Albertini Cesare S.p.A. Cesare Spa Company Profile.pdfAlbertini Cesare S.p.A. is a European Company...
Transcript of Albertini Cesare S.p.A. Cesare Spa Company Profile.pdfAlbertini Cesare S.p.A. is a European Company...
Albertini Cesare Albertini Cesare S.p.A.S.p.A.
Aluminum Die-Casting ProductsAluminum Die-Casting Products
General General PresentationPresentation
Albertini Cesare S.p.A. is a
European Company leader in
Aluminium High-Pressure
Die-Casting
andCasting
Who is Albertini?
Machining
offering specific solutions for the
Mechanical Industry
starting from the Design concept
phase to the production of
finished products
Design Concept
Casting
Machining
Finished Products
• 4 Production Plants
• Turate (Como)
• Villasanta (Milan, Italy)
• Cormano (Milan, Italy)
Albertini Main Figures
• Quero (Belluno, Italy)
• Production capacity: 30.000 ton Aluminium Alloy
• Budget Turnover 2015: 100ML€ with 18.000 ton Aluminium Alloy produced
• 660 Employees (2014)
• Quality Certification ISO TS 16949 and ISO 9001
Albertini Vision
Manufacturing
of finished
products
Development of
Co-Design and
Technological
Innovation
CUSTOMERCUSTOMERQuality assurance
throughout the
production
process
International
presence to cover
Customer’s
demands
Flexibility to adapt
to Customer’s
needs
CUSTOMERCUSTOMERSATISFACTIONSATISFACTION
New Projects (2012-2013)
Customer: Pierburg
Part: Audi FSI, Ford Puma RWD,
RSA K9K etc. Pump Bodies
Delivery condition: Machined
Quantity: > 1.000.000 pcs/year
Customer: BorgWarner Transmission
Systems
Part: Actuator & Valve Body Fiat DCT635
Delivery condition: Machined
Quantity: 30.000 sets/year
Customer: BorgWarner Turbo
Part: Compressor Housing Ford 1.5
Delivery condition: Machined
Quantity: 450.000 pcs/year
Customer: BMW
Part: Rear Housing PL6 AL205
Delivery condition: Raw
Quantity: 150.000 pcs/year
Customer: ZF AG
Part: Gearbox Bracket MQB
Delivery condition: Raw
Quantity: 1.000.000 pcs/year
Customer: ZF-LS
Part: VW MQB Steering housing
Delivery condition: Machined
Quantity: 1.000.000 pcs/year
Customer: ZF AG
Part: Stator
Delivery condition: Machined
Quantity: 250.000 pcs/year
2 x 250 t
8 x 600 t
11 x 750 t
5 x 800 t - 840 t
2 x 950 t
10 x 1.100 t
8 x 1.350 t
CASTING MACHINING
60 x CNC Units (1-Mandrel)
40 x CNC Units (2-Mandrel)
14 x Transfer Units (High volume)
10 x Machining Units (specific products)
OTHERS
Sand blasting
Tumbling
RX testing
High-pressure Washing
Leak proof testing
Plants & Facilities
Albertini Cesare S.p.A. can process up to 35.000 tons of
ALUMINUM CASTINGS
8 x 1.350 t
5 x 1.600 t – 1.800 t
10 x 2.000 t – 2.200t
1 x 2.500t
2 x 2.800t
64 Die Casting Machines > 120 Machining Units
Impregnation
Various assembling
> 200 Robots
Plants & Facilities
CormanoCormano Plant (MI) Plant (MI)
Aluminium HP die-casting
Machining
QueroQuero Plant (BL) Plant (BL)
Aluminium HP die-casting
Machining
VillasantaVillasanta Main Plant (MI) Main Plant (MI)
Operation site
Aluminium HP die-casting
Machining - Moulds production
Machining
TurateTurate Plant (CO)Plant (CO)
Aluminium HP die-casting
Machining
Aluminium
furnaces
TURATETURATE
PlantPlant
(Como)(Como)
Plants & Facilities
Finishing
and warehousing area
Die-casting area
(small presses) and machining
VILLASANTAVILLASANTA
PlantPlant
((Milan)Milan)
Machining areas with
High-speed Transfer lines and
robotized CNC Machines
Plants & Facilities
Die casting production
(machines up to 1800 Tons)
Headquarters :
Engineering, Sales,
Finance & Administration
CORMANOCORMANO
PlantPlant
(Milan)(Milan)
Die casting production (big
presses) and warehousing
Machining, impregnation
and warehousing
Plants & Facilities
Big presses up to 2800 Tons
Aluminium
furnaces
QUEROQUERO
PlantPlant
((BellunoBelluno))
Plants & Facilities
New die-casting area (Presses over
2000 Tons), finishing and
warehousing area
Die-casting area
(small presses) and machining
furnaces
Sales Breakdown by Application (2014)
Albertini Products
Automotive (93,0%)
Trucks (2,1%)
Electronics & Telecom (4,9%)
Sales Breakdown by Product (2014)
Raw parts (22,7%)Assembled parts (2,5%)
Albertini Products
Machined parts (74,8%)
Sales Breakdown by Automotive System
Powertrain (14,8%)
Chassis (17,1%)
Engine parts (15,3%)
Albertini Products
Powertrain (14,8%) Engine parts (15,3%)
Power steering (52,8%)
Power Steering System
Customer: ZF-LS (for VW)
Part: Steering housing PQ36
Delivery condition: Machined
Quantity: 2.000.000 pcs/year
Customer: JTEKT (for Nissan)
Part: Steering housing X11
Delivery condition: Machined
Quantity: 22.000 pcs/year
Customer: ZF-LS (for VW)
Part: Steering housing MQB
Delivery condition: Machined
Quantity: 750.000 pcs/year
Albertini Products
Quantity: 2.000.000 pcs/year
(3 references - 2013)
Quantity: 22.000 pcs/year
(2013)
Customer: JTEKT (for PSA)
Part: Servo housing A806
Delivery condition: Machined
Quantity: 70.000 pcs/year
(2012)
Quantity: 750.000 pcs/year
(2013)
Customer: ZF-LS (for BMW)
Part: Steering housing X5
Delivery condition: Machined
Quantity: 130.000 pcs/year
(2013)
Customer: Opel-Gm
Part: Clutch housing F13/F17
Customer: PSA
Part: Gearbox housing D4D
Albertini ProductsPowertrain
Part: Clutch housing F13/F17
Delivery condition: Raw part
Quantity: 100.000 pcs/year
(2013)
Part: Gearbox housing D4D
Delivery condition: Assembled
Quantity: 15.000 pcs/year
(2005 – now spare part only)
Customer: Renault
Part: Gearbox housings (fam.)
Delivery condition: Raw part
Quantity: 10.000 pcs/year
(2013)
Customer: BorgWarner
Part: Actuator Body
Delivery condition: Machined
Quantity: 240.000 pcs/year
(2013)
Chassis (Anti-vibration & Brackets)
Customer: Renault
Part: Engine & Gearbox brackets
X70/X76/X84/X85/X90/X91/X95
Customer: AUDI
Part: Gearbox brackets B8
Albertini Products
X70/X76/X84/X85/X90/X91/X95
Delivery condition: Raw part
Quantity: 1.200.000 pcs/year
(2013)
Part: Gearbox brackets B8
Delivery condition:Raw/Machined part
Quantity: 650.000 pcs/year
(2013)
Customer: Trelleborg
Part: Brackets & Housings
Delivery condition:Raw/Machined part
Quantity: 3.800.000 pcs/year
(2013)
Engine Blocks and Bedplates
Albertini Products
Customer: IranKhodro
Part: Cylinder block XU7
Delivery condition: Raw part with first
machining and impregnation
Quantity: 30.000 pcs/year
(2013)
Customer: PSA
Part: Bedplate DV6
Delivery condition: Raw part with
5 cast iron inserts
Quantity: 300.000 pcs/year
(2013)
Customer: PSA
Part: Cylinder block TU1-TU3
Delivery condition: Raw part with first
machining and impregnation
Quantity: 170.000 pcs/year
(2012)
Engine Parts
Customer: Volkswagen Customer: BorgWarner
Albertini Products
Customer: Daimler Customer: Volkswagen
Part: Cylinder head cover
Delivery condition: Assembled
Quantity: 10.000 pcs/year
(2012)
Customer: BorgWarner
Part: Turbochargers
Delivery condition: Machined
Quantity: 600.000 pcs/year
(2013)
Customer: Pierburg
Part: Oil/Water pumps and covers (fam.)
Delivery condition: Raw/Machined parts
Quantity: 4.700.000 pcs/year
(2013)
Customer: Daimler
Part: Oil-pan OM642 4x4
Delivery condition: Assembled
Quantity: 12.000 pcs/year
(2013)
Truck Products - Powertrain
Albertini Products
Customer: Daimler/Mitsubishi
Part: Gearbox housing G131/Fuso
Delivery condition: Raw part – 21,8 kg
Quantity: 10.000 pcs/year
(2013)
• Product requirement and function analysis
• 3D Model design
• Finite element Meshing
• Static Analysis
• Modal Dynamic Analysis
• Fit for function design
• Structural optimisation
• Weight Saving
R&D - Co-design
• Stress Analysis
FEM Mesh Static Analysis Modal & Dynamic Analysis
• Fast prototyping (Sand-casting Process)
• Prototyping with Die-Casting pilot moulds
• Mould Manufacturing & Testing
R&D - Tooling
• Development of Casting Model (CATIA)
• Design of the Dies by 3D CAD System
• FEM Casting Simulation (MAGMA)
• Development of Vacuum & Squeeze Systems
• Combined Moulding of Steel & Aluminium
• Measurements by 3D Simulation program
R&D - Casting
• Measurements by 3D Simulation program
In-house
Filling and
Solidification
Simulations
• Development of Machining Fixtures
• Testing of Cutting Tools
• Development of Process on CNC machining units (4-5 axis, 1-2 spindles)
• Specific high volume solutions on Transfer Machines
R&D - Machining
• Development of Automation Concept
• Robot integration (Software and
Mechanical)
• Video camera Check & Feed-back
• Automatic Laser measurement
Control
R&D - Automation
Control
• In-Line Post Process Quality Control
& SPC
• Integration of Leakage Tests and
Assembling processes
• Fully automated Production Units
(Casting, Machining & Assembling
Units)
Quality Policy
Environmental
compliance
Application of
process
methods
Operator
involvement
Quality Certification ISO TS 16949 Quality Certification ISO TS 16949
Focus on
Customer’s
needs
Cost
efficiency
Technological
innovation
QualityQuality
Quality Certification ISO Quality Certification ISO 90019001