GESTAMP POLAND

VW Crafter

When versatility becomes a challenge.

Key points of the project

  • 4 Complete Assembly Lines.
  • 43 Robots, with over 20 part references on the same line.
  • MAG Welding, Spot Welding, Adhesive Application and Handling.

Parts

  • Front Rail.
  • Rear Rail.
  • Floor frame.
  • Gear-box Beam.

Let us go into detail

The VW Crafter project is essentially characterised by the flexibility and creativity to design extremely versatile lines within a limited time and space.

Since the onset of the project in mid-2015, we knew that developing this project would present us all manner of challenges that we would have to overcome.

To this end, our customer trusts in us.

The successive versions and modifications throughout the operating life of the product have been successfully resolved by our team.

The lines were conceived, designed and assembled by our specialist team at our premises. There, we executed and supplied the first sets, always meeting the required quality level.

Transferral to Poland was performed in mid-2016. Since then, our lines have been supplying parts to Volkswagen, a customer with strict quality standards.

Opel España

Opel Mokka

Comprehensive reverse engineering project.

Key points of the project

  • 3 Complete Assembly Lines + 1 Restyling
  • 9 Robots
  • Welding, Marking, Handling, Adhesive Application, Roller Hemming, Hinge Screwing, Clinching.

Parts

  • Hood (New + Restyling).
  • Tailgate.
  • Sunroof.

Let us go into detail

In 2013, Opel entrusted us to take on a stimulating challenge for MB SISTEMAS.

The production of their Mokka vehicle, which, at that time was globally supplied from Korea, had to be reproduced at the Figueruelas plant (Zaragoza, Spain).

To this regard, Opel trusted in our comprehensive solution (dies and assembly lines) accompanied by our reliable partner, Matrici.

We approached the project, motivated by the challenge of developing a comprehensive reverse engineering project to reproduce parts whith extremely strict quality requirements and with a new customer the procedures and standards of which we were unfamiliar with. In addition, there was also the need to reduce time frames in order to bring forward the cessation of the supply of parts from Korea.

Our engineers conducted a thorough job which our specialists completed in the try-out phase. This excellent technical team, with extensive experience, together with our partner, and, without a doubt, the support and collaboration provided by the customer, resulted in the successful completion of the project at the beginning of 2015.

This effort was rewarded by the customer's satisfaction, who valued positively and highlighted aspects such as our compliance with their technical requirements and our customer focus.

Mercedes-Benz Vitoria

Mercedes V-Class

From supplier to strategic partner

Key points of the project

  • The adaptation of 6 complete lines
  • + 200 Robots.
  • Resistance Welding, Arc Welding, Track, Bolts, Mastics with Vision, Arc with vision and correction, Hinges with Arc, Palleting and Pallet Removal, Handling with geometry, Drilling with vision, etc.

Parts

  • Front module, Rear module, Self-supporting chassis, Sides, Assembly of Modules + Sides + Ceiling, Finish Line.
  • Automated final assembly: Dashboards, Batteries, Window Glazing, etc.

Let us go into detail

Our journey with Mercedes began over 10 years ago.

The international production of the VITO and V-CLASS vans is carried out at the Mercedes Benz Vitoria plant, where, state-of-the-art manufacturing technologies enables production quality levels comparable to the company’s passenger cars.

Over the years, Mercedes stopped producing its old models to make way for new ones.

From the word go, the specialist team trusted our experience and capacity to provide engineering solutions for this extensive and ambitious project.

This outstanding collaboration between both teams has resulted in the satisfactory resolution of each of the different stages of the project. Simultaneous production of old and new models, stopping production of the old models, dismantling of old facilities and the optimisation of current facilities.

We continue working towards success.

CAFUSA Elmira NY

AMTRAK Viewliner II

Exposed quality weld

Key points of the project

  • 2 Facilities (57 and 36 m. - 12 cars/month).
  • 3 Robots on tracks.
  • Resistance welding + Seam welding.

Parts

  • Sidewalls.
  • Roof.
  • Front Ends.

Let us go into detail

In 2011, after a successful record in various projects in the sector, CAF USA - Amtrak confided in our team’s experience to provide a solution to their exceptional case.

Amtrak has an identifying trait: no paint finish on its units. Accordingly, as the weld spots are visible, their quality and cosmetics as well as their position and alignment must be impeccable, in line with their strict quality standards.

Within this context, our robotic solution successfully met this challenge, removing any variability that another habitual manual solution in this sector could have provided.

The facilities were assembled at our premises in Urduliz in the first stage of the project, as the diversity of the references required proximity and flexibility solutions, which were dealt with as a whole with our customer, CAF Beasain. They were later integrated in the CAF USA (NY) plant, meeting the delivery milestones for the first cars prior to mass production.

During the entire process, fulfilment of the UL standards were very much in mind, which are applicable in the destination plant, as well as all other certificates and other quality and safety requirements.

Gestamp México

Daimler A-Class Sedan | GLB Class | Concept EQ

Showing involvement and committed to internationalisation

Key points of the project

  • 1+1 Assembly Line + Extension.
  • 9+9 Robots.
  • Projection Welding, Spot Welding, Glue Application and Handling.

Parts

  • Front Rail.

Let us go into detail

In 2015, under the impulse of our customers, we decided to embark on a exciting journey of internationalisation, opening our plant in Mexico.

The top manufacturers of the automobile industry supply the NAFTA market from Mexico. We had to live up to this.

We embarked on the project awarded by Gestamp Mx together with Daimler Mx for its A-Class Sedan vehicle from Puebla, the historic centre of the sector; a strategic location required to constantly monitor the correct realisation of the project.

With tight schedules and strict quality standards, our team, made up of Mexican and Spanish talent, tackled this challenge with processes, experience and know how, providing a solution that not only met the initial requirements, but that also envisaged the possible extension of the facilities.

As planned, in 2017, we were awarded the design and realisation of the extension, adding the Front Rail shared by the GLB-Class vehicle and the electric prototype “Concept EQ”.

Just as was the case with the initial project, our Mexican team, was 100% engaged from the onset of the project, with the engineering stage being particularly outstanding.

The mechanical team’s operations had to be carried out in operating windows that did not leave any margin for error. The design and simulation team had to ensure the feasibility of operations with no faults whatsoever.

The lines are now producing at maximum output rates with the highest quality levels.

Mexican talent, and excellent “Made in the Basque Country” management systems, guaranteed success.

Consortium for Innovation

FUSELAGE Project

Innovation for development

Key points of the project

  • New principles of disruptive architecture design.
  • Development of materials.
  • Innovative technologies of production processes.

Parts

  • Large composite structures for Belly Fairing.
  • Rear fuselage sections.

Let us go into detail

FUSELAGE - IDI-20170991  (Development of automated manufacturing processes and highly-integrated airframe structures in a connected industry environment), is aimed at the research and development of new principles of disruptive architecture design, the development of materials and innovative technologies of production processes to, controlling and monitoring the process at all times in an environment of connected industry, manufacture large composite structures for Belly Fairing and rear fuselage sections of the new generation of commercial aircraft and focused on more eco-efficient, competitive, reliable and resistant aircraft with a cadence able to reach 100 aircraft / month.

 

This project is developed by a consortium made up by AIRBUS OPERATIONS SL (project leader), UTINGAL SL, MB SISTEMAS S COOP, DANOBAT S COOP and LGAI TECHNOLOGICAL CENTER SA (APPLUS GROUP), supported by several research and technological centres. The project is planned to be executed in 3.5 years, from 20017 to 2020.

 

This project has the CDTI financial support through CIEN Program for strategic research projects in consortium and was granted in November 2017.

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