54
Investing in good connections
Kale Clamps,
Tuzla-Istanbul
The Kale Group has been manufacturing worm drive hose clamps since 1996. In the last year the
company has doubled its production capacity and made major investments to assure the quality and
performance of its products.
The Kale Clamp factory is located south east of Istanbul on the Anatolian side of the Sea of Marmara. It is ten years since the company moved to
a modern production facility although it shows no sign of that age. A total of 75 people work a two-shift system mainly producing Kale’s WD series
9mm and 12mm band worm drive clamps to DIN 3017. Six material combinations are offered, ranging from zinc-coated steel through the corrosion
resistance spectrum to AISI 316 stainless steel, with a number of screw head variants.
The production floor is scrupulously clean, evidently the result of regular
housekeeping and not special preparation for visitors, as well as efficiently laid out – in
all aspects a credit to plant manager Safiyettin Çamur. Pride of place are two new
Bihler, high-speed, automatic machines, the acquisition and installation of which last
year doubled Kale’s capacity to make clamp housings, as well as delivering increased
precision and efficiency. The patented housing is designed as a single piece, utilising a
mechanical locking system to resist higher torque values and avoid misshaping as a
result of the axial and radial forces exerted during tightening.
At the other side of the plant, four presses produce bands with the smooth
internal surfaces and the convex edges required to obviate damage to, particularly
soft, rubber hoses when the clamp is installed. In common with other hose clamp
manufacturers Kale sources the final component, the screw, externally. Production is
computer controlled using bar code technology to allow immediate oversight by the
plant management as well as full traceability of materials. The company is using the
technology to apply lean manufacturing principles that allow it to work closer to a just
in time basis for both material supplies and finished goods.
Kale also manufactures a range of CC series retaining clamps to DIN 3016, which
have an EPDM (ethylene propylene diene monomer) or neoprene lining suiting them
particularly to vibration environments, where cable, hose or pipes need additional
protection against deformation.
The company manufactures its own tooling in a well-equipped facility, employing
electrical discharge technology in addition to other machining techniques. The tool
making resource and expertise enhances Kale’s ability to respond to specific customer
requirements, a point that Safiyettin Çamur reinforces by showing a prototype
manufacturing set-up in development on the production floor.
The laboratory, located close to the main production floor, houses a tensile tester
for checking incoming band materials as well a profile projector and a range of
other modern physical testing equipment for assessing the screws. For production
quality the laboratory has sensitive torque and clamping force equipment to assure
the performance of finished worm drive clamps. A new salt spray cabinet is due for
installation so that Kale can carry out its own corrosion tests. The laboratory evidences
a clear commitment to produce and assure a quality product.
Eight percent of Kale’s sales are to automotive tier suppliers, primarily in Turkey,
leading to ultimate fitment to Ford and PSA vehicles, as well as other well-known
commercial vehicle and agricultural brands. The company is accredited to TS 16949
by DEKRA. Ninety percent of sales, though, are export - servicing some thirty-five
countries worldwide including the USA and several Asian markets in addition to most
of Europe.
Elvan Şenörer joined Kale a year ago as sales manager. Qualified as a chemical
engineer her background in automotive hose technology is clearly invaluable to Kale.
She emphasises three key areas of competence for Kale Clamps – competitive prices;
responsiveness to customer requirements; and European production techniques.
“Working with the automotive sector in Turkey has driven Kale’s approach to
quality, flexibility and responsiveness to the customer,” she explains. Essentialy Kale’s philosophy is simple although the commitment required to
deliver it should certainly not be underestimated. Elvan Şenörer expresses it succinctly: “We know what we are and we are constantly working to
get better at it.”
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