a global end-to-end leader, from steel mill to forge. global end-to-end leader, from steel mill to...
TRANSCRIPT
A Global End-to-End Leader, from Steel Mill to Forge.
July 2014
Index
Company Background 2
Health & Safety and Environment 9
Quality 11
Customer Care 13
Manufacturing Process 15
Key Products and Clients 22
Contacts 30
1
A Global End-to-End Leader, from Steel Mill to Forge.
2
Company Background
Background
Group Structure and Shareholders
Metalcam Key Figures
Management – Key Roles
Background
Founded in 1907 in the Northern Italian region of Valle Camonica, Metalcam is today a leading manufacturer of open-die forged steel components
Metalcam is one of the few companies with an end-to-end integrated production cycle, from the steel mill to precision forging and finishing, allowing for timely delivery of a wide range of finished products, tailor made based on clients’ specifications
Metalcam Group operates through 4 production sites plus 2 machine shops and employs a total of 380 people
Forged components weight between 500 kg and 35 tons and are used for a variety of industrial applications in the Mechanical, Oil & Gas, Energy, Shipbuilding and Extrusion sectors among others.
Global presence in over 40 countries, covered directly and through an extensive proprietary network of established agents and sales representative team
Longstanding relationships with over 100 key clients worldwide thanks to best in class performance for product quality and customer care / after-sale services
3
Group Structure and Shareholders
4
Metalcam S.p.A. (Italy)
Group Structure Key Shareholders
Adamello Meccanica
(Italy)
Vorlaender (Germany)
B.S. (Italy)
Valforge (Italy)
Adamello Steel (Italy)
Medium and Large Forgings
Steel Plates
Small - Medium Forgings
Small - Medium Forgings
Rolled Rings
Machine Shop
Rough Machining
Machine Shop
Finish Machining
54,9%
80%
100%
60%
100%
LAVORO 3 S.p.A.
48%
Italian financial holding with investments in energy, financial and industrial sectors .
Founder of Metalcam S.p.A.
Italian Private Holding Company
42%
10%
Management and employees owned entity
Metalcam Key Figures
5
10%
7%
12%
6%
65%
Average annual turnover of 110 Mln€ during last 7 years
Highest level in 2008 with 145 Mln€ of business finalized
Metalcam Key Figures
6
16%
15%
12%
7%
10%
2%
1%
2%
2%
Metalcam Key Figures
7
17% Mechanical Sector
Power Gen 8%
Raw Material 7% Oil & Gas
58%
Shipbuilding 4%
Petrochemical 6%
Management – Key Roles
8
Mario Cocchi CEO
Laura Putelli Quality Control
Luca Mossoni Quality Assurance
Marco Gnaffini Health & Safety
Giorgio Polonioli Chief Metallurgist
Roberto Rizza Production - Steelmill
Lino Cocchi Production - Forge
Massimo Cocchi Sales & Marketing
Ezio Scalvenzi Administration & Control
Mauro Norini Maintenance
9
Health & Safety and Environment
Health & Safety and Environment
Health & Safety and Environment
Metalcam’s number of days lost has halved in the period 2005-10, despite a rising workforce, from 0.16% to 0.06%;
Strong commitment to health and safety:
2 audits to all departments per month
4 medical examinations per year
Weekly meetings on production and safety
In-house medical center twice per week
Key safety features include:
Use of individual protective clothing
Safety book and internal procedures
First AID training
10
83 70
57 51 44 39 34 31 29
230 240 270 273 276 278 280 280 280
0
50
100
150
200
250
300
0
10
20
30
40
50
60
70
80
90
2005 2006 2007 2008 2009 2010 2011 2012 2013
Days Lost Workforce
First forge in Italy to obtain an environmental certification in compliance with IPPC (Integrated Pollution Prevention and Control)
Metalcam performs monthly inspections on equipment emissions
Next step ISO 14000 Accreditation
11
Quality
Quality Control and Assurance
Quality Control and Assurance
Quality Assurance
Metalcam is qualified ISO 9001:2008 (Lloyd’s Register)
Metalcam works with the most important 3rd Party Inspection Bodies such as ABS, TUV, BV, Lloyds Register, DNV, GL and RINA
Quality Control
Chemical analysis on melted material
Non Destructive testing:
Ultrasonic, Hardness, Magnetic Particle, Liquid Penetrant, Visual and Dimensional
Destructive testing:
Tensile, Impact, Bend, Creep tests
Micro and macro-graphic examination
12
13
Customer Care
Customer Care
Customer Care
Request for Quotation and Offer
8 people fully dedicated from Engineering Department
Quick response time: offer to client within 3 days from request for Quotation
Sales Department
9 people dedicated to coordinate information flow between Customers and Metalcam for any kind of matter especially from a commercial point of view
Expediting
5 people fully dedicated
Customer visits and/or conference call
Status report by e-mail on a bimonthly basis
Management of Quality Matters
6 people fully dedicated
Always available for all specific questions and ad-hoc meetings/conference call
Quality certification submitted by e-mail for information only / approval
Pre-Production Meeting / Kick-Off Meeting
14
15
Manufacturing Process
Manufacturing Process Overview
Key Product Features
Steel mill
Forging
Heat Treatment
Machining
Finish Machining
Manufacturing Process Overview
Metalcam is one of the few companies with an End-to End capability
Steel mill
Scrap
Melting Furnace
Refining Furnace
Vacuum degassing
Bottom pouring
Forge
Ingot heating
Forging
Preliminary Heat Treatment
Machining (rough and finish)
Quality Heat Treatment
Final Inspection
Packaging & Shipment
16
1)
2)
3)
4)
5)
6)
7)
8)
9) 10)
Metalcam is in constant contact with the client throughout the production process and after the sale through
a customer care department
11) 12)
Steel Mill
Equipped with:
A 45 tons capacity arc melting furnace
A ladle furnace for refining
A degassing unit with V.O.D. system
Bottom pouring system
17
Forging Department
Equipped with:
n° 6 heating furnaces with a total 500 tons capacity
n° 1 semiautomatic hydraulic 6.300 tons press
n° 1 semiautomatic hydraulic 3.500 tons press
n° 4 manipulators from 24 to 70 tons capacity
18
Heat Treatment Department
19
Equipped with:
n° 19 methane gas-fired furnaces with 20 to 80 tons load capacities
n° 1 electric furnaces with 10-20 tons load capacities
n° 2 quenching tanks with 130 and 200 m3 water capacities
n° 2 quenching tanks with 110 and 200 m3 polymeric solution capacities
Rough Machining Workshop
Equipped with:
n° 6 horizontal lathes (3 CNC)
n° 3 CNC vertical lathes
n° 7 CNC milling and boring machines
20
Finish Machining Workshop
Equipped with:
Tacchi horizontal lathe
Max length: 10 mt
Max diameter: 2.8 mt
PAMA vertical milling machine
Forgings up to 10 tons
21
22
Key Products and Clients
Mechanical
Oil & Gas and Petrochemical
Energy
Shipbuilding
Extrusion
Raw Material
Major Clients
23
Mechanical
Pistons, cylinders, mandrels, columns and crosspieces for presses Coupling boxes, extensions, gaskets and cylinders for rolling mills Segments, mandrels and rolls for coiler tape train of rolling mills Mandrels and cylinders for the production of tubes Rolls and axles for cement factories Bushes and yokes for paper mills Shafts, pinions and wheels for gearboxes Crankshafts
24
Key Products
30 CrMoV 9 18 CrNiMo 7.6 35 NiCrMo16 40 NiCrMo 7 42 CrMo 4 30 CrNiMo 8 39 NiCrMo 3 Carbon Steel
Steel Grades
David Brown Flender GUSTO MSC KHD Humboldt Metso SMS Group Siemens VAI Tenaris Group Weir Minerals
Major Clients
Oil & Gas and Petrochemical
Valve bodies for subsea and surface trees
BOPs
Wellheads
Stress joints for riser system
Structural parts for tension legs platforms
Tube sheets, shells, flanges, gates and other forged equipment for refineries and chemical plants (heat exchangers)
25
Key Products
AISI 8630
ASTM A182 F22
AISI 4130
F6 NM
AISI 410
ASTM A182 F91/92
F60 / F65
Steel Grades
Major Clients
Aker Solutions
BEL VALVES
Cameron / OneSubsea
Drill Quip
FMC Technologies
GE Oil & Gas
N O V
Power Generation
Turbine discs and shafts for hydro applications Rotor shafts for steam turbine Discs and shafts for gas turbine Generator shafts Wind turbine shafts Compressor discs Thrust shafts Valve and pump bodies
26
Key Products
ASTM A182 F6NM 30 CrMoV 9 35 NiCrMo 16 40 NiCrMo 7 30 CrMoNiV 5.11 20 CrMoNiV 4.7 ST462T Carbon Steel
Steel Grades
Major Clients Alstom Andritz Hydro Ansaldo Energia Flender General Electric MAN Diesel & Turbo Voith Siemens
Metalcam is equipped to perform internally heat stability test on steam turbine shaft
Shipbuilding
Propeller shafts Intermediate shafts Gyrofin shafts Thrust bearing stub pipes Rudder shafts Pintles Cylinder and piston heads Connection rods Turbine shafts Piston rods Pinion and gears for reduction units
27
Key Products
42 CrMo 4 C 35 ST 52.3 34 CrNiMo 6
Steel Grades
Major Clients
ABB Oy Marine
Becker Marine
Fincantieri
IHC
Rolls Royce
Extrusion
Outer-castings
Bushes internal
Bearing bushes
Punches
Matrixes and various forgings for extrusion presses
28
Key Products
W 1.2343
W 1.2344
W 1.2367
W 1.2714
W 1.2323
Steel Grades
Major Clients
Battenfeld Extrusions
Kind & Co
Presezzi Extrusion
Schmidt & Clemens
Raw Material
Polygonal Ingots
Round Ingots
Round / Square pre-forged blooms
Round / Square pre-forged bars
29
Key Products
Carbon Steel
Low Alloyed Steel
Medium Alloyed Steel
High Alloyed Steel
Stainless Steel
Steel Grades
Major Clients
Forge Fedriga
Forgiatura Marcora
Forgital Group
Manoir Industries
Siderforgerossi
30
Contacts
Contacts
Headquarters
Via Leonardo da Vinci, 3
Breno (BS) - Italy
Tel: +39 0364 238 310
Fax: +39 0364 320 768
www.metalcam.it
31
Contacts Role Telephone Email
Massimo Cocchi Sales Manager +39 0364 238 289 [email protected]
Giorgio Polonioli Chief Metallurgist +39 0364 238 229 [email protected]
Laura Putelli Quality Control +39 0364 238 261 [email protected]
Luca Mossoni Quality Assurance +39 0364 238 269 [email protected]