
Friday, 29 January 2016 11:11

Schuler opens Hot Stamping TechCenter

Schuler has just opened its new research and demonstration center for hot stamping at its home base in Göppingen, Germany. At the so-called Hot Stamping TechCenter, the company will be showing its customers innovative applications for the future of lightweight vehicle construction. Schuler has invested some 6.5 million euros in the line, which is equipped with hydraulic press, roller hearth furnace, and automation. It was developed at the company’s Waghäusel site.

In the hot stamping (or press hardening) method, sheet steel is heated to 930 degrees Celsius, and cooled and thus hardened in the subsequent forming process. This enables the production of extremely light but highly rigid vehicle parts. Schuler is the global market leader for hot stamping equipment. Due to the growing requirements for passenger protection and the need to reduce CO2 emissions, demand is expected to grow in the coming years.

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caption: At the Hot Stamping TechCenter, Schuler will be showing innovative applications for the future of lightweight vehicle construction. photo source: Schuler

“Hot stamping is an important method for producing lightweight car bodies and plays an important role in Schuler’s product spectrum,” stated CEO Stefan Klebert. “Our new Hot Stamping TechCenter is proof of both our innovative strength in the field of fully automatic, networked production lines and of our firm commitment to Germany as a high-tech manufacturing location.”

Increased productivity and decreased energy consumption
The 1,600-metric-ton press at the Hot Stamping TechCenter already boasts Schuler’s PCHflex technology. “PCHflex allows a flexible and economical production of hot stamped parts with up to 40 percent higher output performance and consistently high quality, combined with maximum process reliability and availability,” explained Dr. Martin Habert, Managing Director of Schuler in Waghäusel.

The press line is also equipped with EHF technology (Efficient Hydraulic Forming), which drastically reduces energy consumption. Thanks to its condition monitoring system, the wear and tear of machine components can be precisely anticipated.

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caption: In the hot stamping method, sheet steel is heated to 930 degrees Celsius, and cooled and thus hardened in the forming process. photo source: Schuler

First line in Schuler’s new machine design
The press line is also the first to feature Schuler’s new machine design, which the company will gradually roll out across its entire product range. The new design aims to symbolize Schuler’s technological lead and ensures a high degree of recognition.

The Hot Stamping TechCenter will mainly be used for the ongoing development of machine technology and lightweight vehicle construction processes. However, Schuler also plans to use the center for customer presentations and training.

Apart from Göppingen, Schuler also has demonstration and reference centers at its German sites in Erfurt, Gemmingen, Göppingen and Hessdorf, as well as in the USA. In contrast to trade shows, TechCenters are open all year round and enable customers to receive individual support and run their own tests. In spring 2016, a further TechCenter will go into operation in the North Chinese coastal city of Tianjin. It will feature a 1,600-metric-ton press with TwinServo Technology (TST).

Published inSheet Metal

Official award ceremony at Cedual training center / Final exam set by German Chamber of Commerce and Industry

At Schuler’s vocational training center in the Mexican city of Puebla (Centro de Especialización Dual or Cedual for short), the first intake of apprentices have now received their leaving certificates. The official award ceremony was attended by the governor of the Mexican state of Puebla, Rafael Moreno Valle, and the chairman of the supervisory board of Allgaier Werke GmbH, Prof. Dr. Dieter Hundt.

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The newly qualified industrial and tool mechanics all passed their German Chamber of Commerce and Industry exams with flying colors. They are the first skilled workers in Mexico to have completed a three-year apprenticeship based on the acclaimed German dual education standard.

The 25 fledgling mechanics have been given a three-year contract to continue working at their respective companies. In addition to Schuler, the companies include the autopart suppliers Allgaier, ThyssenKrupp Presta, ThyssenKrupp Materials, LuK, Gestamp and PWO. All partner firms have facilities in the vicinity. A total of 69 apprentices from 15 different countries currently attend the Cedual training center.

In order to alleviate the shortage of skilled labor in Mexico, the center has been training industrial mechanics in plant and machinery construction and tool mechanics in blanking and forming technologies since 2012. The course is based on the curriculum for apprenticeships in industrial engineering professions.

In addition to the drilling, turning, milling and grinding machines, and numerous work benches, CEDUAL also houses a technical college. As in Germany, there are both theoretical and practical phases during the apprenticeship. German trainers and Mexican teachers instruct the apprentices in an audio-visual lecture theater and three classrooms.

The training costs are borne by the various partner companies. In addition, Cedual receives financial support from the German-Mexican Chamber of Commerce and Industry, the German Federal Ministry of Education and Research, the Mexican state of Puebla, and the Mexican Ministry of Economics.

As well as providing education for apprentices, Cedual also offers training for the employees of companies in the field of die and press technology, sinker EDM, welding, hydraulics, pneumatics, CNC technology, turning and milling.

Published inSheet Metal
Tuesday, 06 October 2015 10:06

Test run proves decisive

For the production of stampings from high-strength steel with maximum flatness and precision, SKA in Attendorn uses Schuler’s highly rigid fine leveling machine.

Precision stampings not only require cutting-edge press and die technology, but also high-performance levelers: several rollers straighten the sheet metal as it leaves the coil and eliminate any defects – such as cross bows which cannot be completely avoided in production – with the aid of an alternate bending process. The specific requirements for an optimum straightening process are defined by the material and finished component. In order to find the right machine, it was important for SKA and Schuler to define precisely which materials would be used in production for which end products.

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Guido Schneider (right) with the extremely flat and precise component produced by the overall system

“Until the end of the 90s, we used levelers with nine rollers as we used to produce guide rails from relatively soft materials,” recalls Guido Schneider, SKA’s Chief Technology Officer. However, the requirements regarding materials and tolerances for part quality have grown steadily over the years and this necessitated the use of classic multi-roller levelers. But even these machines were not completely suitable for the targeted production portfolio.

Schuler then offered to run tests with different strips of material on a leveler for one day, in addition to providing on-site expertise. “It turned out that the number of rollers was not the decisive factor,” reports Schneider. “In fact, a 17-roller machine with significantly higher rigidity was the better choice for us.”

One year later, in June 2014, the fine leveling machine was finally put into operation upstream of a 400-metric-ton press supplied by Schuler – one of seven at SKA. The overall system not only increased output and part quality, but even decreased energy consumption.

“The line has since been running without any downtime and has not given us any problems,” says Guido Schneider. “Looking back, I have to say that the test day was the decisive factor for us. Schuler proved that the fine leveler could straighten cross bows in exactly the quality we need. In the past, we often had to readjust the die on a press because the material properties changed within a few meters. Obviously, this also depends on the quality of the coil, but the Schuler device can generally balance out fluctuations so well that nothing is noticed in the die or product. I would definitely work together with Schuler again.”

Published inProduction
Friday, 04 September 2015 14:37

Productivity raised by more than 50 percent

2015-09-04 143656Schuler’s ServoDirect Technology enables manufacturers to significantly increase the output performance of their presses. The prerequisite, however, is that they fully exploit the possibilities of curve programming or the oscillating stroke and do not only operate their machines in eccentric mode like a conventional press with flywheel. Schuler Service provides on-site support for part suppliers around the world and helps them optimize their equipment.

A team of experts from Schuler Service recently traveled to various part suppliers in China, for example, to provide support. It soon became apparent that the full potential of ServoDirect Technology was not known to everyone. Some press operators also worry that setting the parameters is too complicated. These fears are unfounded though, as it soon transpired: the Service staff demonstrated to customers in their own language how the productivity of their equipment could quickly and easily be raised by up to 55 percent. This significantly reduced production costs per part.

By optimizing the complete press system – including coil line, transfer system and die – output performance can be increased even further. And if other upstream and downstream processes are also considered, the entire production path from raw material to finished part storage can be improved. Schuler Service offers support to customers all over the world – so that their investment in ServoDirect Technology quickly pays off.

Caption: In China, Schuler Service provides on-site support in the local language to help part suppliers optimize their equipment - Schuler photo.

About the Schuler Group – www.schulergroup.com

Schuler is the technological and global market leader in forming equipment. The company offers cutting edge presses, automation, dies, process know-how and services for the entire metal forming industry and lightweight vehicle construction. Its clients include car manufacturers and their suppliers, as well as companies in the forging, household equipment, packaging, energy and electrical industries. Schuler is the market leader in coin minting presses and supplies systems solutions for the aerospace, railway and large pipe industries. In fiscal year 2014, Schuler posted sales of € 1.18 billion. With around 5,400 employees, Schuler is represented in 40 countries and is a member of the Austrian ANDRITZ Group.

Published inProcessing

Schuler has developed an innovative drawing press for the forming of titanium parts which is suitable for both cold and hot forming processes. The manufacturer unveiled the combi-press to the public at an in-house fair in Waghäusel over the past few days. Over 60 guests looked on as the hot-cold drawing press formed one titanium part after the other for the aerospace industry.

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Over 60 guests had come to see the hot-cold drawing press (left) and the hydroforming press line. photo source Schuler 

Whereas conventional deep drawing dies with widths of up to 1.60 meters are used for the cold forming process, a specially designed heating chamber is installed in the press for hot forming. It heats the titanium blanks to temperatures of between 700 and 950 degrees Celsius before they are formed in the hot-deep-drawing die. The press bed is equipped with water cooling and a ceramic insulation layer for protection. Schuler succeeded in integrating the draw cushion with high-temperature-resistant pressure pins into the system. With the aid of the pressure pins – which are led through several temperature layers – the blankholding forces can be set with particularly high accuracy.

In cold operation, the press has a slide force of 3,150 kN and a bed cushion force of 1,250 kN, compared to 800 and 250 kN in hot operation. The forming speed for the titanium parts ranges from 0.1 to 2.0 millimeters per second for hot forming and five to 30 millimeters per second for cold forming. The fair visitors experienced the combi-press in cold operation on Wednesday and in hot operation on Thursday. The press is to be delivered to a customer in the aerospace industry.

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Titanium parts for the aerospace industry: door surrounding part, housing, support rod, cooler outlet duct, turbine blades (from left). photo source Schuler 

Titanium is becoming an increasingly important material for aircraft construction. Whereas the high-strength metal accounts for around six percent of materials used in conventional aluminum aircraft construction, this ratio rises to between 15 and 20 percent for modern composite designs. As this makes aircraft lighter, fuel consumption per seat and kilometer flown decreases.

A further press displayed at the in-house fair in Waghäusel has been earmarked for the aerospace industry: a hydroforming press line with 1,600 metric tons of press force for manufacturing specialist tubular parts. The monoblock press features a water hydraulic system and two axial cylinders.

About the Schuler Group – www.schulergroup.com

Schuler is the technological and global market leader in forming equipment. The company offers cutting edge presses, automation, dies, process know-how and services for the entire metal forming industry and lightweight vehicle construction. Its clients include car manufacturers and their suppliers, as well as companies in the forging, household equipment, packaging, energy and electrical industries. Schuler is the market leader in coin minting presses and supplies systems solutions for the aerospace, railway and large pipe industries. In fiscal year 2014, Schuler posted sales of € 1.18 billion. With around 5,400 employees, Schuler is represented in 40 countries and is a member of the Austrian ANDRITZ Group.

Published inProcessing

Joint venture with Yadon sealed – access to dynamic mid-market segment.

The press manufacturer Schuler AG has acquired a majority shareholding in the Chinese machine tool manufacturer Yangzhou Metal Forming Machine Tool Co., Ltd. (Yadon) and thus strengthened its position in the world’s most important growth market for machine tools. This was announced by Schuler’s CEO Stefan Klebert in Göppingen on June 23, 2015.

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Yadon is one of China’s leading press manufacturers. The company’s main base is located in Yangzhou, Jiangsu Province, 300 kilometers north of Shanghai.

Schuler has signed an agreement to purchase a majority stake of at least 51 percent in Yadon. There is also an option to increase this shareholding. Both sides have agreed not to disclose the purchase price, which Schuler will finance from its own funds. The current management team and some employees will continue to hold a stake in the joint venture. The cooperation is still subject to approval by the relevant anti-trust authorities.

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German Press manufacturer Schuler has signed an agreement to purchase a majority stake of at least 51 percent in Yadon.
Photo (from left to right): Stefan Klebert, CEO Schuler AG, Yunhu Pan, Chairman of the Board, Yangzhou Metal Forming Machine Tool Co., Ltd. (Yadon), Dr. Wolfgang Leitner, CEO ANDRITZ AG and Chairman of the Supervisory Board Schuler AG, Hongbin Dong, General Manager Yadon, Oemer Akyazici, Managing Director Schuler China

“China is our fastest growing sales market and the world’s largest market for presses. By acquiring a stake in Yadon, we will gain access to a large group of Chinese customers who we previously hadn’t served,” stated Klebert.

With around 1,100 employees, Yadon generated revenue of approximately € 120 million in 2014. Founded in 1958, the majority of the company’s shares are held privately. Yadon is one of China’s leading press manufacturers. The company’s main base is located in Yangzhou, Jiangsu Province, 300 kilometers north of Shanghai.

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German machine tool maker Schuler acquires majority stake in Chinese press manufacturer Yadon.
Photo (from left to right): Stefan Klebert, CEO Schuler AG, Yunhu Pan, Chairman of the Board, Yangzhou Metal Forming Machine Tool Co., Ltd. (Yadon), Dr. Wolfgang Leitner, CEO ANDRITZ AG and Chairman of the Supervisory Board Schuler AG, Hongbin Dong, General Manager Yadon, Oemer Akyazici, Managing Director Schuler China

At its three facilities, Yadon produces mechanical presses for metalforming processes, such as C-frame presses, blanking presses and tie rod presses. “These will expand Schuler’s product portfolio in the medium and lower price segments,” added Klebert. Yadon’s clients include major Chinese companies in the automotive supply industry, as well as manufacturers of heat exchangers for air conditioning units, suppliers of electric motors, and the entire metalworking industry.

The company is targeting growth in China and other markets with new presses for the mid-range segment. Schuler will support the development of these presses by providing its extensive technological know-how.

Schuler is represented in China since 1992 and has around 400 employees at several sites in China – including facilities in Shanghai, Tianjin and Dalian.

About the Schuler Group – www.schulergroup.com
Schuler is the technological and global market leader in forming equipment. The company offers cutting edge presses, automation, dies, process know-how and services for the entire metal forming industry and lightweight vehicle construction. Its clients include car manufacturers and their suppliers, as well as companies in the forging, household equipment, packaging, energy and electrical industries. Schuler is the market leader in coin minting presses and supplies systems solutions for the aerospace, railway and large pipe industries. In fiscal year 2014, Schuler posted sales of € 1.18 billion. With around 5,400 employees, Schuler is represented in 40 countries and is a member of the Austrian ANDRITZ Group.
About Yangzhou Metal Forming Machine Tool Co., Ltd (Yadon) – www.yadonpress.com
Yangzhou Metal Forming Machine Tool Co., Ltd has over 50 years of experience in the field of metal forming equipment. Founded in 1958, the company generated revenue of € 120 million (900 million RMB) in 2014 with around 1,100 employees. Under the Yadon brand, the machine tool manufacturer produces a variety of mechanical presses, presses for metalforming processes – such as C-frame presses, blanking presses and divided presses – as well as forging presses. The company’s main base is in Yangzhou, Jiangsu Province, 300 kilometers from Shanghai. The majority of shares in Yadon are held privately.
Published inSheet Metal
Monday, 22 June 2015 19:55

Die-free production of shaped blanks

Daimler orders two Laser Blanking Lines from Schuler

Daimler AG has ordered two Laser Blanking Lines from Schuler for its Mercedes-Benz facility in Kuppenheim, near Baden-Baden, Germany. The two lines cut blanks out of a moving sheet metal coil which are then formed into car body parts in further steps. As fiber lasers are used for the cutting process, no dies are required – in contrast to conventional blanking lines.

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As the Schuler line uses fiber lasers, no dies are required – in contrast to conventional blanking lines. Photo : Schuler

The flexible blanking method means there is no more need for procurement and handling of blanking dies. Product changes can be made almost without any set-up time – simply by loading the corresponding cutting program. Additionally, material can be saved by optimizing nesting: If more shaped blanks can be cut from the same surface area, this significantly reduces coil waste.

Production launch scheduled for fall 2016

“An important argument was also the fact that both lines can do without a basement and elaborate press foundations,” explains Schuler Managing Director Stephan Mergner: “In contrast to blanking presses with dies.” The two Laser Blanking Lines are due to be installed in November 2015 and the production launch has been scheduled for fall 2016.

At the heart of the line is a laser cell with three simultaneously operating fiber lasers. To ensure maximum production output, the blanks are cut from a moving sheet metal coil (DynamicFlow Technology). Each line is also equipped with a coil line with automatic cassette change and straightener with crowning capability, in order to balance out quality fluctuations in the coil stock, and a robot-aided transfer station for scrap separation with automated tool changing.

Of particular importance for flawless outer panel blanks: the cleaning device for improving surface quality. With its automatic stop setting, the Stop2Drop stacking unit is also very gentle on the finished blanks. The shaped blanks are subsequently used to produce car body parts for the Daimler Group’s latest models – on a press line also supplied by Schuler.

Published inSheet Metal
Wednesday, 13 May 2015 10:58

Large pipe lines ready for delivery

Pre-assembly of spiral pipe mills for Saudi Arabia and Mexico completed / First line due to begin production in spring 2016

Pre-assembly of the two spiral pipe mills for which Schuler received orders last year has been completed. Tuberías Procarsa – one of the leading Latin American manufacturers of steel pipes – is due to accept delivery of the first line in the coming weeks. The various components will then gradually leave the production halls. In the case of the line for Group Five Pipe Saudi Ltd., acceptance is planned for September.

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In the background are the two forming stations – the heart of the lines for Mexico and Saudi Arabia. Photo source - Schuler

In Mexico, Schuler will assemble the line. The production launch has been scheduled for spring 2016. Tuberías Procarsa will use the offline spiral pipe line to produce large pipes with diameters of between 508 and 2,235 millimeters (20 to 88 inches) and lengths of twelve to 24.4 meters. When assembled, they will serve as pipelines for oil and gas. The pipes are made from high-grade steel (up to X100) with thicknesses of up to 25.4 millimeters which is wound onto coils. This is formed into a spiral tube and submerged arc welded to a spiral welded pipe.

The coil preparation stand ensures short changeover times, a high degree of safety, and an exact 90-degree cut at the beginning of the coil. Crane transfers are no longer necessary. At the forming station, all relevant steps are automated: the settings are no longer made manually, but entered directly via the easy-to-use control panel and then implemented with the aid of servo motors. The outer or inner diameter calibration system ensures consistently reproducible, high product quality.

The line for Group Five Pipe Saudi Ltd. is largely identical. With a total length of 450 meters, the two pipe plants also comprise various devices to test the large pipes in accordance with the API standard. This entails the use of ultrasonic, X-ray, and hydrotester stands.

About the Schuler Group – www.schulergroup.com

Schuler is the technological and global market leader in forming equipment. The company offers cutting edge presses, automation, dies, process know-how and services for the entire metal forming industry and lightweight vehicle construction. Its clients include car manufacturers and their suppliers, as well as companies in the forging, household equipment, packaging, energy and electrical industries. Schuler is the market leader in coin minting presses and supplies systems solutions for the aerospace, railway and large pipe industries. In fiscal year 2014, Schuler posted sales of € 1.18 billion. With around 5,400 employees, Schuler is represented in 40 countries and is a member of the Austrian ANDRITZ Group.

Published inProcessing

Schuler has expanded its facility in the heart of Mexico’s automotive industry. The German press manufacturer’s sales and service company in Puebla has moved into new leased property with 3,000 square meters of floor space, which also houses a production plant and a training center. Schuler invested around 1.6 million US dollars (around 1.4 million euros) in new plant and machinery for die repairs and service.

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SchulerCEOStefanKlebert(center) andMexico's managing director StefanAntel(2nd from right) at the openingceremony.photo sourceSchuler

“The Mexican economy has grown strongly in recent years and we have been able to participate in this growth,” stated Schuler’s CEO Stefan Klebert at the official opening in front of invited customers and representatives from business and politics. Schuler received numerous major orders from Mexico in 2014. In addition to servo presses and blanking lines for the automotive industry, these included a spiral pipe plant for a Latin American steel pipe manufacturer.

However, Schuler not only exports presses to Mexico but also Germany’s dual education system in the form of the Cedual vocational training center (Centro de Especialización Dual). Although Mexico’s economy is booming, its industry is suffering from a serious lack of skilled labor. This led Schuler to set up its own training center in Puebla in 2012, where young Mexicans can learn their profession.

Mexico does not have an organized vocational training system like Germany’s. Young staff are simply taught on the job. At the same time, youth unemployment is a massive problem for Mexican society. “We are always on the lookout for skilled workers who can service our presses at the customer’s facility. Often in vain though,” says Stefan Antel, CEO of Schuler’s subsidiary in Mexico. As he did not regard staff and service personnel on assignment from Europe or America as a sustainable solution, he decided to set up a dual education system for engineering professions in Mexico based on the German model.

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Schulerhascelebratedthe expansionof its locationin Puebla, Mexico, to thetraditional soundsofmariachi groupphoto source Schuler

For almost three years now, 90 young Mexicans have been learning their trade at Cedual’s drilling, turning, milling and grinding machines, as well as at work benches and in classrooms – making them fit for the future. On completing their three-year course, the future skilled workers are awarded a certificate from the German Chamber of Commerce and Industry. This is equivalent to the qualification received at Germany’s vocational schools. In addition to Schuler, the companies Audi, Allgaier,Embraco, Gestamp, Lego, Luk, Metalsa, PWO, ThyssenKrupp Presta and ThyssenKrupp also use the facility to train their young staff. After successfully completing the course, all apprentices can look forward to a safe job.

And there is another reason why 2015 is an important year for Schuler Mexico: the subsidiary is celebrating its tenth anniversary. It all began in 2005 with a service contract for a large-scale press and four employees. Today, the sales and service company employs around 120 people at its main base in Puebla and in Saltillo, in the north-east of the country.

About the Schuler Group – www.schulergroup.com

Schuler is the technological and global market leader in forming equipment. The company offers cutting edge presses, automation, dies, process know-how and services for the entire metal forming industry and lightweight vehicle construction. Its clients include car manufacturers and their suppliers, as well as companies in the forging, household equipment, packaging, energy and electrical industries. Schuler is the market leader in coin minting presses and supplies systems solutions for the aerospace, railway and large pipe industries. In fiscal year 2012/13 (ending Sep. 30), Schuler posted sales of € 1,185.9 million. With around 5,400 employees, Schuler is represented in 40 countries and is a member of the Austrian ANDRITZ Group.

Published inProduction
Tuesday, 25 November 2014 07:23

Energy savings also pay off in the press shop

With its new Ecoform program, Schuler presents sustainable and efficient systems solutions for the metalforming industry

Rising prices and ever stricter legal regulations have made energy a key cost factor of industrial production. Sustainability and energy efficiency are also becoming increasingly important topics for press shops, as forming systems account for a major proportion of a company’s energy costs. With its new Ecoform program, Schuler is now presenting sustainable and efficient systems solutions for the metalforming industry.

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“Resource efficiency is one of Schuler’s innovation drivers,” says Chief Technology Officer Joachim Beyer. “Our Ecoform sustainability program brings together all our efforts for raising energy efficiency: from analyzing and optimizing existing machinery to developing new processes, components and system solutions. Our aim is to conserve all resources and reduce energy consumption, while at the same time maintaining maximum productivity.”

Schuler already boasts numerous successful projects in the field of sheet metal forming, forging and automation. Its EHF (“Efficient Hydraulic Forming”) technology, for example, offers energy savings of up to 60 percent compared to conventional hydraulic presses. The latest generation of servo press lines has reduced energy consumption by up to 50 percent: in contrast to conventional mechanical high-speed press lines, they now have their own DC power supply (Schuler Smart DC Grid), variable-speed and regenerative drive systems, intelligent stand-by and pause switching, as well as energy-efficient components like Schuler’s Energy Saving Cushion. This reduces consumption to three million kilowatt hours per year – the equivalent of 750 to 800 four-person households.

20 to 60 percent reduction in energy consumption

The new MSC 2000 automatic blanking pressalso offers 50 percent energy savings compared to previous lines – thanks to its innovative drive system with two electrically coupled, freely programmable pressure points without gear transmission. As well as shedding half its former weight, the intelligent energy management system and integrated energy recovery of the new Crossbar Robot 4.0 for automating press lines also make it 50 percent more energy-efficient than the previous model, according to recentstudies. A new linear hammer featuring servo technology enables savings of 20 percent compared to conventional forging hammers. By retrofitting existing equipment, Schuler Service can quickly tap considerable energy savings potential.

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The energy costs of a press are not only restricted to electricity consumption, however, but include resources such as air and cooling water. “As a systems supplier, we take an holistic approach,” explains CTO Joachim Beyer. “We are capable of improving the energy requirements of all important metalforming processes and systems solutions. Ecoform lays the foundation for sustainability and energy efficiency in the press shop.”

About the Schuler Group – www.schulergroup.com

Bild4As the technological and global market leader in metal and plastic forming equipment, Schuler offers cutting edge presses, automation, dies, process know-how and services for the entire metal forming industry and lightweight vehicle construction. Its clients include car manufacturers and their suppliers, as well as companies in the forging, household equipment, packaging, energy and electrical industries. Schuler is the market leader in coin minting technology and supplies systems solutions for the aerospace, railway and large pipes industries. The company can trace its roots back to a locksmith shop founded by Louis Schuler in 1839 and celebrates its 175th anniversary in 2014. In fiscal year 2012/13 (ending Sep. 30), Schuler posted sales of € 1,185.9 million. With 5,500 employees, Schuler is represented in 40 nations around the world. The Austrian ANDRITZ Group holds a majority share in Schuler.

Published inProduction

Tuberías Procarsa orders a complete pipe mill from Schuler

Within only a few months, Schuler has received its second major order for delivery of a spiral pipe machine. This is from one of the leading manufacturers of steel pipes in Latin America: Tuberías Procarsa, subsidiary of Industrias CH S.A.B. de C.V., with its headquarters in Monclova, Coahuila, Mexico. As recently as last May, Group Five Pipe Saudi Ltd. placed a major order for an almost identical mill.

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At its heart is the offline spiral pipe machine on which pipes with diameters from 508 to 2,235 millimeters are produced. image source Schuler

Tuberías Procarsa will use the offline spiral pipe machine from Schuler to produce large pipes with diameters from 508 to 2,235 millimeters (20 to 88 inches) and lengths from 12 to 24.4 meters. They will be mainly used for building pipelines in oil and gas extraction. The input stock for the large pipes is a coil-wound strip up to 25.4 millimeters (1 inch) thick comprising high-grade steel (up to X100); the spiral pipe machine forms this material into the required pipe diameter and connects the edges by tack welding. Following that, welding of the pipe is completed on a separate welding stand using the submerged-arc method.

The pipe mill has a length of more than 450 meters and also includes various facilities for testing the large pipes according to API standards. Ultrasound, X-rays and pressurized water are used for this process. The mill from Schuler will increase Tuberías Procarsa's production capacities by 220,000 tonnes per year.

Published inProduction

New orders up by around 20 percent – slight growth in consolidated earnings

schuler 1“With its first-quarter results, Schuler has got off to a successful start in the new fiscal year 2014,” explained CEO Stefan Klebert on presentation of the company’s interim report in Göppingen. From January to March 2014, orders were up 19.8 percent year on year to € 319.8 million. The press manufacturer made strong gains in Asia, and especially China, as well as in South America and the Gulf region. In Europe, Schuler received its largest-ever service order. At € 258.0 million, sales were 16.0 percent below the corresponding prior-year figure. As expected, sales suffered from falling orders in the previous year.

Due to this decline in revenue, earnings before interest, taxes and amortization (Ebita) of € 17.5 million fell short of the prior-year figure of € 26.4 million. The Group profit for the period, however, rose from € 10.7 to € 11.3 million year thanks to lower interest expenses and taxes.

At the end of the quarter, Schuler’s net financial status improved to € 307.8 million. Equity rose by 4.2 percent to € 286.3 million.

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“Over the past few years, Schuler has worked hard to establish a strong market position and solid financial basis. We must now continue along this successful path,” stated Klebert with reference to the company’s key financial figures.

The company has also confirmed its guidance for the fiscal year 2014. Schuler continues to expect total sales of around € 1.1 billion in 2014 with an Ebita margin of 6 to 7 percent. “The high order backlog of around € 1.1 billion provides a solid basis for our 2014 sales and earnings forecast,” concluded Klebert. At the end of March 2014, the Group employed 5,494 people.

The complete financial report can be found here

Photo Source: Schuler

Published inSheet Metal

High quality, low maintenance

Beverage can manufacturer Beihai Jinmeng penetrates Chinese market with aid of Schuler cupping press

One name is to be found on many of China’s best-known beverage brands, such as Qingdao beer or the popular herbal tea Wanglaoji: Guangxi Beihai Jinmeng Zhiguan AG (short form: Beihai Jinmeng). Recently founded, the company has quickly penetrated the Chinese market. This success is due in no small part to a cupping press for the production of beverage cans supplied by Schuler.

Last year, Beihai Jinmeng launched production of beverage cans at its new facility in which it had invested around € 80 million. At the heart of the production line is Schuler’s DA 140 cupping press. “The Schuler press displays a high degree of stability in continuous operation, with relatively low operating costs and maintenance investments,” explains Project Manager Tan Jintu of Beihai Jinmeng’s Production Technology division.

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“Because of the comparatively higher wear, similar machines with sliding jib systems require regular adjustment and maintenance – or even the replacement of the sliding jibs – to ensure stable operation,” adds Tan Jintu. By contrast, Schuler’s cupping presses are completely wear-free and do not require maintenance of any kind.

Due to the immense dynamic loads involved, cupping presses operating at high speeds and with heavy weights always run the risk of unevenly distributing the press force across the two sides – with negative consequences for the quality of the dies and products. Schuler’s DA 140 cupping press is therefore equipped with a dynamic counterbalance system which balances out the machine vibrations caused by high press forces during operation.

Play-free pretensioned slide guidance

The machine needs neither a solid concrete foundation nor for its base to be screwed to the floor – only the line’s own weight has to be taken into consideration. The play-free pretensioned slide guidance guarantees precise slide motions with only minimal tilting, thus significantly prolonging die service life. Moreover, the maintenance-free direct drive and very fast clutch/brake combination ensure the cupping press operates with a high degree of efficiency.

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“Apart from regular minor servicing, our production line can operate continuously around the clock,” says Tan Jintu. “So far, our cupping press from Schuler has shown no defects or malfunctions of any kind. This has led to considerable savings in staff and maintenance costs.”

Beihai Jinmeng is currently producing beverage cans for Wanglaoji, China’s oldest herbal tea manufacturer. “With regard to Wanglaoji’s quality standards and its positioning in the beverage market, we can safely say that their requirements with regard to beverage cans are among the highest in China,” says Tan Jintu. “The cupping press supplied by Schuler meets all our manufacturing needs with a consistently high level of quality.”

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Up to 300 strokes per minute

Most of the beverage cans produced by Beihai Jinmeng have a dimension of 330, 355 or 500 milliliters. With a press force of 140 metric tons and up to 300 strokes per minute, the DA 140 guarantees the flexible and economic production of high-quality beverage cans. At the same time, it is also suitable for particularly thin cans and complex production processes.

The hook-in die change brackets, hydraulic roller bars, and motorized slide adjustment all ensure fast die change times. “If there are fluctuations in the thickness of the aluminum used, for example, this can lead to problems with the pressed can bodies,” explains Tan Jintu. “The Schuler press enables us to react to this within just a few minutes – we simply have to adapt the parameters by changing the inner and outer slide height.”

Complete turnkey delivery

With regard to the cooperation with Schuler, Tan Jintu says: “Schuler’s engineers are top-class experts. They found the right solution for all of our wishes, such as linking the individual processes, supplying software to control the production line, providing basic technical support or designing the system’s wiring.” Schuler’s turnkey delivery of the production line included a coil line, feed device, coil lubrication unit and dies, so that production could be launched immediately on site.

Schuler’s experts not only travelled from Germany to install and set up the line, however, but also to train Beihai Jinmeng’s employees with regard to production, operation and maintenance. A joint venture company German Machine Tool Service Co., Ltd (GMS), is responsible for providing the complete technical customer service, including spare parts and advice on accessories and technical solutions. “The service provided is extremely professional and well structured,” concludes Tan Jintu: “We are highly satisfied.”

Published inSheet Metal