11 Press Presentation 130905 [호환 모드] - Hyundai Wia MACHINE PLANER ... -Human & Machine Safety-Utility and site condition-Manual, Spare Parts and Training-Review of Specification

PRESS INTRODUCTION

I. Company Introduction

II. Press Business1. Major Customer

2. Press Shop

3. Major Products

Ⅲ. Quality System

Contents

II. Press Business

- Main Press Products

Blanking Press

Hot Forming Line

Progressive Press

Modular Press

Tandem Press

Servo Press Transfer Press

All rights reserved and copyrighted by HYUNDAI WIA

Major CustomerHyundai WIA Press Shop Major Products Quality System

Section Customer Press Installed

GeneralMotors

GM Australia 1600T , 2300T , 2400Ton Line, 2400T Trial

GM Korea 2500T Trial, 2250T, 800T B/K Line

GM Mexico 2250T Line(3Lines), 2250T Trial

GM Thailand 1800T Line

GM India 1800T Line

GM Poland 1800T Line

GM UZ 2250T Line, 1800T Line, 600T B/K Line

GM Brazil 2250T Trial, 800T B/K Press

GM USA 2250T Line(4 Lines), 2250T Trial

Magna

Russia 800T Line, 250T Mini Line, 630T B/K Line

Mexico800T Pro, 400T Pro(3Lines), 1000T Press(2sets), 1200T Hot Forming(2Lines), 800T Hot Forming1000T T/F, 2000T T/F, 3000T Transfer Line

USA 2000T Line, 1600T Line, 1200T Hot Forming Press (3 sets)

Canada 1200T Hot Forming Press

Brazil 630T Pro, 400T Pro

China 800T Pro, 1000T Line, 1000T Trial, 2500T Trial

India 1600T Line(2Lines), 800T Pro.(2Lines) 250T Mini Line (2 Lines)

Korea 800T Hot Forming Press(2sets)

HyundaiKia

Motors

Kia Korea 2300T Line and Others (total 9Lines),600T B/K Line (4Lines), 200T DSP(2sets)

Kia Slovakia 600T B/K Line, 2400T Trial Line

Hyundai Korea 2300T Line

Hyundai India 5400T Modular Line

Hyundai China 500T B/K Line

Hyundai Turkey 2300T Line

Major Customer – 25 Countries, 35 Customers



Sales Record to GM – 10 countries, 85 presses

Automation System (without press)

IndiaIndia

KoreaKoreaPolandPoland USAUSA

MexicoMexicoThailandThailand

UzbekistanUzbekistan

AustraliaAustraliaBrazilBrazil

ChinaChina

Tandem Press Line

• 8 countries• 16 lines• 71 presses

Blanking Line


Trial Press

• 5 countries• 5 presses

• 2 countries• 4 lines

Die Spotting Press

• 2 countries• 2 presses



Sales Record to Magna – 8 countries, 52 presses

IndiaIndia

KoreaKorea USAUSA

MexicoMexico

RussiaRussia

BrazilBrazil

ChinaChina


Blanking Line

• 1 country• 1 line• 1 press

Trial Press

• 1 country• 2 presses

Hot Stamping Line


CanadaCanada

Progressive Line


Tandem Press Line Transfer Line

• 1 country• 3 line• 3 press



Welding Shop

● ANNEALING FURNACE(8mX8mX16m, 200Ton)

● SHOT BLAST(8mX12mX6m)

● GANTRY CRANE(70T, 50TX2, 40TX2, 30TX2)

● OVER HEAD CRANE(40T,25TX3,10T, 5T)

● AUTO CUTTING MACHINE

● SHEARING MACHINE

● FLAME CUTTING MACHINE

● Area : 17,000 m2



Machining Shop

● HOR. BORING MACHINE (7 set)- 1,520 x 4,500 x 14,000 mm

● GEAR HOBBING MACHINE- Max. Dia 7 m

● CYL. GRINDING MACHINE

● PLANER

● HEAVY DUTY LATHE

● VERTICAL TURNING LATHE

● RADIAL DRILLING MACHINE

● OVERHEAD CRANE

● Area : 5,700 m2



Assembling Shop

● PIT FOR TRIAL(W:10m, H:5m, L:42m)

● OVERHEAD CRANE(100/50T, 30/5TX2, 10T)

● HOIST JIB CRANE

● WALL TRAVEL CRANE

● WALL JIB HOIST

● LOAD CELL- 4000T

● Area : 5,000 m2



Modular Press Line

1. Main Customer : Hyundai, Kia Motor

2. Production Rate : max. 15 spm

3. Line Composition

1) 2400T (1 set)- Bolster : 4,800 x 2,500 mm - Stroke : 1,400 mm- 15 spm continuous Mode

2) 3000T Modular Press (1 set)- Bolster : 4,800 x 2,500 mm- Stroke : 1,250 mm- 15 spm Continuous Mode

3) Front of Line- Destacking System- Washer- Centering System

4) Press to Press Automation- High Speed Cross Bar Type



1. Customer : KIA Motor, Korea


3. Line Composition

1) 2400T (1 set, 4600 x 2500 mm)- equipped with NC Hyd. Cushion- 1400 mm stroke- 15 spm Continuous Mode

2) 1000T (3 sets, 4600 x 2500 mm)- 1250 mm stroke- 15 spm Continuous Mode


4) Press-to-Press Automation- High Speed Cross-bar Type

Tandem Press Line - with Cross Bar Automation



1. Main Customers : Asia Automobile Companies and Tier 1


3. Line Composition

1) 2400T (1 set, 4500 x 2500 mm)- 1000 mm stroke- 12 cpm Intermittent Mode

2) 1000T (3 sets, 4500 x 2500 mm)- 1000 mm stroke- 12 cpm Intermittent Mode


4) Press-to-Press Automation- Single Arm Type

Tandem Press Line - with Single Arm Automation



1. Main Customer : GM- Mexico(3 Lines), Uzbekistan(2 Lines), Australia, Thailand, India, Korea, Poland,

USA(4 Lines)

2. Production rate : max. 12 spm

3. Line Composition 1) Press

- XL Line (4500x2400 mm) : 2250T (1) + 1000T (3)- L Line (3800x2400 mm) : 1800T (1) + 800T (3)

2) Front of Line : Destacker + Washer/Oiler + Vision Centering3) Press to Press Automation : Robots with Main Boom4) End of Line : Exit Conveyor + Sorting tray

Tandem Press Line – Robot Automation



Tandem Press Line – Robot with 7 axis

1. Main Customer : Cosma- India(2 Lines), USA(2 Lines), Russia, China



- G1 Line (4500x2500 mm) : 2000T (1) + 1000T (4 sets)- G2 Line (3500x2500 mm) : 1600T (1) + 800T (4 sets)

2) Front of Line : Destacker + Washer/Oiler + Centering3) Press to Press Automation : Robots with 7 Axis4) End of Line : Exit Conveyor



Tandem Press Line – Double Action Press

1. Main Customer : GM Holden (Australia), Kia Motor (Korea), Iran Khodro (Iran)



- G1 Line (5000x2500 mm) : 2300T D/A (1) + 1000T (4 sets)- G2 Line (3700x2200 mm) : 1600T D/A (1) + 600T (3 sets)

2) Front of Line : Destacker + Washer/Oiler + Centering3) Press to Press Automation : Robots with 7 axis4) End of Line : Exit Conveyor



Servo Press

Progressive/Blanking Tandem Press1. Capacity

- 800Ton (4500x2500 mm) - XL (4500 x 2500 mm) : 2400T + 1000T (3 sets)- 400Ton (3000x1500 mm) - L (3800 x 2500 mm) : 1800T + 800T (3 sets)

2. Stroke- max. 300 mm, variable at Pendulum - max. 1,200 mm

3. SPM- 20 ~ 60 spm at 300 mm stroke - 12 ~ 20 spm- 20 ~ 100 spm at 100 mm stroke

pendulum mode * Servo System : Siemens or Fanuc



Blanking Press Line

1.Customer - GM - Hyundai/Kia - Tier 1- Operation Korea, Uzbekistan, Slovakia, Korea, Russia, China, Turkey

Site Brazil Beijing USA, Korea, etc.

2. Capacity - 800Ton 700T, 600Ton 600T, 500T, 400T

3. Bolster Size - 4700 x 2600 mm 4300 x 2500 mm 3600 x 2400 mm

4. Stroke - 350 mm 300 mm 300 mm

5. SPM - 12 ~ 60 spm 10 ~ 80 spm 10 ~ 80 spm



Transfer Press Line

1. Main Customer Tier 1 located in Korea, China, USA, Thailand, etc.

2. Capacity - 3000Ton - 2400T - 1600T - 1500T

3.Bolster Size - 6000x2500 mm - 6000x2500 mm - 5000x2500 mm - 4800x1600 mm

4.Stroke - 760 mm - 760 mm - 760 mm - 600 mm

5. SPM - 8~30 spm - 8~30 spm - 8~30 spm - 10~25 spm



Progressive Press Line

1. Main Customer Tier 1 located in Korea, China, India, Mexico, Brazil, Thailand, etc.

2. Capacity - 800Ton - 400T - 1600T - 1200T

3. Bolster Size - 4500x2500 mm - 3000x1500 mm - 3500x1600 mm - 3500x2200 mm

4. Stroke - 350 mm - 300 mm - 250 mm - 400 mm

5. SPM - 20~60 spm - 30~70 spm - 15~55 spm - 20~60 spm



1. Main Customer Tier 1 - Magna, Gestamp, Posco, Hysco, IS Tech,

Yifeng, Morex, etc., - in Korea, USA, Mexico, Canada, China- Total 19 lines (9 in Korea, 10 in overseas)

2. 1 Cycle : within 10 sec. - max. 4 parts production at the same time

3. Line Composition

1) Press : 1200T, 800T- Bolster : 3000 x 2000 mm- Stroke : 1,200 mm- Slide Speed : max. 1,000 mm/sec.

2) Furnace : German or Korean Manufacturer

3) Destacking System

4) Loading and Unloading Automation : Robot or Gantry Robot

Hot Forming Press Line

Ⅲ. Quality System



Quality System and Certificate

INTERNATIONAL QUALITY MANAGEMENT

SYSTEMInternational Authorization

Testing And CalibrationLaboratories

Information SecurityManagement

System

Environmental Management

System

Manufacture and AssemblyOf Piping, Vessel, Boiler

Control System

ISO 17025

ISO 9001

ISO 27001

ASME

ISO 14001



Design Quality Control

■ Available CAD & CAE

Section Brand Usage

Modeling

Catia 3D Modeling

Inventor Structure Analysis

UG Dynamic Analysis

FEA

Ansys Structure, Vibration, Fatigue Analysis

Nastran Structure, Vibration, Fatigue Analysis

Stadd Pro Structure Analysis

Dynamic Analysis Adams Dynamic & Kinematic Analysis

SimulationDelmia Automation Simulation

Robo Guide Fanuc Robot Simulation

CADAutoCAD Mechanical design

Eplan Electric control design

Note : More CAD & CAE tools are available with HWIA partners.




■ Engineering Process

Design FlowScope

RemarksWIA Customer

Clarification of Specification ● ●

Order ●

Kick off meeting ● ●

Basic Design ●

Order of Long Delivery Item ● Long lead items to be released in advance.

Design Verification ● 3D Modeling, FEA

Design Review(1st) ● ● Design will be reviewed with customer.

Design Acceptance ●

Design for Manufacture ●

Design Verification ● FEA, Simulation

Design Review(One or Two times ) ● ● Design will be reviewed with customer.

Drawing Release ●12

※Additional specification and requirement shall be agreed by mutual consent in writing statement.

11

10

9

8

7

6

5

4

3

2

1




■ Design Verification via 3D Modeling, FEA and Simulation




■ Design Verification via FMEA




■ Design Varification via Risk Analysis (CE, NFPA)




■ Design Verification via Design Review

Customer Engineering Manufacturing

- Review of Specification of Request- Operation, User & Die Interface - Human & Machine Safety- Utility and site condition- Manual, Spare Parts and Training

- Review of Specification of Request- Process and delivery- Long Lead Items- Transportation and Installation- Line commissioning and Running

Design Reviewwith

Customer

Design Reviewwith

Manufacturing

Note : Issues at a meeting to be recorded in the Minutes of Meeting.



Project Management Quality

■ Project PM and Project Engineers will be designated when order is received.

- Sharing Organizational Chart and Contact Information with Customer

PM Team Leader MS Yoon

PM Team Leader

MS Yoon

Project Manager

WS Jeong

Lead Engineer

MJ Lee

Mech.

Engineer

YS Kim

Elec.

Engineer

YH Kim

Manufacturing

KI Yook

Manager

JH Ha

Quality

PS Kang

Manager

SW Choi

Procurement

YM Hwang

Sales

KC Lee




■ Initial Project Schedule will be established with MS Project program and Milestone will be defined by PM together with Customer.




■ Project Schedule will be controlled and maintained by PM and

reported to the Customer through e-mail and regular conference call.

Recovery Plan, if delayed

Weekly Progress Report with Photo through e-mail and Conference call




■ Regular Visit and Face-to-face meeting will be held

- Project Kick-off Meeting- Design Review Meeting- Regular Progress Check Visit- Initial Acceptance Test- Installation Kick-off Meeting




■ Special attention will be taken to the long lead items.

- Early confirmation and approval on specification is required.




■ Kick-off Meeting for Installation will be held on site before installation.

- Installation team and system will be introduced to the Customer.

Foundation Inspection and Safety Fence Installation

15 30 15 30 15 30 15 30 15 30 15 30

150 1 105 45 150

90 1 63 27 90

Design. Q.A for FAT 30 3 63 27 90

Mechanical (2) 150 2 210 90 300 Press Installation & 2250T Crown Assembly

Piping (2) 120 2 168 72 240 2250T 1000T,Auto Line trial

Electrical (2) 120 2 168 72 240

WIA SUB-TOTAL 660 11 777 333 1,110

Isgec Mechanical - 1000T Press S/V 90 1 63 27 90 1000T Installeration S/V

Bokwang Mechanical - Automation S/V 70 2 98 42 140

Orion Electrical - Press S/V 135 1 95 40 135

H/Mechanics Electrical - Automation S/V 90 1 63 27 90

CONTRACTOR SUB-TOTAL 385 5 319 136 455

SITE PROJECT MANAGER 90 1 63 27 90

Installer 80 12 672 288 960

Piping 70 10 490 210 700

Electrical 70 8 392 168 560

Helpers 60 8 336 144 480 2250T Automatio 1000T

MEXICO LOCAL SUB-TOTAL 370 39 1953 837 2,790

Maintenance Mechanical 150 5 525 225 750

Electrical 120 5 420 180 600

Operator Operator 100 5 95 40 500

O.H Crane Driver 110 1 77 33 110

GM MEXICO SUB-TOTAL 480 16 1117 478 1,960

TOTAL 1895 71 4166 1784 6315

Division Day Man

Man-day 2007

2250TLine

2250TT/O

TOTALMay June July Aug Sep Oct

GM Mexico

Installer(WIA)

MexicoLocal

Presmec

WIA

Site manager

Electrical Engineer

Subcontractor

2250T 1000T

Installation Schedule with Man-power PlanRoute Survey and

Installation Layout Plan

Project Board Preparation



Press Quality Control Plan

DesignQualityControl

AdvanceQualityControl

Noncon-formanceControl

BasicStrategy

Ⅰ Reinforcement of internal quality system

Ⅱ

Ⅲ

Strengthen maker’s (ODM) product quality control system

Strengthen Sub vendor’s (OEM) product quality control system

DesignQualityControl

• Strengthen design review- Implement step by step review with customer- Implement internal review with engineering, production management & quality team

• Design reflection through lesson learned from previous similar projects

AdvanceQualityControl

• Casting and forging items• Stabilization of welding quality• Accuracy of machining items• Electric panel & motor• Sub Ass’y & general Ass’y

Noncon-formanceControl

• Nonconformance items management• Activity to prevent recurrence nonconforming products (Remind meeting)



Press Quality Control Plan

Design and Dwg. release

Manufacturing

Maker Self‐Inspection

Submit insp. report to HYUNDAI WIA

Inspection by Witness

Evaluation

Countermeasure plan for Improvement

Inspection Application to Buyer

NCR ON COMPUTERSYSTEM

1. Inspection standard (I.T.P)2. Schedule for inspection and

manufacturing3. Sub‐vendor list (Procurement items foreign purchasing itemsdomestic purchasing items)

NO

NO

< Quality Control Flow > < Non – Conforming Flow >

Non‐Conformance Occurrence

Inspection Discrepancy Report Or Inspection Report

Identification

M.R

Next Process

Corrective Action Plan

P.R

Customer MRBdisposition(if necessary)

Disposition

Repair Scrap Use as isRework

Inspection

AcquirementAuthority

NO

P.R = Preliminary ReviewM.R= Material ReviewM.R.B= Material Review Board



Inspection before Shipment

■ Full Initial Acceptance Test in the Pit and

Crown Driving Test under Sub-assembled condition



Press Service Center and Partner

Brazil – INCO GM Industria e Manutencao

Brazil – INCO GM Industria e Manutencao

Mexico -PressmecMexico -Pressmec

NA Service CenterNA Service CenterKorea –H WIA

Korea –H WIA

Thailand – JK T

Thailand – JK T

India –SMI India

India –SMI India

Poland -Comau

Poland -Comau

Russia - JK RRussia - JK R

China –H WIAChina –H WIA

Australia - SonnexAustralia - Sonnex



Press Service Process

• E-mail (To WIA service team)• Phone call (To responsible person)• WIA engineer customer site visit (BS)

Customer

ServiceReceive

TakeAction

FollowUp

• Problem analysis - Understanding the problem, finding

root cause etc.• Urgency judgment

- In case of emergency site visit within 6 to 8 hours

• Supply service man and A/S parts• Take proper action for countermeasure

• Recurrence prevention plan- Damaged parts return to WIA and

investigate and quality improvement plan

• Regularly keep in touch with the customer about problem inquiry

WIA SERVICE

TEAM

Service Center Service man

+

★ SERVICE OVERVIEW ★

Computerize Service

Information

HYUNDAI WIA CorporationSep. 5th , 2013 Contact Point : Kyu Cheon Lee / General Manager ‐ Industrial Machinery Sales Team

‐ Office : +82‐55‐280‐9473, Mobile : +82‐10‐3575‐9002, E‐mail : kcl@hyundai‐wia.com

Documents

11 Press Presentation 130905 [호환 모드] - Hyundai Wia MACHINE PLANER ... -Human & Machine Safety-Utility and site condition-Manual, Spare Parts and Training-Review of Specification