Ready for take-off
The AMAG components Masterplan Phase 1 is complete.
As extensively detailed in AluReport 01/2023, AMAG components has drawn up a master plan, charting the future direction of the company. This masterplan, which will be implemented in several phases at the company’s Übersee and Karlsruhe sites, aims to improve all operational KPIs with the aim of giving customers the best possible service.
This includes increasing the output of high-quality products in shorter periods and by agreed deadlines. Phase 1 involved focusing the companies’ sites on their respective core competencies and making targeted investments in modernizing the manufacturing facilities at both sites. We are proud to report that Phase 1 proceeded precisely on schedule and has now been completed. We reviewed every inch of the Übersee site in 2023. This included regrouping a considerable number of systems to optimize internal material flows and create space to add new, high-productivity systems. A stated aim of this initiative was to increase our production capacities in existing production halls.
Large aluminium components
In Hall 2, the focus is now on aluminium components measuring up to 4.0 m in length (Figure 1). The first step in increasing the output of this area was commissioning two state-of-the-art, semi-automated Bavius AEROCell machining centers. Following their installation on schedule, the new machining centers in Übersee were officially opened on September 6, 2023, by the Management Board of AMAG Austria Metall AG and the Management Board of AMAG components for Übersee and Karlsruhe. This concluded the first step in implementing the masterplan at the Übersee site.At the Karlsruhe site, the first Bavius high-performance machining center for aluminium parts up to 4 meters in length was installed in May and has since entered series operation. The investment in identical machines at both AMAG components production sites offers additional certainty for customers by providing redundancy and minimizing risks.The newly procured, state-of-the-art machining centers also expand the company’s expertise in the processing of large-scale aviation components. By making these investments, AMAG components has laid further foundations, ensuring it is able to support customers in the aviation industry with the anticipated ramp-up. The combination of AMAG components’ locations, the foundry and rolling mill in Ranshofen, and its systematic focus on the sustainable production of innovative, specialist products make AMAG a globally unique supplier to the aviation industry.
Small carbide components
Two new twin-spindle machining centers made by Chiron (Figure 2) have been commissioned in Übersee to facilitate processing of small carbide components with block dimensions up to 600 mm. Thanks to foresighted planned by the project team, there is now sufficient space to supplement the pair of machines with a third production system. All production systems for small and medium-sized parts measuring up to 1.5 m in length are gathered in Hall 1, with all systems for medium-sized parts connected to a Fastems pallet handling system. Hall 1 also houses the mechanical processing of not only aluminium components but also titanium and steel components. We will report on the implementation of the masterplan for AMAG components’ Karlsruhe site and measures to make it a center of excellence for carbide in a subsequent issue of AluReport.
Benefits for customers:
The masterplans for the AMAG components sites in Übersee and Karlsruhe deliver long-term certainty for customers, who can feel further assured of receiving structural aviation components on time and of the requisite quality. This is ensured by modern, future-proof machinery, a systematic focus on customers’ requirements, efficient processes, dedicated employees and economically sustainable use of resources.
From plates to finished parts
The vertical integration of AMAG’s setup presents a further advantage, namely its ability to offer products in its Al4®ever range as finished, ready to-install components. AMAG components’ two production sites for aviation components in Übersee and Karlsruhe procure 100% of their energy requirements from renewable sources and also process and recycle their materials. Consequently, choosing Al4®ever plates from AMAG also presents an opportunity for our customers to acquire AMAG Al4®ever certification - for components for use in the aviation industry, too. A significant aspect of Phase 2 of the masterplan in Übersee is overhauling and expanding the site’s sward processing activities. Material separation and recycling are established practice at AMAG and must now be adapted for the rising production volumes at AMAG components.
