Dürr Ecoclean supplies standard off-the-shelf PZR conveyors to Nemak in Mexico
05/29/2008
Wixom, Michigan (USA), May 2008 – Dürr Ecoclean, a 100% subsidiary of Dürr AG, has received an order from Mexico-based Nemak, a division of ALFA also based in Mexico. Dürr Ecoclean will supply standard Powered Zone Roller (PZR) floor conveyors to Nemak’s facility in Saltillo (Ramos Arizpe, Coahuila, Mexico). The customer selected standard off-the-shelf PZR because of its low power consumption, quick delivery, and low cost. Nemak will integrate over 100 modules of PZR into their line.
Nemak was established in 1981 and specializes in the production of aluminum cylinder heads. Nemak’s Saltillo location began operations in 1999 making engine head and block castings for a U.S. automaker. Products from Nemak are exported to the US, Canada, Europe, Australia, and Asia. Nemak Saltillo holds the Coahuila Award for Quality, was twice named GM Supplier of the Year, and has received the Perfect Engine Site Award and the National Award for Quality (Mexico). Currently they produce heads for several global engine programs.
Since their beginnings in 1981, Nemak have enjoyed an impresive growth rate with the purchase of facilities from Rautenbach, Hydro, Teksid, and Castech. They presently operate 29 plants in 13 different countries located in the Americas, Europe, and Asia.
Expanding one of their existing production lines, Nemak initially sought a turnkey program from several system suppliers. As the program developed, however, Nemak recognized the need to manage portions of the project internally in order to keep costs down and maintain quality. When the acquisition philosophy changed, timing became a leading factor. As part of the newly streamlined project, other Dürr Ecoclean technologies were purchased including an EcoCTrans transfer-style washer with a cooling tunnel and an HR Black Washer Filter.
To facilitate the need for speedy deployment, Dürr Ecoclean proposed off-the-shelf PZR floor conveyors which are in stock and readily available for shipment. Nemak, who already planned to contract the electrical controls locally, were attracted to the concept of catalog-standard conveyor products that are easy to deploy, integrate, and maintain. A notable selling point was the PZR’s energy savings over traditional conveyors for engine parts.
The scope of supply for the Nemak purchase was developed using Dürr Ecoclean’s 3D SnapPlanner software. The proprietary software comes with a catalog of standard PZR modules which can be dragged onto a virtual plant floor and snapped together to form complex conveyor paths. The easy to use software generates a graphical layout and a priced Bill of Materials which can be exported as a spreadsheet or emailed to Dürr Ecoclean.
With PZR, Dürr Ecoclean is helping the customer keep to a tight schedule by providing a product that is easy to install, available quickly off-the-shelf, and that caters to the customer’s preference for local controls and installation support. Additionally, PZR is ideal for future line reconfigurations or expansions since it is made up of pre-engineered modules which can be rearranged easily, like building-blocks.
The PZR concept is simple. Standard PZR conveyor modules are arranged in a series of “zones,” with each zone driven by a bi-directional motor. Parts are driven out of a zone only when the next zone is vacant, so parts do not bump up against other parts, and no pallet is required to keep parts from touching. Parts ride directly on the PZR’s rollers which can be supplied as plastic rollers or optional steel. The spacing between rollers can be adjusted to suit different parts making the PZR system reusable should the customer’s part type change in the future.
PZR operates only when a part enters or exits its zone, as opposed to traditional engine production conveyors which run continuously. Reduced operating time results in energy efficiencies and dramatic cost savings through reduced power consumption. Safety is improved as well because PZR eliminates the numerous pinch points and finger traps found in part-to-part accumulating systems.
PZR fits well with Nemak’s production plans at the Saltillo facility. Machining of 4-cylinder heads will be accomplished by horizontal machining centers with loading and unloading via manual hoist to and from the PZR conveyors. After the EcoCTrans washer, parts will index atop the PZR to inline gauge and leak-test operations. Three operations will be performed directly on top of the standard PZR conveyor: a marking station, water jacket plug insertion & screw station, and an inspection table. PZR will also carry parts to the manual pack-out area at the end of the line.
About Dürr Ecoclean
Dürr Ecoclean Group is the leading provider of solutions for industrial cleaning, automation and filtration. The group supplies the automobile industry, their suppliers as well as general markets around the globe with innovative standard systems, as well as tailor-made system solutions and services. Dürr Ecoclean is a member of the Dürr Group and represented in Germany, France, Czech Republic, USA, China and India.
Dürr is a mechanical and plant engineering group at the top of the world market in its areas of activity. It generates about 85% of its sales in business with the automotive industry. It furthermore supplies sectors such as the aircraft, machinery, chemical, and pharmaceutical industries with innovative production and environmental technology. The Dürr Group operates in the market with two divisions. The Paint and Assembly Systems division supplies production and painting technology, especially for car bodies. Machinery and systems from the Measuring and Process Systems division are used in engine and transmission manufacturing and in final vehicle assembly, among other areas. Worldwide, Dürr has 47 business locations in 21 countries.
Contact:
Dürr Ecoclean
Juan-Pablo Fernández
Sales & Value Service Manager, Mexico
Dürr Ecoclean Inc. - Cleaning and Filtration Systems
Tel: +52(55) 9171-1594
eFax: +52(55) 1084-7472