2011-2-22 10:29:02PRINT

Shanghai General Motors puts faith in new press lines from Schuler Group

With the two press lines from Schuler, SGM is establishing perfect manufacturing logistics in Shenyang.

Synchronized and automated manufacturing with perfect logistics and an overall control system – the car plant of the future is expected to run more and more like clockwork. This is perfectly illustrated when new factories are built and the complete manufacturing process has to be precisely coordinated right from the planning stage. The latest example is a new press shop for Shanghai General Motors (SGM) in Shenyang, north-east China, to be constructed on a greenfield site. Production of stamped parts for two car models is due to start as soon as mid 2012. The forming experts of Schuler have been chosen as partners for the project. They will be installing two new press lines for the manufacturing of around 40 different body panel parts. This represents the second round of a successful partnership with SGM: technology supplied by the Schuler Group is already being successfully employed at a different facility. The decisive factor for SGM were the specifications of the lines, which fit seamlessly with the company’s declared aim of establishing perfect manufacturing logistics in Shenyang.

At the moment, SGM''s facility in Shenyang does not have its own press shop: parts have to be brought in from a group facility in the north-eastern city of Yantai, 600 kilometers away. It''s a difficult logistical operation for SGM''s planners to ensure the just-in-time supply of parts over such a huge distance. Obviously, having its own press shop will mean the forming processes for car models can be synchronized more precisely with downstream operations. However, it also means the press technology used must be able to meet these demands, explains Frank Viola of the Schuler Group’s Large Mechanical Equipment division.

Seamless integration of metalforming technology

SGM''s choice of Schuler was indeed closely connected with two special characteristics offered by the lines: their high level of availability and process reliability. The two identical press lines will feature a draw press with 20,000 kN of press force and three follow-on presses with 10,000 kN of force each. Both press lines will be equipped with automation systems which can transport even large body panels between presses, as well as handling part discharge, part repositioning, and part placement into the subsequent forming station. The fact that the lines produce at a rate of 14 strokes per minute, however, only hints at their true output performance. As Frank Viola explains: The decisive factor is the high average productivity of the system as a whole. We can guarantee a permanent output of around 14 parts - or 28 two-out parts - per minute, and not just during brief peak periods. At the same time, both press lines can be quickly and flexibly set up for different parts several times per shift. Following a fully automatic die change, it takes less than three minutes for the lines to start producing again. This is especially important for SGM, as the company produces mainly lean batch sizes. With such a fast and flexible system, the company can optimize valuable production time and thus save costs.

Good experience

SGM knows from its own experience that the technology used by the press lines will guarantee permanent operational availability. Schuler already installed a similar line at SGM''s Yantai facility in 2008. The technology has proved highly successful. This obviously played a major role in the company''s current investment decision, confirms Frank Viola. What''''s also important in this context is that SGM''s production planners have not included a backup solution for the press lines at the new Shenyang press shop. This means that any permanent downtime of the lines cannot be quickly compensated for at other sites. This can be seen as an indirect statement of faith which SGM has declared in Schuler''s press technology, says Viola.

Final assembly and service know-how from Schuler China

Obviously, SGM will also benefit from the proximity of Schuler''s facilities in China - even before production begins. Major parts of the two press lines will be finally assembled at the Schuler Group''s Chinese facility in Dalian. Key components such as the press bed and crown will be supplied from Germany, while the uprights will be manufactured at Schuler’s facility in Shanghai. This means that the design and final assembly of the lines can be discussed in detail in China and closely coordinated with the various planning stages for the new press shop. We guarantee a high degree of delivery reliability. Moreover, this also means that our Chinese colleagues in Dalian know the design details inside out. And this, of course, is the ideal starting point for our service engineers - whenever SGM should need them, explains Frank Viola.

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