DESIGN OF MANUFACTURING RESOURCES - C-Con Gmbh

c.con.de

DESIGN OF MANUFACTURING RESOURCES - C-Con Gmbh

Automotive

engineering

Automotive

mechanical engineering

Aerotechnics

Professional training


LOCATIONS C-CON GERMANY

Employees: 250

Turnover: 24.000 T€

1991 Formation of company in Dachau

1993 Relocation to Munich

1997 Relocation to our office Taunusstraße 42

1997 Formation of company in Rottenburg

1998 Formation of company Sindelfingen,

Gaimersheim, Dingolfing

1999 Formation of company Cologne and Bremen

2005 Formation of company Lebach

2006 Formation of company Hannover

2007 Formation of company Garmisch and

Wolfsburg

2007 Doubling of the size of production

capacity of mechanical engineering by

participation on inFORM Chemnitz

2008 Move and Extension of the head office Munich


LOCATIONS C-CON WORLSWIDE

Spartanburg, SC

Greenville, SC

German offices

Brasov, Rumänien

Aix en provence,

France 2004 Formation BTL in

New Dehli, India

New Dehli, India

2005 Formation Joint venture of

2AM / C-CON LLC in

Spartanburg, South Carolina US

2006 Formation C-CON USA in

Greenville, South Carolina US

2007 Formation C-CON in

Brasov, Romania and

Aix en Provence, France


C-CON – YOUR PARTNER FOR THE WHOLE PROCESS


AUTOMOTIVE ENGINEERING

� Car bodies & structural parts

� Guides & face plates

� Exhaust systems

� Exterior

� Interior

� Engine

� Propulsion system

� Safety engineering


AERONAUTICAL- & SPACE ENGINEERING,

RAIL VEHICLES, GENERAL ENGINEERING

� 3D-constructions

� Preparation of drawings

� Arial constructions

� Exterior shell

� Reverse engineering

� Design of parts

� Assembly / DMU

� Tools

� DMU / N4D

� Project management

� NC-Programming

� Supervision

� Presentations


PART OF TECHNOLOGY AND DESIGN

� Design & development

� Calculation / simulation

� NC-programming

� Prototype / first sample

� Tool construction / sheet metal forming

� Tool simulation / sheet metal forming

� Tool construction / casting technology

� Project management


DESIGN / DEVELOPMENT

� CATIA ®

� NX ®

� Pro/ENGINEER ®

� ICEM ®

� AutoCAD ®


CALCULATION / SIMULATION

� NASTRAN / DYTRAN

� CATIA GPS / GP0

� C-MOLD / 3-D Quick Fill

� Pamcrash / Pamstamp

� Abaqus / MARC / ANSYS

� AutoForm

� Star CD

� Stress analysis

� Deep drawing simulation

� Crash simulation

� Rheology

� Impact


NC-PROGRAMMING

� CATIA V4 and V5

� Tebis

� WorkNC

� NX NC

Door EC145

EJ200 Blisk

Fairing NH90


PROTOTYPES / FIRST SAMPLE

STL- first sample


TOOL CONSTRUCTION / SHEET METAL FORMING

� Development of parts

� Deep drawing simulation

� Methodology

� Effective surface

� Tool construction

� Drilling tables & parts lists

� Mechanization of tooling


TOOL SIMULATION / SHEET METAL FORMING

� Mechanization

� Tool change

� Part transfer

� Interference check

� Digital factory


TOOL CONSTRUCTION / PIPES

� Plastics injection molding

� Low pressure casting

� Pressure casting

� Lost Foam


PROJECT MANAGEMENT

� Feasibility studies

� Cost calculation

Consulting

� Schedule

� Quality assurance

- R230: SL (2001)

- BR169: A-class

- R171: SLK

- BR251: Van USA

- BR164: M-class

- BR451: Smart for two (MAGNA)

- BR204/207: C-class (in process)

- BMW: X5, X6Sport Hybrid (2007/2008),

X1 (2007/2008)

- ZF Lemförder: GM Holden (China, 2005/2006)

- LÄPPLE/LSP: BMW X6Sport (USA, 2007)


INFOS TO THE FOLLOWING PRIJEKT FOR EXAMPEL: R230

� 125 parts to be supervised

� 14 only administrative (only System care)

� 78 tools and dies respectively 173 single tools

� Project time 04/99 till 10/2001

� „Job Nr. 1“ at 02.07.2001

� Project size about 36000 EM- hours

� On an average of 8 staffs

� 13 supervise tool supplier


EXPLODED VIEW BODY SHELL


MECHANICAL PROCESSING

� Model building

� Mold and die construction

� Machining tools

� Milling (subcontracting)

� Caliper and gauge

� Prototyps

� Mechanical parts


MODEL BUILDING

� Master form, styling models

� Data control models,

Designmodel, Designfreezemodel

� Function- and test cubing

� Test tools from aluminum, zamak, plastics

� Prototype parts GFK- / CFK-parts

� STL and laser interpart

� Aluminum- and magnesium parts


MOULD AND DIE CONSTRUCTION

� Tools for thermo- and duroplaste

� GID (inside gas pressure)

� SMC / GMT

� Lamination tools

� Pressure casting dies

� Foaming tools

� Chill mold

� Core Box


MASCHINING TOOLS

� Form-, hole- and cutting tool

� Transfer jig incl. mechanization

� Follow up progressive die tools

� Cutting tool

� Extended workbench


TOOL SHOP

� Tool shop after own and customer sided records

� Start up of tools

� Pilot run procedure / first parts out of

series tooling and series process

� Tool maintenance

� Tool modification


CALIPER AND GAUGE

� Gauge and measuring gauge / testing device

� Rigging the supervision of series production


DESIGN OF MANUFACTURING RESOURCES

AND SPECIAL PLANT PRODUCTION

Concept illustration

� Special plant production

� Device

� Car body production

� Commissioning


DESIGN OF MANUFACTURING RESOURCES

� Workbenches

� Mounting devices

� Mounting DMU

� 2D conversion of 3D drawings


DESIGN OF MANUFACTURING RESOURCES

� Adjustment gauge, measuring gauge

� Module carrier

� Transport systems

� Test cubing


DESIGN OF MANUFACTURING RESOURCES

Pre-production tension

(REMA Standard)


DESIGN OF MANUFACTURING RESOURCES

Roof-fixture (CMT-soldering)


DESIGN OF MANUFACTURING RESOURCES

� Mounting suspension gear

� Skids, carrier


DESIGN OF MANUFACTURING RESOURCES

Multiple gluing cell

Production plant for roof frame


DESIGN OF MANUFACTURING RESOURCES

Camera test position for fender protector

Camera test position for cowl louver


DEVICE

Punching device - & drilling jig

Daimler R171 bumper


DEVICE

Gluing technique body shell VW Polo

Adhesion from door and rear lid


SPECIAL PLANT PRODUCTION

Punching technique punching device integral

bearing Daimler W 203, 220 & 211


INTERIOR

Robot bonding technique

interior Daimler W/S 211


BODY SHELL

Weld and rivet a main chassis beam


BODY SHELL

Clamp welding tool for Daimler


CAR BODY CONSTRUCTION PLANNING

Concept Development

� Product specification and appraisal of bids

� Detail planning

� Sequence planning and time studies (MTM)

� Project supervision / start-up optimization

� CAD-design (CATIA V4/V5)

� Robot simulation (RobCAD)

� Technical documentation

� Change management

� Monitoring of dates

Software:

� eM-Planner

� eM-Plant

� eM-Workplace

� Microstation

� Process Designer

� Process Simulate

� CATIA V4

� CATIA V5

� RobCAD


CAR BODY CONSTRUCTION PLANNING

Normalienpark

production VW Hannover


CAR BODY CONSTRUCTION PLANNING

Mounting add-on

components / finish


CAR BODY CONSTRUCTION PLANNING

Body making plants

door production


CAR BODY CONSTRUCTION /

MANUFACTURING ENGINEERING

SAD Production plant for VW Polo,

Touran, Passat and Jetta Variant

Preparations for headframes & mounting into the state coach of a

VW Passat


REFERENCE PROJECTS

Volkswagen

� Polo

� Golf (Platform)

� Passat

� Phaeton

� Touareg

� Tiguan

Volkswagen Commercial Vehicles

� Caddy

� Multivan

� Transporter

� LT / Crafter

Daimler

� A-class

� C-class

� E-class

� SLK-class

� SL-class

Current Examples

� Porsche Panamera

� VWN RPU / CPU

� VW Multi-model plants

Kaluga / Pune

� Daimler BR 212 ...


MANUFACTURE OF COMPONENTS

� Sheet metal parts

� Plastic parts

� Aluminum parts

� Special plant parts


SHEET METAL PARTS PRODUCTION

� Pressing / punching

� Forming / deep drawing

� Tox clinching

� Lasering

� Canting

� Welding

� Passivating

� Mounting

Lawn mower case

Main bearing for

AUDI TT Verdeck

Floor panel for cockpit

Structure part

Porsche


PLASTICS PARTS

� Design of parts under consideration

of function, design, surface feel,

ergonomics

� Tooling design

� Design of prototypes in laser

sinter technique, PU-castings off

silicon molds

� Production of Parts in a 2K-

Plastic injection molding die

� Assembly, welding and

surface engineering

� Quality assurance,

supervision of series

production

2 component injection molding for die machinery

Front spoiler Škoda Octavia


SPECIAL PARTS

Design, Prototype, Tooling, Batch production

Achievements

� Package – studies with add-on parts

� Design of parts

� Design of prototypes in laser sinter

technique, PU-castings off silicon molds

� Experimental installation in vehicle

� Series tooling

� Production of parts

� Assembly, surface engineering (painting,

printing)

� Quality assurance, supervision of series

production

Tank panel fastener

AUDI TT

Driving school mirror

Additional counter for

driving school vehicle

Cover fire extinguisher


IT – NETWORK AND SYSTEMS

Service contracts

� Installation and administration

� Hotline with permanent availability (365 days / 24h)

� Maintenance contracts

Consulting

� Design of complex IT-solutions

� Communication concepts for local and global data transfer

� Emergency services

� Security management, anti-virus protection

� Data saving concepts

� Communication

� Training

Network systems

� Design and installation of active and passive network architecture

� Selection of network components (switches, router, firewalls)

� Network analysis

� Documentation, management (SNMP) and monitoring

� Data base solutions (SQL, Oracle…)

� Application programming

� Integration of peripheral devices

� Server solutions


C-CON TOOLS

Improvement efficiency by automation

� Analysis of cutting angle and shearing angle in 3D

� Establishing the optimal working direction

� Recursive renaming

� Flat projection of component flanges


C-CON TOOLS – ANALYSIS OF CUTTING ANGLE AND

SHEARING ANGLE IN 3D

Flexible inspection of cutting angle with evaluation of the cutting and shearing

angles without cumbersome link to the CATIA V5-structure.

Analysis in one working plane normal to 2D-cutting contour or to the normal of

the effective area.


C-CON TOOLS –

ESTABLISHING THE OPTIMAL WORKING DIRECTION

Determination of the optimal slide feed or orientation of axis under

consideration of standard slide feed angles based on an arbitrary number of

curves and (or) center points of cut-outs.


C-CON TOOLS – RECURSIVES RENAMING

This macro replaces a text block with another within the entire product structure.

This is a fast method of defining different versions.


C-CON TOOLS –

FLAT PROJECTION OF COPONENT FLANGES

Flat projection of flanges via points with equal spacing that can be freely selected

via “extreme points” or in user-defined combination under consideration of the

folding edge and a user-defined spine. The correction of the length is computed

using an equation as per DIN 6935.


C-CON CONTACT ADDRESS

national: international:

C-CON Holding GmbH

Herrenkreuth 12

82431 Kochel am See

Germany

Tel.: +49 (0)8851 15 42

Fax: +49 (0)8851 61 101

info.kochel@c-con.de

C-CON GmbH

Knorrstr. 135

80937 München

Germany

Tel.: +49 (0)89 358 82 0

Fax: +49 (0)89 358 82 100

info.muenchen@c-con.de

C-CON GmbH

Kolumbusstrasse 1

71063 Sindelfingen

Germany

Tel.: +49 (0)7031 79 39 1 0

Fax: +49 (0)7031 79 39 121

info.sindelfingen@c-con.de

C-CON GmbH

Mengkofener Strasse 29

84130 Dingolfing

Germany

Tel.: +49 (0)8731 75 89 0

Fax: +49 (0)8731 75 89 50

info.dingolfing@c-con.de

C-CON IFT GmbH & Co. KG

Dieselstrasse 15

84056 Rottenburg

Germany

Tel.: +49 (0)8781 94 88 0

Fax: +49 (0)8781 94 88 25

info.rottenburg@c-con.de

C-CON GmbH

Friedrichshofener Str. 1

85049 Ingolstadt

Germany

Tel.: +49 (0)841 220561 20

Fax: +49 (0)841 220561 40

info.ingolstadt@c-con.de

C-CON GmbH

Leibnizpark 1

51503 Rösrath

Germany

Tel.: +49 (0)2205 89 74 681

Fax: +49 (0)2205 89 74 68 6

info.koeln@c-con.de

C-CON GmbH

Poststelle Daimler AG

Mercedesstrasse 1

28190 Bremen

Germany

Tel: +49 (0)421 41 95 31 7

Fax: +49 (0)421 41 97 99 692

info.bremen@c-con.de

C-CON Sondermaschinen GmbH

Auf dem Graben 17

66822 Lebach

Germany

Tel.: +49 (0)6881 93 61 70

Fax: +49 (0)6881 93 61 710

info.lebach@c-con.de

C-CON GmbH

Unterfeldstrasse 12

82467 Garmisch-Partenkirchen

Germany

Tel.: +49 (0)8821 96 76 40

Fax: +49 (0)8821 96 76 410

info.garmisch@c-con.de

C-CON GmbH

Schilfkamp 13

30851 Langenhagen

Germany

Tel.: +49 (0)511 47 54 19 0

Fax: +49 (0)511 47 54 19 50

info.hannover@c-con.de

C-CON GmbH

Dieselstraße 33

38446 Wolfsburg

Tel.: +49 (0)5361 43 66 100

info.wolfsburg@c-con.de

C-CON France S.A.R.L

1, avenue René Bigand

F-04860 PIERREVERT

France

Tel.: +33 (0)388 37 08 52

Fax: +33 (0)388 37 08 52

info.france@c-con.fr

InterEngs d.o.o

Vratnik Mejdan 40

71000 Sarajevo

Bosnia

Tel. : +387 33 534 868

info@interengs.com

C-CON s.r.l. Rumänien

Str.Zizinului Nr. 43 Ap.3

RO-500403 Brasov

Romania

Tel.: +40 (0)268 31 03 45

Fax: +40 (0)268 31 03 57

Best Technologies Pvt. Ltd.

38 KM Stone, Delhi-Jaipur Highway

Bahrampur Road, Village-Khandsa

Gurgaon 122001 (Haryana)

India

Tel: +91 (0)124 50 38 436

Fax: +91 (0)124 23 72 204

contact@btl.in

2AM / C-CON LLC

201 Commerce Court

Duncan, SC 29334

Post Office Box 170397

Spartanburg, SC 29301

Tel: +1 (0)864 43 38 686

Fax: +1 (0)864 43 38 687

info@2AMGroup.com

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