CPT International 4/2019

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LOGISTICS Forklift fleet keeps the castings moving The compact RX 70 diesel forklift combines dynamic maneuverability with state-of-theart hybrid drive control for particularly low consumption The industrial trucks at Fondium’s production works in Singen have been brought up-todate by forklift expert Still to enable the company to continue asserting itself in the intense competition for automotive castings. Still’s FleetManager is an important component of this fleet modernization. All in all, a considerably higher level of fleet operational readiness has been achieved despite a reduction from 136 to 119 vehicles. Gerd Knehr, Reutlingen Photos: Still This downsizing of the fleet effectively cuts maintenance and repair costs. 23 maintenance-free lithium-ion warehouse vehicles are now also stationed directly in the departments with their own charging points – eliminating both the long paths to the former central charging station and supplementary substitute wet-cell batteries. Prepared for the future Since the site at Hohentwiel in Singen was founded in 1895, Georg-Fischer (GF) Automobilguss has become a leading company for heavy-duty cast-iron vehicle components. Examples include brake calipers for the well-known company Knorr-Bremse, as well as wheel hubs and steering knuckles for truck producers such as Daimler, MAN, Renault, DAF or Volvo. The GF sites in Singen and in Mettmann near Düsseldorf achieved sales of 550 million euros with about 2,000 employees in 2018. The Singen works mainly manufactures vehicle parts for trucks, while car components are principally produced in Mettmann. Both foundries were taken over by the Fondium Group at the end of last year, following restructuring of the product portfolio of the GF Group, based in 36
Safety has top priority at Fondium. All front loaders are equipped with the Safety-Light 4Plus from Still. With their own charg ing points, the li-ion industrial trucks are immediately available in the departments – eliminating long paths and long waiting times for the batteries to charge. The RX 70 is a key vehicle for internal transports in the melting shop. Schaffhausen, Switzerland. GF and Fondium, however, have continued to work together in some segments. Manuel Veser, Manager of Fondium’s Logistics Center in Singen, is confident: “With our production capacity and sales of about 180,000 tonnes per year we can produce large serial numbers – with a total of more than 12,500,000 ready-to-install castings – thanks to our computer-supported design and manufacture.” FleetManager keeps everything in view Production and logistical processes, as well as the production plants at the Singen works, are regularly modernized. Whereby a fleet of forklifts adapted to the needs of production is a very important factor. All vehicles have GPRS radio data transmission and an RFID chip for drive authorization. Mathis Märgner, responsible for fleet maintenance in Singen, stresses that “If the defined acceleration value is exceeded during a forklift operation the vehicle can be forced into creep mode, depending on the setting of the acceleration sensor in the accident recorder. This reaction can not only be selected to prevent collisions, but also if the vehicle moves too quickly over uneven surfaces.” Manuel Veser adds that “We have been logging collisions for several years using the FleetManager from Still. Together with Still we have analyzed pictures of the damage to both vehicles and the operating materials transported and have been able to determine and eliminate potential sources of risk on the drive paths at the works. The drive behavior of the forklift drivers has improved enormously due to annual training and the filling in of operation control books, in coordination with the Works Council. As a result, the accident rate has fallen by about 80 percent.” The transparent vehicle biography also shows whether particular forklifts are working to capacity while other vehicles have already done too many operating hours. This form of recording minimizes the risk of further maintenance and servicing costs due to non-compliance with the contractually agreed level of operating hours. Moreover, as a result of standardization and fleet-oriented optimizations, the forklifts can be exchanged between the works departments more easily. The fleet is therefore better utilized. State of the art: li-ion warehouse technology increases availability For the first time, 23 warehouse trucks with lithium-ion batteries have been stationed in the individual departments. The advantages are clear: separate charging devices in the departments mean that the EXV 20 high-lift pallet trucks from Still are now available at any time. Mathis Märgner finds the new technology convincing: “The most important reason was the time savings achieved by cutting out the long path to the central charging stations and the long charging times required there by the wet-cell batteries. With their own charging stations in the departments, we can recharge the li-ion trucks at short notice during breaks. The li-ion batteries reach 50 percent of their charge capacity after only 30 minutes, whereby the service life is not impaired by the rapid interim charging. This removes the need for replacement batteries and long charging cycles, as well as the complicated maintenance of the wet-cell batteries in the dusty CASTING PLANT & TECHNOLOGY 4/<strong>2019</strong> 37
Page 3 and 4: EDITORIAL Die-casting in focus! EUR
Page 5 and 6: CONTENTS LOGISTICS Fondium‘s iron
Page 7 and 8: “Today you have to be very agile
Page 9 and 10: Figure 1: Adam Hönig Iron Foundry
Page 11 and 12: Figure 7: Monitor-based control of
Page 13 and 14: Figure 9. Detail view of the furnac
Page 15 and 16: Demonstrator for a measuring techni
Page 17 and 18: MOTIVATED BY CHALLENGES Casting ser
Page 19 and 20: Order your benchmark part now 3D Co
Page 21 and 22: PRESSURE DIE CASTING Photo: Bühler
Page 23 and 24: Situation Today Today’s Market of
Page 25 and 26: 30.00 25.00 20.00 15.00 10.00 5.00
Page 27 and 28: forming of the part and adjusting t
Page 29 and 30: a Nuremberg, Germany 14 -16.1.2020
Page 31 and 32: An automatic extinguishing device i
Page 33 and 34: Romain Zorzi, Project Manager for N
Page 35: Workpieces before and after blastin
Page 39 and 40: OE750 - NEXT LEVEL OES METALS ANALY
Page 41 and 42: Plant production in Plüderhausen.
Page 43 and 44: Technician carrying out precision w
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CPT International 4/2019

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