35
fagor ederlan group 2010 edition
fagorederlangroup
2010 edition
fagorederlangroup
Innovation is the key driver of our current andfuture business allowing our technologicalchallenges and generating new activities.
As a cooperative company within MondragonCorporation, our essential objective isemployment generation. We apply a managementmodel based on sustainable development andsocial commitment.
Our Business Units, Chassis and Powertrain, arefocused on the knowledge of productfunctionality covering a wide range of addedvalue proposals in each and every product line.
management
business
innovation
groupWe are a leading automotive business groupfocused on Chassis and Powertrain businesssectors that offers integral solutions to themarket with global service vocation.
valorañadido
fagorederlangroup
group
fagorederlangroup
chassisbrake - suspension
brake calliper
knucklesand arms
front corners suspension and rear axles
powertrainengine - transmission
enginecomponentsinnovation
casting
machining
coating
component assy
subassemblies
module assembly
brakediscs and
drums
brakehousings
function
valueadded
i n t e r n a t i o n a l p r e s e n c e
We are a leading automotive businessgroup focused on Chassis and Powertrain, which offers integralsolutions to the market.
transmissioncomponents
aluminium
iron
group
fagorederlangroup
Highlights
workforce
541million euros
2010estimated
sales investment
17million euros
2010estimated
2010estimated
3.312 3.312
2009
541
2009
66
2009
1
15
1
1-13
3
1
2
2 56
7
4
2
3
14-15
group
fagorederlangroup
Our clear service vocation
chassis1 Eskoriatza foundry2 Usurbil foundry3 Uribarri foundry4 Markulete foundry5 Uribarri machining6 FIT Automocion7 Automodulos Aragon8 Fagor Ederlan Borja9 Uribarri Low Pressure
14 Fagor Ederlan Brasileira machining15 Fagor Ederlan Brasileira foundry
powertrain10 Aluminium Eskoriatza11 Aluminium Aretxabaleta12 Fagor Ederlan Tafalla13 Fagor Ederlan Slovensko
technology centreEDERTEK
globalisationprojects
1 USA2 Russia
sales offices1 UK2 France3 Germany4 Italy5 Korea6 Japan7 China
has led our international market presence, allowing us tobecome a global service supplier for the main market regionsthrough production plants in West-East Europe and Brazil,alliances in market regions such as Asia and Nafta.
production alliances1 China2 Korea3 Nafta
12%
VW G
roup
2% 2%
Get
rag
8%
Bos
ch
4%
Cont
iTev
es
1%
TRW
1%
Bre
mbo
8%5%
Oth
ers
5%2%
Dai
mle
r
2%
Fiat
15%Fo
rd G
roup
8%
GM
1%
Hon
da
6%
PSA
16%R
enau
lt
1%
Tata
Mot
.
V.In
dust
rial
BM
W
Susu
ki
group
fagorederlangroup
Customers40 years of experience with the main automotive manufacturersand related Tier 1's endorsed us a full service supplier.
sales 2009 by customer
ederlan
group
fagorederlangroup
investmentworkforcesalesMondragon Corporation
Mondragon CorporationWe are part of the biggest cooperative group in the world,Mondragon Corporation.
Industry Automotive
ederlan
13.853million euros
13.889
2009 2010estimated
84.165
2009
316million euros
615
20092010estimated2010
estimated
84.142
group
fagorederlangroup
AutomotiveMondragon Ederlan
Mondragon Automotive Divisionis an amalgamation of common strategies and synergies ofall the automotive companies of the group.
investmentworkforce
1.215million euros
1.189
2009 2010estimated
8.0747.733
2009
sales
38million euros
69
2009
Automotive Division
2010estimated
2010estimated
innovation
fagorederlangroup
Conception Implementation Market
Innovation, our way of doingThe base of our innovation capacity is our knowledge, as anexpert supplier. With more than 45 years experience in theAutomotive Industry, we are a technology leader in aluminiumcasting, iron casting, machining and assembly processes.
material
process
product
Requirement Analysis
Idea Generation
Idea Evaluation
Project Planning
Development/Construction
Prototype Dev.
Pilot Application
Testing
Production
Market Launch andPenetration
innovation
fagorederlangroup
Edertek: Our technological centreInnovation is the key driver for Fagor Ederlan Group acitivityand generation of new business.
Edertek, our technological centre,has as a primary target theinvestigation and development of newproducts, processes and materialsthat met the highest market placechalleges. Registered as a scienceand technological agent it is locatedin the Garaia Innovation park, a spacefor excellence that joins companies
and technological centres fromMondragon corporation such asMondragon Universtity, Ikerlan andTecnalia, with which Edertek hassigned collaboration agreements.Our technological alliance policy leadsus to set collaboration agreementswith market technological leader.
innovation
fagorederlangroup
weight
performance
cost
We offer solutions in the mostimportant key drivers of the marketWe work through material researchand product design to obtain opti-mum product solution: short cycleproduct life (lead time from launch to
weight
performance
cost
market) light product solution (designof light casting product and use oflight materials) and high performance.
innovation
fagorederlangroup
material
process
product
From the concept to the solution
design CAD
concept
validation& test
product
Our development expertise apply to all products within FagorEderlan Group and to the complete process chain value phases.
design CAE
innovation
fagorederlangroup
material
process
product
Chassis: Product Design Experience
innovation
fagorederlangroup
Powertrain: Product Design Experience
material
process
product
innovation
fagorederlangroup
We focus on areas such as processflexibility, continous improvementprocess capability and synergiesoptimization within different process
steps in order to eliminitae no valueoperations so consecuently reduceprocess leadtime.
We investigate in order to increase and reinforce thecompetiveness of our process.
material
process
product
With focus on process
metalurgical qualityelaboration
development of highcapable processes
maximun flexibilityand synergies with
casting andmachinning
Flexibility linesaccording to product
requierements
Adding valuecontinuously
melting casting post-casting machinning assembly
innovation
fagorederlangroup
With focus on tools
material
process
product
We understand the tools design as part of our integral processdevelopment activity and it gives us a technological differentialbecause we reduce the launch project leadtime and the impactof tools on cost and product quality
maintenanceCAD design &
simulation manufacturing assembly on production
integral tool ing management
innovation
fagorederlangroup
With focus on materialOur research in this are is aligned with product requirement,looking for the best properties and material solutions.Optimisation of metallurgical quality isour focus for high quality performance
product, coverall all the process stagesin casting and treatment.
material
process
product
Use of secondary alloys (recycled)
Weight reduction
Micro- and Nano-reinforcing particles
lightalloys
Al
Mg
MMC
A356A380
Thermal properties
Thin wall thickness
High mechanical properties
iron
grey LGI
compact CGI
ductile SGI
innovation
fagorederlangroup
Innovation in house facilities:pre industrialisationWe have internal innovation production facilities that allowus to validate, try and improve our design capacity. We havea prototype area equipped with the latest technologies.
2700 Tn. locking force
1Tn/h melting capacity
2 Tn. holding capacity
2800 kg. dosing capacity
Vacural & conventionalvacuum technology
Robot for lubrification
High pressure cellRobot for extracting the partWater & oil thermal regulators20 ThermocouplesmonitoringFlow & temp. automaticcontrol in 5 circuits640x480 pixelthermocamera
1000 kilo aluminium castingfurnace
Moulds for parts up to1200x1775mm & 60 kg.
Xray equipment,
Machining control
Quick cooling system
Low pressure cell
material
process
product
innovation
fagorederlangroup
Innovation in house facilities: testwe have internal innovation facilities for creating prototypes,carrying out testing, validating product and processinnovations.
24 hydraulic actuators
Inertia dynamometer
Drop Impact tester
Noise&vibration analyser
Testing equipment
material
process
product
innovation
fagorederlangroup
Data and project management:Windhchill
Product and tooling design:Catia v5, Unigraphics NX, Pro- Engineer Wildfire, I-deas
Product verification:Abaqus, Nastran, Fluent, Adams, Fatigue, Patran, HyperWorks, …
Process verification:Procast, Magma, Tecnomatix Plant Simulation
Data interchange:KVS , OEM-Advantage, Leapfile, Autoweb, Odette, Galia, FTP,...…
Innovation in house facilities:engineering applicationsWe support our customers with collaborative designs as an
expert supplier, with knowledge of the product function and
the process.
chassis powertrain
business
fagorederlangroup
Our Business UnitsChassis and Powertrain, are focused on their knowledgeof production functionality covering a wide range of addedvalue proposals in each and every product line.
powertrainchassis
business
fagorederlangroup
ChassisThe Chassis business unit is a master for the key componentsof Brake and Suspension functionality. From our experiencesand innovation resources, we are able to offer the best optionof products and modules in terms of weight, material, processand cost to the global service demand required.
workforce
2.000 2.000
2009
394million euros 384
2009 2010estimated
sales investment
11million euros
20
20092010estimated
2010estimated
powertrainchassis
business
fagorederlangroup
200.000tonnes
ironcasting
3.000.000components
low pressurealuminium
15.700.000units
machinedparts
4.450.000units
assembly
40.000.000units
componentsproduced
technologies capacity
value added
plants inEurope and Brazil
11
powertrainchassis
business
fagorederlangroup
technologies
value added
8.000.000components
70.000tonnes
cast iron:grey
1 machining plantIn Europe:
Uribarri
2 foundriesIn Europe:
Uribarri and Markulete
capacity
(14 flexible machining lines)
machinedparts
discs and drums
powertrainchassis
business
fagorederlangroup
technologies
value added
brake calliper
67.000tonnes
3.000.000units
3.000.000units/year
capacity
brakecalliperassembly
machined
cast iron:nodular
1 machining plantIn Europe:
FIT Automoción
2 foundries1 in Europe:
Usurbil
1 in Brazil:Fagor Ederlan Brasileira
powertrainchassis
business
fagorederlangroup
knuckles and arms
67.000tonnes
3.000.000units
9.000.000units
machined
low pressurealuminium
cast iron:nodular
2 foundries1 in Europe: Eskoriatza1 in Brazil: Fagor Ederlan Brasileira
Production alliances inKorea, China and USA
1 low pressurein Europe:
Uribarri
2 machining plants1 in Europe:
Uribarri
1 in Brazil:Fagor Ederlan Brasileira
technologies
value added
capacity
powertrainchassis
business
fagorederlangroup
front corners and rear axles
moduleassembly
500.000pairs of front corners
700.000rear axles
2 assembly plantsin Europe
Fagor Ederlan Borja
technologies
value added
capacity
chassis powertrain
business
fagorederlangroup
PowertrainOffers to the market complete solutions, improving its position
on the basis of its knowledge of the Engine-Transmission function.Technological leaders in high-pressure aluminium die-casting, iron casting andmachining for engine and transmission components, we offer high added valuesolutions.
workforce
1.171 1.069
2009
152million euros 152
2009 2010estimated
sales investment
6millon euros
42
20092010estimated
2010estimated
chassis powertrain
business
fagorederlangroup
38.000tonnes / year
1.440.000units / year
140.000tonnes
technologies capacity
value added
machining
grey castiron, engineblocks andcylinderheads
high pressurealuminiumdiecastingcomponents
plants inEurope
4
chassis powertrain
business
fagorederlangroup
technologies
value added
transmission components
23.000tonnes
high pressurealuminiumdiecasting
3 aluminium diecasting plants
2 in Spain
1 in Slovakia
capacity
chassis powertrain
business
fagorederlangroup
1 iron foundryin Europe:
Fagor Ederlan Tafalla
3 machining plantsin Europe:
2 in Spain
1 in Slovakia
3 aluminium die castingin Europe:
2 in Spain
1 in Slovakia
technologies
value added
15.000tonnes
1.440.000units / year
140.000tonnes
capacity
grey cast iron,engine blocksand cylinderheads
aluminiummachining +assembly
high pressurealuminiumdiecasting
engine components
management
fagorederlangroup
Social commitmentContinuous job creation, preferably on a co-operative basiswith full value added, progressively turning our subsidiariesinto co-operatives, and promoting social models of work.Participation and internal democracy as an ethical and humanform of relationship and governing the co-operativeorganisation.In-service training and personal development as abasis for the future, with high levels of internalpromotion and a boost to professional and personalqualifications at all structural levels.
Solidarity and involvement in the community throughthe Co-operative Promotion and Education Fund(FEPC) and the Inter-co-operative Promotion and
Education Fund (FEPI). Direct collaboration with civiladministration to establish and develop cultural andsustainability policies.
Exceptional internationalisation model aimed atmaintaining activity and employment levels at theparent organisation level.
members
3.3123.448
2009 2008
53%48%
2009
workforce
2008
management
fagorederlangroup
Environmental commitmentThat goes beyond the legal requirements and is deployedwithin the framework of government collaboration.
Environmental Guidelines with the Basque Government (2004),and signing of Voluntary Agreements as a contribution tothe Basque Environmental Strategy for SustainableDevelopment 2002-2020.
Strategic initiatives aimed the full life cycle of thevehicle.
Awareness that excellence in environmentalmanagement requires behaviour from people in tunewith their values.
Environmental management increasingly moreintegrated in the notion of the sustainable companywhere sustainability is understood from a social,economic and environmental perspective born fromour own co-operative principles.
costs
2008 2009
investments
2008
476thousands of euros
1.368thousands of euros
1.660
management
fagorederlangroup
ManagementOur Management Model is part of a people-based project,focused on the principles and values that are the identifyingfeatures of an outstanding socio-business project.
Management systems certified to the highest marketstandards:ISO-TS 16949:2002ISO 9001:2000ISO 14001OHSAS 18001
An environmental commitment within a framework ofsustainability beyond the legal requirements:establishment of Voluntary Agreements with theBasque Government as part of collaboration in theBasque Environmental Strategy for SustainableDevelopment.
basic policies
missionandview
stake-holders
processes
managerialstaff
values
businessstrategy
managementstrategy
www.fagorederlan.es
h e a d o f f i c ePaseo Torrebaso, 7 • 20540 Eskoriatza, Gipuzkoa • SPAIN
Tel. 34 943 719 000 • Fax. 34 943 719 001
GermanyFagor Industriecommerz GmbHPostfach 604 D73008 GöppingenNördliche Ringstrasse 100D-73033 GöppingenTel:+497161200423Fax:+497161200451
FranceFagor Ularco France8 rue de l´EsterelBat. Rome SILIC 55694643 Rungis CedexTel:+3341730111Fax:+3345605530Branch office Director: Jesús Ayala
UKFagor Industrial ComponentsDBH Dudley CastlemillBurnt TreeDudley DY4 7UFTel: +44121 226 3542Fax: +44121 226 3540Contact name: Nigel Coysten
ItalyCustomer Assistant: Marco [email protected]: +39 340 1838945fax: +39 02 95301298
KoreaBranch office Manager: Yoo Soon [email protected]: +82-(0)322028842H.P.+82-(0)1077612412
JapanCorporate representative: Yukio [email protected].+81-9029062844
ChinaFagor Ederlan Shanghai Auto Parts Trading Co.LtdRoom 3211,Haitong Securities Building, No.689Guangdong Road, 200001,Shanghai, P.R.CTel: (86 21) 6341 0726Fax: (86 21) 6341 1073Corporate representative: Xu [email protected]: (86) 139 1682 8575
s a l e s o f f i c e s
fagorederlangroup
