Kracht door samenwerking VDL Groep
Presentation VDL Castings
VDL Groep Information
Family owned international company specialized in developing,
producing and sales of semi-finished products, busses, other
end products and assembling cars
Sales mid 2017 : 2.400 MEUR
Result mid 2017: 75 MEUR (after taxes)
Equity: 60% (1.037 MEUR)
Employees mid 2017: 15.581
94 companies, 4 divisions, 19 countries
Website: www.vdlgroep.com
VDL Castings (Former Componenta)
Foundry Heerlen: Moulding Line 850 x 630 x 330/330 » Capacity moulding line : 130 moulds / hr
» Melting : Cupola furnace 20t/hour
» Core making : FCS 60 / H16 / H12 / H 6,5
» Fettling : 15 cabines / 1 automatic grinding machine
Foundry Weert: Moulding Line 1.250 x 850 x 400/400 » Capacity moulding line : 60 moulds / hr
» Melting : Electric induction furnace 10t/hour
» Core making : L130 / L150 / H40 / L16
» Fettling : 18 cabines / 1 automatic grinding machine
VDL – Componenta synergies
Main markets: Heavy trucks, Construction and mining,
Machine building, Agriculture, Wind power
Main customers: Volvo, MAN, Caterpillar, Bomag, Kawasaki,
Scania, Daimler, VCE, Borg Warner, NCB,
Atlas Copco
Products: brackets, hubs, housings, axles, vessels,
hydraulic blocks, turbo housings
Product Range: 20-300 kg in medium size volumes
Materials: ductile cast iron (incl. Simo/ADI/HiSi) and
grey iron
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VDL Castings Heerlen
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VDL Castings Heerlen History
1974/1975: Globon
■ co-operation of De Globe and Oranje Nassau Mijnen
2005: Componenta HWS
■ Finish Stock exchange listed company based in Finland with
production in Finland, Sweden, Netherlands and Turkey
2017: VDL Castings Heerlen
■ Family owned Company based in the Netherlands with production
facilities in 19 countries
Organisation VDL Castings Heerlen
Adjunct Director
Ruud Pisters
Admin / housekeeping
Sales
Frank Kunert, Norbert Müller
Engineering
Adriaan Keppel
Manager operations
Bert Duit
Core Shop Moulding Melting Shop Aftercare Maintenance Shipping
Quality assurance
Paul Hutschemeakers
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VDL Castings Heerlen Plant lay-out
230 m
Core
shop HWS
pouring
Cooling +
shake-out
paintin
g Fettling +
inspection expeditio
n
melting energy Sand
prep.
Tech.serv. offices
Old Furan line
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Heerlen Capacity:
■ 36.000 ton/year in 3 shifts
Materials:
■ 97 % S.G. Iron (incl. Simo, ADI, HiSi)
■ 3 % Grey iron
VDL Castings Heerlen Capabilities
50 100 150 200 250 300 350 400 450 500
GJS, GJL, ADI, SSF
GJS, GJL,
SSF, ADI, SiMo VDL Castings Heerlen
VDL Castings Weert
Component weight
Heavy trucks
62%
Construction
and mining
19%
Machine
building
18%
Agricultural
machinery
1%
Automotive
0%
VDL Castings Heerlen customer segments (2016)
10 30 January 2018
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Main characteristics VDL Castings Heerlen
Melting
■ Hot wind lining-less Cupola , 1250 mm, 20 ton/hour,
oxygen Linde enriched
■ holder furnace (2x) 20 ton
Moulding machine HWS (‘91)
■ 130 moulds/hour
■ 850 x 630 x 330/330 (‘95)
Automated sand plant 70 ton/hour
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Fettling shop
■ 15 booths.
■ 1 Automatic grinding machine (Koyama)
■ heat treatment (normalizing)
■ Inspection (Visual, US, Magnetic particle inspection, certificates)
Painting
■ dipping (only primer)
shipping
■ in- and external storage
Main characteristics VDL Castings Heerlen
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Fettling shop
■ 15 booths.
■ 1 Automatic grinding machine (Koyama)
■ heat treatment (normalizing)
■ Inspection (Visual, US, Magnetic particle inspection, certificates)
Painting
■ dipping (only primer)
shipping
■ in- and external storage
Main characteristics VDL Castings Heerlen
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VDL Castings Heerlen Products
20-120 kg, (complex)
cored
small and medium size
series
brackets, hubs,
housings, axles,
vessels, hydraulic
blocks, turbo housings
axle housing for a truck , EN-GJS-
500, 55 kg
Swing Swing frameframe forfor a mini a mini excavatorexcavator,,
ENEN--GJSGJS--500, 16 kg500, 16 kg
housinghousing forfor hydraulichydraulic motormotor,,
ENEN--GJSGJS--400, 74 kg400, 74 kg
axle housing for a truck , EN-GJS-
500, 55 kg
Swing Swing frameframe forfor a mini a mini excavatorexcavator,,
ENEN--GJSGJS--500, 16 kg500, 16 kg
housinghousing forfor hydraulichydraulic motormotor,,
ENEN--GJSGJS--400, 74 kg400, 74 kghousinghousing forfor hydraulichydraulic motormotor,,
ENEN--GJSGJS--400, 74 kg400, 74 kg
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VDL Castings Weert
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VDL Castings Weert History
Founded in 1963, completely renewed in
different phases from 1987 – 1995
2005: Componenta Weert HWS
■ Finish Stock exchange listed company based in Finland with
production in Finland, Sweden, Netherlands and Turkey
2017: VDL Castings Weert
■ Family owned Company based in the Netherlands with production
facilities in 19 countries
Organisation VDL Castings Weert
Director
Eddy Kremers
Admin / housekeeping
Sales
Jeroen van Dijk, Jan-Philipp Müller
Engineering
Giel Jongen
Manager operations
Paul Stelten
Core Shop Moulding Melting Shop Aftercare Maintenance Shipping
Quality assurance Paul
Hutschemeakers
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Office / Canteen
Melt shop
Grinding
Stock
Shotblasting Moulding / pouring
Core storage Core shop
Sand plant
Maintenance
& Patternshop
CPV
Quality &
Process
Warehouse
CPV & Raw
material
Foundry
Componenta Weert, 51.200 m²
Total buildings: 18.000 m²
Paint
shop
▲ Entrance
VDL Castings Weert Plant lay-out
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VDL Castings Weert Capabilities
50 100 150 200 250 300 350 400 450 500
GJS, GJL, ADI, SSF
GJS, GJL,
SSF, ADI, SiMo VDL Castings Heerlen
VDL Castings Weert
Component weight
Weert Capacity ■ 34.000 ton/year in 3 shifts
Materials:
■ 92 % S.G. Iron (incl. Simo, ADI,
HiSi)
■ 8 % Grey iron
Heavy trucks
12%
Construction
and mining
40%
Machine
building
27%
Agricultural
machinery
17%
Automotive
0%
VDL Castings Weert customer segments (2016)
28 30 January 2018
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Core shop:
4 Core shooting machines
(cold box method)
Automatic core sand preparation (7 mixtures)
3 Core assembly lines
100% water based core coatings
Main characteristics VDL Castings Weert
Moulding line:
HWS Moulding Machine (1987)
Box size: 1250 x 850 x 400/400 (LxWxH/H)
70 moulds/hour (technical capacity)
Green sand moulds (autom. sand preparation)
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Melting Department:
2 x 8 tons MF (8 MW)
induction furnaces Capacity:
9,5 tons/hour.
Temperatures: Tmax-melting =
1580 °C
Main characteristics VDL Castings Weert
Automatic pouring:
Pouring ladle: 1350 kg
In stream inoculation
Registration of pouring
parameters
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Shot blasting: (GF/Disa)
3 Chambers – Hi-speed
Rotation turbines
Removing gating
systems and feeders:
Hydraulic Wedges in
counter balances
Hammers (manual)
Main characteristics VDL Castings Weert
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Fettling shop:
18 cabins for manual grinding,
1 automatic CNC grinding
machine (MAUS)
2nd In progress (ABB Robot Lieber)
Painting (only primers): Paint applied by dipping, several colours
Non water-based primers
Main characteristics VDL Castings Weert
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VDL Castings Weert Products
50-300 kg, (complex)
cored
small and medium size
series (100 – 10.000)
Axles, Housings, hydraulic
motors, carriers, Hubs,
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Hammerbody, ADI
VDL Castings Weert Products
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VDL Castings Weert Products
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VDL Castings Weert Products
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VDL Castings Weert Products
Financing and Investments
Both foundries do have substantial added value for the VDL
group and huge synchronization advantages are expected for
the foundries and the VDL group as well
VDL is accepting a loss making situation in 2017
VDL group is planning to invest in both foundries:
■ Replacement and Maintenance investments
■ Investments to improve quality, productivity and output
(automation)
Investment Planning (Overdue)
Maintenance only
Year 1 Year 2-3 Year 3-5 Total
Weert 1,898 1,183 0,274 3,355
Heerlen 2,702 0,806 3,505 7,013
Total 4,600 1,989 3,779 10,368
Replacement and maintenance investments for period 1-5 year (M€):
The above mentioned investments will secure and improve the performance of
the foundries in production reliability, quality of products and processes and thus
delivery performance and safety.
Investment Plan Weert Foundry 2017-2021
• Investment Planning:
• Year 1:
• Sand process Improvement / Powerfull shotblasting / Special tools hardrunners
• Fettling shop lay out and preparations automation
• Year 2:
• Automatic Grinding (1st stage) / Mouldbox closing
• Year 3:
• Re-position Moulding line, incl. short loop mouldboxes / Hydraulic wedging
• Autom. grinding (2nd stage) / Melt shop increased output
• Year 4-5:
• Upgrading Mould line / New sand plant
• Increase cooling capacity (depending nr of heavy parts)
• Long Term:
• Relocate the dip paint building in combination with shipping docks
Year 1 Year 2 Year 3 Year 4-5
Weert 310 k€ 1.200 k€ 1.700 k€ t.b.d.
Investment Plan Heerlen Foundry 2017-2021
• Investment Planning:
• Year 1:
• Process Data Collection & Management / New Ladle heaters
• Year 2:
• Automatic Grinding / Larger holder furnace / Automated Mould numbering / Dosage Cupola
• Year 3:
• Core storage / Replace H16 core shooters / Residual heat usage
• Autom. grinding next phase.
• Year 4-5:
• Larger mould box / Upgrading Mould line / new Desulf-process
• Next steps automatisation (core shop / fettling)
• New casting cooling process in combination with shot blasting
• Long Term:
• Install a new moulding DISA/HWS line in adjacent (furan) building
Year 1 Year 2 Year 3 Year 4-5
Heerlen 375 k€ 1.200 k€ 2.000 k€ t.b.d.