CPT International 04/2016

K COMPANY
three modern, fully automated Carat
die-casting cells from Bühler, Uzwil, Switzerland,
with clamping forces of 1,300
tonnes and 1,600 tonnes, as well as the
necessary upstream and downstream logistical
chain – from the separate incoming
metals store with its own spectral analysis
system, through heat treatment and
processing equipment, to dressing and inspection
stations – were setup and audited.
Parallel to this, the employees received
appropriate training, and the processes in
the company were structured in line with
the new needs. Serial production of structural
castings for the Mercedes S-Class and
its GLC models started in mid-2015. In
the meantime, the development of parts
for other vehicles from Porsche, Audi and
VW has already advanced to the samples
phase in some cases.
Double strategy for optimum
Europe-wide logistics for structural
castings
“Thanks to this strategy, the two DGS
works now act as a team for their European
customers with different, but coordinated,
performance profiles – and can
therefore cover an extraordinarily wide
product range,” explains Schmidt. Each
of the sites has its specific advantages. In
St. Gallen, DGS has a recognized high
level of expertise in the development
and production of large-format structural
castings that has made the site a
sought-after partner for joint projects in
the further development of such applications.
In addition, the company has
particularly large die-casting cells with
clamping forces of up to 3,200 tonnes
here. The works therefore also remains
indispensable for its function as a development
site, as well as a production site
for particularly demanding large-format
structural castings. On the other hand,
the works in Liberec is continuously improving
its level of competence thanks
to constant transfers of technology and
expertise, and can thus also serve other
market segments. The procurement
of another Bühler Carat 160 plant is already
planned for autumn 2016.
Massive capacity expansion in
the Czech Republic
“In view of the enormous interest in
our products we will steadily expand
A ‘marshalling yard’: the castings are passed through a fully automatic furnace
plant to achieve the desired properties
the Liberec site during coming years,”
Pfohl reveals. As the existing buildings
are already fully occupied, several new
halls will be constructed on an area of
the works grounds that has not already
been built on. Up to eight new Carat
plants with clamping forces of up to
2,500 tonnes – and all the associated
upstream and downstream equipment
such as the melting shop, heat treatment,
processing centers and surface
treatment – will gradually be installed
here during the coming years. Because
the company has been able to make
plans for this land without being bothered
by existing structures the other infrastructure
can be designed to meet
state-of-the-art requirements in terms
of works planning and workflow management.
Another building providing
a separate energy supply, as well as one
that will house an office and personnel
section, are also planned. “This expansion
will equip us to meet all expected
upcoming market needs in the coming
years,” stresses Pfohl. According to current
planning, production in the new
works is expected to start in late 2018/
early 2019.
www.dgs-druckguss.com
Maximum care is taken during final
inspection of this processed suspension
strut dome for the Mercedes
GLC (BR 253)
44 Casting Plant & Technology 4/2016