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The
Final Project for this module will be completed in three deliverables and
submitted in Weeks 4, 6, and 8. You will have a choice of two companies for
your project, but you only need to focus on one organisation for all three of
the project deliverables. The purpose of the Final Project is to apply the
concepts and techniques of the module to the development of the following:
·
Energy monitoring programme for all facilities within
the organisation selected
·
Benchmarking of energy conserving measures in the
respective industry that might be relevant to the organisation of choice
·
Descriptive analysis (pros/cons) of potential
investments for each facility to reduce energy consumption by facility
·
Discussion of appropriate methods to use for
evaluation investment options
·
Recommendations/prioritisation regarding measures to
be implemented by each facility
Organisation A:
Yundai Forging
Yundai
is a Korean-based manufacturer specialising in the provision of heavy equipment
and automobile parts. The organisation’s product portfolio consists of track
chain groups for excavators and tractors; roller groups such as shafts, seals,
collars and bushings; crank shafts and connecting rods; sprockets, tooth and
segments, as well as forging parts. The facility has two manufacturing
operations in South Korea, one manufacturing operation in Malaysia, and one
manufacturing operation in India. The organisation employs 2,250 people.
For
the past 30-odd years, Yundai’s products expanded from one industrial segment
to another and eventually into defence products that require one of the most
stringent quality and durability standards spelled out by U.S. Department of
Defence Specifications, adopted by the Korean Armed Forces.
Yundai
has several different forging capabilities at its different facilities:
Open
Die Forging
This
process is known as hand, Smith, and hammer forging and is applied to all
forgeable metals, ferrous and non-ferrous. Forgings are made by this process
when:
·
They are too large to be produced in closed dies
·
The mechanical properties from a bar or billet needs
improvement
·
The quantity required is too small
Closed
Die Forging
This
process is the shaping of hot metal completely within the cavities of dies and
applied to all forgeable metals, ferrous and non-ferrous. Forgings are made by
this process for:
·
High volume products
·
Tight tolerance products
·
Complex shapes
Upset
Forging
This
process enlarges and reshapes a cross-sectional area of a bar, tube, or other
product form, and is applied to all forgeable metals, ferrous and non-ferrous.
Forgings that are made by this process include:
·
Bolt head shapes
·
Shaft with flange shapes
|
Roll Forging
|
|
This process reduces the cross-sectional area of
bars of billets by passing them between two driven rolls, and applied to all
forgeable metals, ferrous and non-ferrous. Forgings that are made by this
process include:
·
Propeller blade shapes
·
Tapered axle shaft shapes
·
Continuous uniform shapes
Draw Forging
This closed-die forging process allows the work
metal to be deformed at unusually high velocities and applied to all
forgeable metals, ferrous and non-ferrous. Forgings that are made by this
process include:
·
Deep, thin sections
·
Severe deformation
·
Symmetrical shapes
Manufacturing Facilities:
The Yundai organisation has four manufacturing
facilities including the following:
·
Masan, South Korea: This facility within Yundai
offers the flexibility to meet both the medium and high-volume parts needs of
customers with capability in all five forging methods. This facility can
produce parts from the full range of carbon, alloy, and microalloy steels, in
diverse shapes and sizes from one to 100 pounds. The facility’s capabilities
include induction coil preheat systems, die-making equipment (including CNC
electric discharge machines), electric induction heating units, open die
forging systems, and the most advanced, highly productive vertical press
operation in the facility. With point-to-point transfer that utilises a fully
automated walking beam, the 2,500-tonne, five-station press will produce
parts at the rate of one every two seconds.
·
Kunsan, South Korea:
This facility within Yundai offers the flexibility to meet both the
medium and high-volume parts needs of customers with capability in all five
forging methods. The centrepiece of this facility is a 2,500-tonne fully
automated transfer press. Work pieces are moved continuously through the
computer-controlled five-station press by a walking beam mechanism, emerging
as forged parts at a rate of 30 pieces per minute or one every two seconds.
The forging cell is integrated with a 2500kW billet heater. Temperature is
automatically monitored and controlled as induction coils superheat up to 170
pounds of steel billets every minute to a temperature of more than 2100° F.
Induction heating provides uniform, efficient billet heating with minimal
scale formation for better surface quality of forgings and extended die life.
·
Kuantan, Malaysia: This facility(the newest in the Yundai family)has
the newest forging equipment including:
o
HBP-100 forging unit with a maximum diameter of 67
mm and maximum weight of 500 gm
o
AMP50-XL forging unit with a maximum diameter of
104mm and maximum weight of 2 kg
o
AMP70-XL forging unit with a maximum diameter of 168
mm and a maximum weight of 5 kg
This
facility has a series of induction heaters, high-speed milling machines (for
direct milling), CNC milling machines (for graphite electrodes), die sinkers,
specialised In-Sight Vision system, heat treatment furnaces, and more.
·
Taluka Wada,
India: This facility includes upset forging and die-forging equipment, a
variety of friction screw presses and drop hammers, and a state-of-the-art
heat treatment setup to cater to its heat treatment requirements. In
addition, this facility hasa series of induction heaters, high-speed milling
machines (for direct milling), CNC milling machines (for graphite
electrodes), die sinkers, specialised In-Sight Vision system, and heat
treatment furnaces.
Yundai in total owns the
following facilities:
|
Type
of Facility
|
Location
|
Principal
Activities
|
Products
Made
|
|
Corporate Office
|
Kunsan, South Korea
|
Corporate oversight (50,000
sq. metres)
|
No products are made from this location
|
|
Regional Office
|
Mumbai, India
|
Regional Sales Office (20,000
sq. metres)
|
No products are made from this location
|
|
Regional Office
|
Masan, Malaysia
|
Regional Sales Office (15,000
sq. metres)
|
No products are made from this location
|
|
Manufacturing Facility
|
Motka, Finland
|
Manufacturing
|
Forged ferrous and non-ferrous metal products
|
|
Manufacturing Facility
|
Voala, Finland
|
Manufacturing
|
Forged ferrous and non-ferrous metal products
|
|
Manufacturing Facility
|
Kuantan, Malaysia
|
Manufacturing
|
Forged ferrous and non-ferrous metal products
|
|
Manufacturing Facility
|
Taluka Wada,
India
|
Manufacturing
|
Forged ferrous and non-ferrous metal products
|
|
|
Organisation B: Motkamills
Motkamills
is a forest products organisation based in Finland. The organisation
specialises in laminating paper, matt coated bulky paper, and sawn products.
Motkamills has three production plants in Finland and a production plant in
Sweden—all of them strategically located for excellent customer service and
logistics.
The
annual production capacity of Motkamills is 300,000 tonnes of Trisorbex Kraft
Paper, 80,000 tonnes of Imprex products, 280,000 tonnes of Tolaris paper, and
330,000 m³ of sawn timber. The organisation employs 1,570 people.
Motkamills’
products are valued all over the world for their excellent and uniform quality.
The facility is also known for its accurate service and technical know-how,
which it gladly shares with its key customers. Trisorbex, Imprex, and Tolaris
are well-known brands that are the result of several decades of customer
orientation and extensive R&D work.
The
organisation’s own pulp mill in Motka is the biggest consumer of sawdust in
Finland (nearly one million solid cubic metres annually) and the only pulp mill
in the world that exclusively uses sawdust as a raw material.
Products:
Trisorbex
Motkamills
is a leading global producer of core material for decorative high pressure
laminates. With nearly 50 years’ experience in the production of Trisorbex
Kraft Paper, the product range covers virtually all unbleached saturating base
kraft grades used throughout the world.
The
latest paper grade development is called Trisorbex Eco—ecological and
quality-competitive material for the production of laminates. The raw fibre
materials used for Trisorbex Eco are forest industry by-products, sawdust, and
recycled fibre.
Typical
applications of Trisorbex are decorative and industrial high pressure laminates
(HPL) including compact and post-forming laminates and continuously pressed
laminates (CPL), as well as different types of electrotechnical and technical
products. Trisorbex has a wide range of tailor-made paper grades with basis
weights ranging from 30 g/m² to 245 g/m².
Imprex®
Imprex
Core Stock is a resin-treated core material for high-pressure laminates used in
various decorative and industrial applications. During its manufacturing,
Trisorbex kraft paper is treated with thermosetting resins. Therefore, Imprex
Core Stock is a converted form of Trisorbex and is used in similar end-use
applications to Trisorbex.
Imprex
Surface Films are phenolic resin treated products designed for wood-based
panels used in concrete shuttering and in the transport and construction
industries for overlaying of both hardwood and softwood based panels such as
plywood, particle board, fiberboard, blockboard, and oriented strand board
(OSB). In addition to Imprex Surface Films, the product range includes Imprex
Glue Film developed for gluing the veneers together in furniture manufacture,
and Imprex Painting Film used as a painting base on wooden panels.
The
latest development in weatherproof overlays is Imprex Novox, a non-phenolic,
special thermosetting and flexible product that tolerates tough weather
conditions well, especially UV light. Imprex Novox is used for wood-based floor
and wall panels, digitally printable panels, and furniture surfaces.
Imprex
products are produced both in Finland and Sweden.
Tolaris
Tolaris
is a stiff matt-coated magazine paper that is mainly designed for heat-set Web
offset printing (HSWO). It has a bulk that guarantees a high yield, and is an
economical alternative for the customer. Tolaris gives magazine publications
extra character with a combination of high bulk and excellent brightness and is
available in different bulks for differentiation of client publications.
Tolaris’s
competitive advantages are strength and the optical properties, printability,
and runnability of the product. An important quality aspect is the gloss
contrast between the printed and unprinted surface. Tolaris is used in
magazines, books, catalogues, leaflets, supplements, and inserts.
Tolaris
is made of thermo mechanical pulp (TMP) and bleached chemical pulp. Tolaris is
produced with basis weights of 48 to 75 g/m².
The
EU ecolabel has been granted for Tolaris products.
Wood
Motkamills’
sawmill is an efficient and modern facility that produces high-quality spruce
products for demanding joinery and construction purposes.
The
main end uses of the sawn products are profile boards, planed-around items,
different types of home building materials, glued beams, basic construction,
and packaging. The sawn products have high strength properties, a visually
high-class appearance, and are an excellent choice for the end uses.
Motkamills’
sawmill also has a planing mill, producing primarily profile boards for various
markets. Spruce logs are procured from certified forests in Finland and Sweden.
Facilities
Motkamills
has the following facilities:
|
Type
of Facility
|
Location
|
Principal Activities
|
Products Made
|
|
Corporate
office
|
Heinola,
Finland
|
Corporate
oversight (40,000 sq. metres)
|
No
products are made from this location
|
|
Regional
office
|
Hamburg,
Germany
|
Regional
Sales Office (10,000 sq. metres)
|
No
products are made from this location
|
|
Regional
office
|
Barcelona,
Spain
|
Regional
Sales Office (10,000 sq. metres)
|
No
products are made from this location
|
|
Manufacturing
facility
|
Motka,
Finland
|
Manufacturing
|
Trisorbex,
Tolaris, Imprex, and wood
|
|
Manufacturing facility
|
Voala,
Finland
|
Manufacturing
|
Trisorbex,
Tolaris, Imprex, and wood
|
|
Manufacturing facility
|
Mikkeli,
Finland
|
Manufacturing
|
Trisorbex
and Imprex
|
|
Manufacturing facility
|
Katrineholm,
Sweden
|
Manufacturing
|
Trisorbex,
Tolaris, Imprex, and wood
|
Week 4 –
The project proposal is the first deliverable of the Module Project. For this
week, choose one of the two organisations, Yundai Forging or Motkamills, and provide reasoning for
selecting the particular organisation as it relates to managing energy.
Be sure to incorporate the
topics below in your proposed project proposal:
·
Identify background information of why you chose the
particular organisation as it relates to your understanding of managing energy
sources
·
Recommend an energy monitoring programme for all
facilities within the selected organisation
·
Evaluate the potential for benchmarking of energy
conserving measures in the respective organisation that might be relevant
·
Provide references to similar companies within a
similar geographic location for reference
