An update on the AMAG components master plan
Sustainable and efficient manufacturing of aviation components
AMAG components has initiated a comprehensive master plan (see AluReport 02/2023 and 03/2023) with the goal of delivering outstanding quality and efficiency standards for customers. Not only will the master plan elevate the Übersee and Karlsruhe production sites to a new level in technological terms, it will also ensure even more sustainable and efficient production. Following the successful completion of phase 1 at the end of 2023 and further investments in 2024, it is clear that the measures implemented to date have borne fruit and generated real added value for our customers.
Übersee: Upgraded technology and sustainable infrastructure
Barely a single stone has been left unturned at the Übersee site. The centerpiece of this modernization was a comprehensive redesign of Hall 2, with the installation of two state-of-the-art AeroCell 160 systems (Figure 1) representing a particular milestone. Not only do these systems significantly increase the site’s capacity to produce large-format aluminium components, they also achieve marked improvements in product quality. This also makes it possible to seize the full benefits of AMAG’s unique closed- loop setting. For our customers, this means even more precise processing accompanied by increased capacity to support the ramp-up of production for the aviation industry.
Another highlight of the Übersee overhaul was upgrading the site’s carbide processing capacity by adding two new Chiron machines for ultra-precise processing. This modernization was accompanied by a complete overhaul of the time-proven Fastems pallet-handling system, with updated software and control technology now providing even greater flexibility and efficiency. This investment has opened up new possibilities for digitalization of the production system. However, new standards have been set in Übersee for more than technology. A number of improvements have also been realized in relation to sustainability. The site’s infrastructure has been extensively modernized to protect valuable aluminium scrap effectively against the weather. In addition, the site’s power infrastructure has been upgraded to meet more stringent requirements. These measures contributed to a successful outcome of an environmental audit in accordance with ISO 14004. This means our customers can proceed with confidence in the knowledge that the products they receive are the result of environmentally responsible practices.
Karlsruhe: Center of excellence for top-class products
As we announced in AluReport 03/2024, AMAG is making targeted investments to expand the Karlsruhe site into a center of excellence for carbide and forged parts.
A modern MCM Clock Tank 1450 has been relocated to strengthen the carbide field in the short/mid-bed range, and a Bavius AeroCell 140 has been acquired to modernize the aluminium long-bed range. These have been accompanied by a range of other investments. Particularly noteworthy is the commissioning of a Hermle C62U system (Figure 2) - a stateof- the-art 5-axis machining center with a traverse path of 1200 x 1300 x 900 mm. Equipped with a pallet changer, a package of precision tools, automated tool measurement and integrated measurement sensors, this system combines precision with maximum productivity. These technologies make it possible to exploit the machine’s full potential in aluminium short-bed and forged parts.
Our customers benefit from first-rate quality along with swift and reliable manufacturing - a huge advantage, especially when it comes to sophisticated forged aluminium parts. A Burkhardt + Weber MCR 900 HVC, set to be commissioned in Q3 of 2025, will be another major step forward in terms of automation and quality assurance. This system also features an automated pallet changer as well as modern, integrated measurement technology. Thanks to its advanced technology, the Burkhardt + Weber MCR 900 HVC will make an important contribution to producing even the most demanding components with maximum precision and efficiency.
Investing in talent: A strong focus on the future
In addition to the modernization of its Übersee and Karlsruhe sites, the development of skilled workers is also a key priority for AMAG. Training workshops in Übersee and Karlsruhe been extensively renovated and equipped with state-of-the-art technology. At present, 15 apprentices in the fields of machining and informatics are benefiting from first-rate training conditions, which provide the ideal preparation for their future duties. While investing in talented youngsters indicates AMAG’s commitment to the future, it also provides benefits for customers, who can count on the expertise and knowledge of a welltrained workforce.
The AMAG components master plan An overview of benefits for customers:
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Innovative technology: State-of-the-art systems guarantee outstanding precision and efficiency.
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Higher product quality: Improved processes and systems deliver first-rate results.
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Sustainable production: Environmentally conscious measures lower our products’ carbon footprint and conserve resources.
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Future-proofing: Continuous investment secures our performance capabilities for the long term.
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Focus on skilled workers: Targeted training and support for our employees keeps their knowledge and skills at the highest level.
