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Y o u r p a r t n e r i n f i n e b l a n k i n g
PRODUCTION PLANTS
THE TECHNOLOGY OF ELAY GROUP
THE WORLD OF FINE BLANKING
ELAY GROUP: INTRODUCTION
OUR PRODUCT
ELAY GROUP: INTRODUCTION
VISIONHISTORYORGANISATIONDATA AND EVOLUTIONCUSTOMERS AND MARKETSQUALITY POLICYR+D POLICYENVIRONMENTAL POLICYOCCUPATIONAL RISK PREVENTION POLICYHUMAN FACTOR
“ELAY is
a global company, leader
in technology, quality and
innovation
that
guarantees
the
involvement
and
satisfaction
of
people
by offering
high‐performance products, meant
to
bring
the
highest
possible
value
to
clients
through
fine blanking
technology
and/or
other technologies
in the
automotive
industry
and
others”.
Introduction: VISION
After more than 40 years of history,…
1996
Constitution
of
ELAY Group
on
January
1st, 1996. Expansion
in 2.500 m2
and construction of
new
offices
in Antzuola
production
plant
(Spain).
1999
Additional
expansion
of
1.300 m2
of
Antzuola
production
plant.
2000
Oficial inauguration
of
CELAY, S.A. de C.V. (Mexico),
a fine blanking, heat
treatment
and
overmoulding
plant
of
10.500 m2 and
a total area of
77.000 m2.
2010
Creation
of
ELAY USA Inc. in Michigan, the
USA sales office.
1970
1982
2010
Introduction: HISTORY
Introduction: ORGANISATION
EUROPE• Spain: HQ Elay Group Production
Plant
• Germany: Commercial Office
AMERICA•Mexico: Production
Plant
• USA: Commercial Office
Introduction: DATA AND EVOLUTION
TOTAL SALES2010 MIO. € 39 16,5 55,5
TOTAL PERSONNEL 220
191 411
Europe America Total
340350360370380390400410420430
2006 2007 2008 2009 2010
TOTAL PERSONNEL
0
10
20
30
40
50
60
2006 2007 2008 2009 2010
TOTAL TURNOVER (Million €)
Introduction: CUSTOMERS
AND MARKETS
Introduction: CUSTOMERS AND MARKETS
USA
MEXICO
BRASILARGENTINA
GERMANYFRANCEIRLANDG. BRITAINPORTUGALITALYHOLLAND
CHINAEGYPT
SOUTH AFRICA
SINGAPORE
AUSTRALIA
Markets
DENMARKPOLANDCHEQUIASWITZERLANDTURKEYROMANIAHUNGARYAUSTRIA
Introduction: QUALITY POLICY
The
concept
of
“quality” in ELAY Group includes:
The
strategy
of
the
company Moving
towards
TQM.
The
product: “ISO Certificate”
for
the
companies
of
the
Group:ISO 9001, ISO/TS 16949, QS 9000, ISO 14001,
OHSAS 18001:1999
A spirit
of
quality
and
service
Introduction: R+D POLICY
Innovating
with
our
customers
Experience
and
know‐how
Constant innovation
Shared
profit
Substitution
of
other
technologies
Colaboration
CERN‐
ELAY Group
Introduction: R+D POLICY, Substitution
of
other
technologies
FROM CONVENTIONAL STAMPING TO
FINE BLANKING
FROM CASTING TO FINE BLANKING
FROM ALUMINIUM INJECTION TO FINE BLANKING
FROM LASER TO FINE BLANKING
Introduction: R+D POLICY, Collaboration
CERN‐ELAY GROUP
Particle
acceleration
project
(LCH).
PARTS MANUFACTURED IN STAINLESS STEEL WITH HIGH MANGANESE CONTENT AND LOW CARBON CONTENT.
MAXIMUM DIAMETER 500 MMS.
Introduction: ENVIRONMENTAL POLICY
The
management
of
our
operation
is
in compliance
with
the
ISO 14001 standards.
We
understand
the
RPP like
a strategic
area of
management.
The
management
of
the
RPP is
in compliance with
the
OHSAS 18001:1999 standards.
Introduction: OCCUPATIONAL RISK PREVENTION POLICY
Introduction: HUMAN FACTOR
University
graduates
(more than
3 years): 31 University
graduates
(three
year
degree): 77
Technical
certification:
167Without
degree:
136
Total personnel:
411 Average age:
37 years
Languages
spoken: 5
Individually
tailored
training programs.
Continuous
training programs.
Other
data:
Personnel
fulfillment
THE WORLD OF FINE BLANKING
ELAY GROUP: INTRODUCTION
THE TECHNOLOGY OF ELAY GROUP
OUR PRODUCT
PRODUCTION PLANTS
THE WORLD OF FINE BLANKING:
DESCRIPTIONPROCESSADVANTAGES
DESCRIPTION:
Fine
blanking
is
a unique
metal forming
process; it
is
a cold forming
process
for
high
volume
production
of
precision
components. Developed in Europe in
the
1920's, its
use
is becoming
more widespread
as engineers
discover
the
value
fine
blanking
can provide in improving costs and improving quality in critical components.
PROCESS
Fine versus conventional
blanking
FINE BLANKING PROCESS
CONVENTIONAL PROCESS
FINE BLANKING TECHNOLOGY: ADVANTAGES
•Production
of
highly
precise parts, with
homogeneous
quality
at a lower
price.
•Outer
and
inner
shapes
with
straight
and
clean
cuts
(up to
16 mm).•Option
of
making
small
holes
with
diameters
and
gaps
relative
to
the
material thickness.•Flat sides
impossible
to
achieve
with
conventional
stamping.
AS A CONSEQUENCE,... ELIMINATION OF COSTLY SECONDARY OPERATIONS
OUR PRODUCT
ELAY GROUP: INTRODUCTION
THE WORLD OF FINE BLANKING
THE TECHNOLOGY OF ELAY GROUP
PRODUCTION PLANTS
OUR PRODUCT
ADDED-VALUE FINE BLANKING
PROTOTYPES
ASSEMBLIES
ADDED‐VALUE FINE BLANKING:Product
Range
amplitude
> Automotion
Car
body system
Transmision
system
Braking
system
Seating
system
Closure
systems
Security
system
Exhaust
and conexion
system
ADDED‐VALUE FINE BLANKING:Diversity > Other
industries
Gardening
tools, cutlery
parts, home appliances, computers, building
elements,
nuclear industry
components,...
ADDED‐VALUE FINE BLANKING:Secondary
operations
FB+GRINDING
FB + INDUCTION
TEMPERINGFB+BAND‐
GRINDING+BENDING
FB+ DEBURRING+BAINITICTEMPERING+ NICKEL‐CHROME
COATING + PLASTICOVERMOULDING
FB+CATAPHORESIS
FB+ DEBURRING+COATING +
PLASTIC OVERMOULDING
Possibility
of
modifying
parts´s
preliminary
design.
Possibility
of
testing
product
operation
in a cost‐effective
manners.
PROTOTYPES:Development
in collaboration
with
our
customers
CAR BODY
PROTOTYPE PARTS FLANGE PROTOTYPES
ASSEMBLIES:
FB+COATING+CONVENTIONALSTAMPING PART + WELDING
FB+ THREADING +
NUT ASSEMBLY
FB+ ASSEMBLY FB+ CONVENTIONAL
STAMPING PART + WELDING
FB+ FINE BLANKING
PART ASSEMBLYFB+BENDING+
COATING+CONVENTIONALSTAMPING PART + ASSEMBLY
THE TECHNOLOGY OF ELAY GROUP
ELAY GROUP: INTRODUCTION
THE WORLD OF FINE BLANKING
OUR PRODUCT
PRODUCTION PLANTS
STATE‐OF‐THE‐ART TECHNOLOGY IN ALL PROCESSES
IN FINE BLANKING DIES IN FINE BLANKING OVERMOULDING IN SECONDARY OPERATIONS
STATE‐OF‐THE‐ART TECHNOLOGY IN ALL PROCESSES:> In Fine Blanking
Dies
Achievement
of
increasingly
complex geometric
forms.
Quicker
completion
of
delivery
times.
DESIGN EDM MACHINING FINISHED PRODUCT
STATE‐OF‐THE‐ART TECHNOLOGY IN ALL PROCESSES:> In Fine Blanking
FINE BLANKING PRESSE
AUTOMATIC FEEDING CELLS
FEINTOOL PRESSES WITH AN AVERAGE LIFE OF 5/6 YEARS
Feintool
presses
from
320 to
1.100 tns.
Automatic
feeding
cells.
Feintool
presses
with
an
average life
of
5/6 years.
STATE‐OF‐THE‐ART TECHNOLOGY IN ALL PROCESSES:> Overmoulding
AUTOMATIC FEEDINGCELLS
OVERMOULDING CAPACITY
TOOLING TECHNOLOGY
Overmoulding
capacity
in Europe
and
Mexico.
Automatic
feeding
cells.
BATTELFELD and
RICO plastic
injection
machines.
STATE‐OF‐THE‐ART TECHNOLOGY IN ALL PROCESSES:> Secondary Operations
Integrated processes:
Bainitic tempering, Nickel‐Chrome
coating, grinding, band‐grinding, deburring, welding and bending.
Subcontracted processes: Machining, thermal
treatments, various coating, assembly, etc.
PRODUCTION PLANTS
ELAY GROUP: INTRODUCTION
THE WORLD OF FINE BLANKING
THE TECHNOLOGY OF ELAY GROUP
OUR PRODUCT
PRODUCTION PLANTS
ELAY (HQ)(ANTZUOLA, Spain)
CELAY(CELAYA, Mexico)
ELAY
•
Covered surface: 10.110 m2
out of 17.878 m2
•
Activity: Production of fine blanking dies and parts. Secondary operations.
•
Machinery: FEINTOOL fine blanking presses from 320 Tns
to 1.100 Tns. “AGIE”
y “CHARMILLES”
EDM machines. Plant
equipped with all the necessary peripherals. BATTENFELD and RICO plastic injection machines. Double face grinding. Band grinding.
•
Personnel: 220•
Certificates:
ISO 9001, ISO/TS 16949, ISO 14001, OHSAS 18001:1999
CELAY
•
Covered surface: 10.500 m2
out of 77.000 m2
•
Activity: Production of fine blanking parts. Bainitic
tempering andNickel/Chrome coatings. Plastic overmoulding.
•
Machinery: FEINTOOL fine blanking presses from 320 Tns
to 800 Tns. Plant equipped with all the necessary peripherals. BATTENFELD and RICO plastic injection machines. Bainitic
tempering and Nickel/Chrome coating facilities.•
Personnel: 191•
Certificates:
ISO 9001, ISO/TS 16949
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