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Total responsibility and innovative ideas attractive to Vaillant as they invested for the future
September 2005
When the German heating systems manufacturer Vaillant decided to build an in-house press line for water heater parts, they invited nine potential suppliers to create the best complete production solution. After an open bidding process, including a 'suppliers day' in which all the bidding parties participated, Vaillant ultimately chose AP&T of Sweden for the project.
The combination of total responsibility and high-tech solutions was the deciding factor. Within six months of their decision, Vaillants new press line was installed and production had begun.
Vaillant learned about AP&T through one of their own customers. "We were having our products pressed at a Dutch firm that is automated with AP&T equipment. AP&T showed us the possibilities afforded by pressing and automation with the help of "One Responsible Partner'," reports Vaillant Production Manager Marc Dörpinghaus.
Open procurement process When Vaillant decided to begin manufacturing water heater frames and front panels in-house, the company approached suppliers throughout Europe to find the best production solution. Such an approach is unusual in Germany, where companies often choose domestic suppliers. 'As a market-leading European company, we operate throughout all of Europe,' explains Marc Dörpinghaus. He noted that AP&T stood apart from the beginning of the process by providing a thorough and well-prepared presentation of a sound, high-tech concept.
This laid the foundation for a relationship based on trust. This relationship was strengthened when all the bidding companies were invited to participate in an open forum during Vaillant's suppliers day.
'Thats where AP&T distinguished themselves with numerous interesting ideas and questions. We were also impressed by the production simulation, which they were the sole supplier to present.'
Vaillant then visited two of AP&Ts existing customers in Sweden to see the companys solutions in practice.
'AP&T's automation was technically brilliant. The presses and automation we saw at Asko Cylinda and at AP&Ts plant made up our minds. We had found the right partner,' affirms Marc Dörpinghaus.
Built for the future
Two general-purpose presses from AP&T's ZM series are at the heart of Vaillant's production line. They deliver 4000 and 6300 kN (450 and 710 US tons) of press force, respectively. The parts being produced are formed in multiple steps. Consequently, each bolster is equipped with three CD feeders. AP&T's efficient CD feeders are specially adapted for moving parts through multiple tool sets in a multiple step forming operation. Having three separate synchronized CD feeders for each bolster makes the press line more flexible and increases productivity.
The presses are also equipped with two AP&T BF blank feeders. Vaillant opted for two feeders even though their current production process is only using one. They view it as a source of adaptability and flexibility for future needs. A conveyor belt transports the finished parts out of the line for inspection and painting.
Flexible and fully automated
The press line is laid out for maximum flexibility enabling it to handle a number of different products. In practice, the equipment can be operated as two separate press cells producing different products, or as a linked press line for products that require multiple press operations.
AP&T also delivered a fully automated tool-changing system for the line. This system has automatic tool clamping which minimizes set-up time during tool changes, increasing availability.
The fully automated production process is controlled by AP&T's proprietary MC32 control system. This enables transparent overall control of every piece of production equipment in the line.
Praise for AP&T project management
In addition to the benefits realized from their technical solution, Vaillant appreciated the benefits of AP&T's project management in which a single dedicated project manager is responsible for the entire project. 'One very important aspect is that of having a single counterpart with whom to communicate throughout the entire project. AP&T has functioned as 'One Responsible Partner', and the project management has been highly professional and friction-free,' says Marc Dörpinghaus.
AP&T's efficient project management makes it easy to move through all phases of a project right up to the first production run. In this case, the installation and start-up was completed in only five weeks and Vaillant was able to begin production less than six months from their order date.
Assurance for the future
Now that Vaillant's production on the new line is in full gear, they can realize the benefits of AP&T's modular design with a 90% availability assurance. In the event of a technical problem, AP&T service personnel will be on-site within 16 to 24 hours. Production Manager Marc Dörpinghaus is more than pleased with both the project and its outcome, and is excited about the future. 'We're looking forward to continued excellent service and quick response times, so that the system delivers maximum availability.'
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