Video Georg Fischer Linamar Foundry USA

Background

GF Linamar is a joint venture between the Swiss Georg Fischer Group (GF Casting Solutions) and the Canadian LINAMAR Corporation.

GF Casting Solutions is a leading manufacturer of aluminum and magnesium die-cast products for the automotive industry with a high level of expertise in structural components. GF Casting Solutions operates die-casting plants in Austria, Germany, and China. 
LINAMAR stands for diversified industrial goods with a high level of expertise in mechanical processing.

With this joint venture, GF Casting Solutions intends to establish a plant in the USA and supply the US market with structural components. The new plant will implement the state-of-the-art manufacturing concepts of the parent plants in Austria and Germany and will be able to respond flexibly to quantities, product mixes, and production volumes.

GF Linamar commissioned PI to handle everything from the design to the complete implementation of the new plant.

Results

• Factory put into operation
• Fully automated production
• Standardised production cells (casting cells)
• Scalable capacities, flexible growth potential in different production areas
• Implementation of the highest standards of occupational safety, environmental protection and energy efficiency

PI services

Factory planning, process planning, logistics planning

Concept design
analogous to VDI 5200, phases 1 to 3

• Manufacturing segments and organization defined
  • Smelting: Shaft melting furnaces specialised for return material from large structural parts, testing laboratory, furnace workshop, local melting at the casting cell for Mg components
  • Foundry: Fully automatic casting cells in separate hall bays for large and very large die-casting machines (up to 44 MN), flexible use for aluminium or magnesium components as well as for process steps such as deburring station, cleaning/sawing cell, blasting system, etc.
  • T6 heat treatment with air quenching
  • Mechanical processing
  • Tool and machine maintenance
  • Measuring rooms, laboratories
  • Office and social areas, energy and media supply, IT networks
• Logistics concept (material flow, conveyor systems, warehouse sizes) created
• Resources (personnel, equipment, buildings, infrastructure) dimensioned
• Rough concept for plant development created
  • Investments, costs
  • Layout Start and gradual expandability
  • Master plan for implementation

Detailing
analogous to VDI 5200, phases 4 and 5

• Detailed manufacturing segments
• Machine layout plan created
• R+I diagram for media supply and disposal created
• Requirements for construction and infrastructure specified (specifications)
• Tender for construction and infrastructure accompanied, quotations obtained and prepared for award
• Supported the client in selecting the general contractor (for construction and infrastructure)
• Interfaces with engineering offices for construction and technical development serviced
• Budget and schedule created

Implementation
analogous to VDI 5200, phases 6 and 7

• Details agreed with suppliers
• Interfaces with customers (planning, production, maintenance) and other suppliers or service providers (construction, media, crane service, etc.) coordinated, solutions developed
• Proper provision of individual services monitored and controlled
• Support provided to client during factory start-up
• Overall layout updated
• Budget (investments) tracked

Topics

Factory planning: Value stream, production segments, material flow, layout, scalability, step-by-step expansion, facilities/infrastructure/buildings, cleanliness, environmental protection

Process planning: Process engineering, plant engineering, simulation of capacity requirements, automation, interlinking, energy efficiency, IT, control technology, machine and process data acquisition, Industry 4.0

Logistics planning: Simulation of movements/inventories, load carrier design, conveyor technology: Warehouse technology/transport technology, fire protection

Trades

Charging, melting, dosing, casting, spraying, removing, cooling, deburring, burr disposal, marking, cleaning, heat treatment T6, testing, straightening, mechanical processing, packaging, transporting, storing; automation, interlinking Buildings, pits, foundations, ventilation technology, cranes, media, infrastructure