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INDUSTRY NEWS/行業新聞


100 jobs at the Hasloch site. Tis resulted in invest- ments amounting to 12 million euro for what is probably the world’s most modern hand mold foundry, a further significant milestone in the over 235-year history of the company, which has included iron casting in its core competences since 1852. Today, the broadly-based product range encompasses,


among other things, planetary carriers, machine beds and pump housings for well-known customers from such branches as mechanical engineering, drive engineer- ing, power engineering, vehicle construction, vacuum engineering and wind energy. A study commissioned in advance attests to the necessary potential for the Kurtz product range to utilize the full capacity of the iron foundry with the production of high-quality cast iron parts for German industry in the future as well. From this, the parties involved in the project have


developed a creative solution which illustrates the trend to “Industry 4.0” and leads to a doubling of productiv- ity with increased efficiency. Te concept: Exploiting as many existing buildings as possible. Smart Foundry focuses on a completely new material flow and continu- ous clocked hand molding production in keeping with the Toyota production system. An SAP-controlled production concept, parceled production areas and an unmanned, universally mobile transport system result in a flexible process chain in which manual production phases and an automated logistics system can be ideally combined. Two of the major figures in the project are the 1,700 sq.m of ground-up renovations and 2,580 sq. m of newly-constructed buildings, but they say little about the very short construction period. For example, the construction of the hall alone required extensive founda- tion work with over 2,000 m of bored pile rammed in far below the water table. Numerous partners contributed to the successful outcome of the Smart Foundry project, from the architects, Menig & Partner, to the developer Riedel Bau und Bauer, the plant supplier F.A.T. Förder, and Anlagentechnik, Nederman Filtration, DEMAG Krane and WFT Fertigungstechnik. And of course, the specially-established Kurtz Ersa Project Team, the staff from the foundry’s IT department and those working on the iron foundry line were critical. “Nobody walking around the factory yard today can possible imagine the situation here on the site between January and August 2014. It was often a question of split-second timing to ensure that cranes, diggers, low loaders, cement trucks and drilling equipment could be accommodated in the very scant space while opera- tions continued,” said Rainer Kurtz, CEO of Kurtz Ersa. “Te construction schedule foresaw September 1 for the commencement of production, with a planned two- and-a-half week interruption of operations. Apparently impossible, but we succeeded—without a single accident. And that warrants a big ‘thank you’ to all involved!” 


从1852年开始,埃莎公司已在铸铁生产方面具备了 核心竞争力。


现在,公司的产品范围广泛,包括行星齿轮架、 机床,以及为工程机械、驱动、电力、车辆制造、真 空技术和风能等行业的知名客户企业提供的泵壳体。 先前进行的一项研究已证明,埃莎公司将具备为德国 机械制造行业生产高质量铸铁件的全部能力。 因此,与该项目有关的各方已研发出了创造性的 解决方案,阐述“工业4.0”的发展趋势并通过提高 生产效率使生产力翻番。其生产理念:尽可能多地利 用现有的厂房设施。智能铸造厂的重点是全新的材料 工艺和连续性的手动造型生产,与丰田的生产系统保 持一致。


SAP控制生产理念、分项生产区域以及无人操控 且普遍适用的移动运输系统构成了灵活的生产链, 使手动生产的各个环节和自动物流系统能够完美结 合。该项目的2个主要数据是:改造的厂房面积为 1700平方米,新建厂房面积为2580平方米,除此 以外,还有未被提及的一个数字是其工程周期非常 短。例如,仅厂房的修建就需要巨大的奠基工程, 需要进行2000米范围的远低于地下水位的螺旋钻打 桩施工。在所有合作方的共同努力下,智能铸造厂 顺利竣工。合作单位包括:建筑设计公司Menig & Partner,开发商Riedel Bau und Bauer,设备供应 商F.A.T. Förder以及Anlagentechnik,Nederman Filtration,DEMAG Krane和WFT Fertigungstech- nik公司等。当然,特别成立的埃莎项目工作组,铸 造厂IT部门的工作人员以及铸铁生产线的工人也是项 目成功的关键因素。


“如果是在2014年1月到8月期间,来到工厂附近 参观的人们是不能想象到现在这里所发生的变化的。 过去,在保持工厂运营的同时,将吊车、挖掘机、低 架装载机、水泥罐车及钻孔设备在很短的时间内在非 常有限的空间准备就绪是一个难题。”埃莎公司CEO 雷纳•库尔茨说,“按建设进度,新建工厂将于9月1 日投产,并中断2周半时间现有工厂的生产运营。尽 管看起来是不可能的任务,但是我们已经获得了成 功,而且没有发生一起事故。这一切都要感谢所有参 与合作的单位。” 


June 2015 FOUNDRY-PLANET.COM | MODERN CASTING | CHINA FOUNDRY ASSOCIATION | 33


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