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MACHINING AND WELDING OF PRECISION MECHANICAL PARTS ACCORDING TO CUSTOMER SPECIFICATION
MACHINING AND WELDING OFPRECISION MECHANICAL PARTS
ACCORDING TOCUSTOMER SPECIFICATION
TriesteFriuli Venezia GiuliaNorth east - Italia
Metal constructionmanufacturer
in Trieste since 1954Family Business for four
generations
3800 sqm – covered production area110kW solar plant
Second building extension - 2018
First building extension - 2016
Original building
TWO FLOORS FACILITIESTWO FLOORS FACILITIES
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Typical production
LASERBENDING
ASSEMBLYINGWELDING
MACHINING
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Typical production
CUT-TO-LENGTHCN LATHE
CN MACHININGCN GRINDING
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SHEET METAL LASER CUTTING
PROCESS QUALIFIED YEARLY – requirement of EN 1090-1CPQR (Cutting Procedure Qualification Record)
EN ISO 9013 - Thermal cutting - Classification of thermal cutsGeometrical product specification and quality tolerances
1
2
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4
5
1
2
3
4
1
2
121
BEST quality level
WORST quality level
perpendicularityprofile height (roughness)dimensional tolerances
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20 mm thickness
10 mm thickness
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SHEET METAL LASER CUTTING
Classes of perpendicularity Classes of profile height (roughness)
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Actual values
thickness (mm) thickness (mm)
SHEET METAL LASER CUTTING
CN SHEET METAL BENDING
Proper procedureto control the final geometry:• Plate fiber alignment due to rolling direction• Separating different plate batches• Specific geometrical checks of first piece• Use of dedicated jigs for geometrical check
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WELDING PROCESS
COMPANY CERTIFIED EN ISO 3834-2Quality requirements for fusion welding of metallic materials Part 2: Comprehensive quality requirements
WELDING PROCEDURES QUALIFIED EN ISO 15614-1 Specification and qualification of welding procedures for metallic materials – Welding procedure test
WELDERS AND WELDING OPERATORS QUALIFIED ISO 9606-1 EN ISO 14732
NDT OPERATORS QUALIFIED ISO 9712 – methods VT, MT, LT, PT
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WELDING PROCESS
WELDING PROCESSES – EN ISO 4063
135MAG Welding with solid wire electrode
136MAG Welding with flux cored electrode
138MAG Welding with metal cored electrode
141TIG welding with solid filler material (wire/rod)
MATERIAL– CEN ISO/TR 15608
1.1-1.2Steels with a specified minimum yield strength 275 N/mm2 ≤ ReH ≤ 360 N/mm2
8.1Austenitic stainless steels with Cr ≤ 19 %
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WELDING PROCESS
WELDING ROBOT WITH DOUBLE TABLEMAG Welding with solid wire electrode
Reduced welding time – increased quality:• Dramatically reduced welding time• Quick change possible to double table • High repeatability of welds’ quality
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MACHINING PROCESS
MODERN CN MACHINES• 11 CN machining centers – max size 3000(x) 800(y) 720(z)• 3 CN lathes – max size diam 600mm
Qualified Sub-Suppliers to extend capability and capacity• Possibility to extend our capability by resorting to
validated subcontractors• Quality of the products is checked and assured by OFM
PROPER CHOICE OF MACHINING CYCLES• The sequence of Machining phases is designed to get the
best final results in terms of geometrical requirements and manufacturing cost
• dedicated jigs are manufactured when cost effective
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MACHINING PROCESS
PRECISION OF MACHINING• Typical geometrical requirements
PRECISION MEASUREMENT• 2 x 3D coordinates measuring machines 1000x640x500• Periodical Calibration of all measuring instruments
(micrometers, Vernier calipers, depth gauges
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PROTECTION-PACKING PROCESS
PAINTING CABIN• Possibility to coat/paint all manufactured parts• Coating/painting according to Customer specific
requirements• Coating thickness measurements by “COATING
THICKNESS GOUGE” – measuring range 0-1250mm accuracy ±2mm
PACKING• Dedicated area for cleaning, protection, packing• Dot peen marking of parts• Data matrix marking of parts
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QUALITY MANAGEMENT SYSTEM
Certified Quality Management Systemaccording to ISO 9001:2015 by RINA
Certified Welding Management Systemaccording to ISO 3834-2 by RINA
Certificate of Conformity of the Factory Production Controlaccording to EN 1090-1 by RINA
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QUALITY MANAGEMENT SYSTEM
• Overall supervision of all processes by dedicated software
• Control panel for constant monitoring of main functions
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QUALITY MANAGEMENT SYSTEM
• Specific reporting• complete Final documentation
of delivered products
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CUSTOMER SATISFACTION
QUALITY• Constant monitoring and improvement of processes• Specific Quality Control Plan for crictical parts • Quality controls and recorded measurements• Effective Concession application process
DELIVERY ACCURACY• Update of production planning on a weekly base• Constant monitoring of work progress• Continuous exchange of information with Customer• Urgent cases managing
PRICE• Continuous improving process in order to get more
efficient process and reduce production costs• Proactiveness in order to find alternative and cost
effective solutions
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MACHINING AND WELDING OFPRECISION MECHANICAL PARTS
ACCORDING TOCUSTOMER SPECIFICATION
