ATEX General Presentation 2012 EN by Piotr Świerzko

12-12-2012

Location in Europe Destination: Berlin Frankfurt Paris Brussels Prague

~ 370 km ~ 750 km ~ 1315 km ~ 1075 km ~ 285 km

ATEX Sp. z o.o. ul. 3 Maja 20c 55-200 Oława Polska tel. +48 71 313 43 47 e-mail: office@atexweb.pl www.atexweb.pl

How to reach us: Wroclaw Airport ~ 40 min. Katowice Airport ~ 2 hrs Berlin Airport ~ 4 hrs

Poland • •

Largest working population in Central Europe

•

One of the youngest populations on the continent:

Market larger than the combined markets of all the other nine countries entered the EU in May 2004 50% under the age of 34 years 35% under 25 years of age

•

About 13 million people will enter the labour market in the near future

•

Automotive share industry in the overall sold production of Polish industry is 8%, total headcount – 180 thousands workers.

Wrocław (Breslau) • • • • • • • •

Fastest developing town in Poland Area of 293 km² Population 634.000 Unemployment rate 9% “Innovative center of Poland” 10 state-run universities 130.000 students Main industries: Mechanical Engineering, Electronics, Chemical Industries, Automotive

Oława

ATEX Sp. z o.o. - ul. 3-go Maja 20c, Oława

-Manufacturing trucks components , off-road

vehicles silencer, fuel tanks, other metal parts

-Established 1996 -Area 5000 m2 ATEX Sp. z o.o. - ul. Bursztynowa 4, Oława

-Manufacturing exhausts clamps, fuel tanks strip, metal parts for OEM AGD

-Established 1989 -Area 500 m2 ART-MOT ŚWIERZKO – Ścinawa Polska 70/4

-Manufacturing tools used in production process -Established 1981 -Area 300 m2

ATEX - Milestones 2013 Next step: ISO/TS 16949:2002 2012 2007 2005

over 750 products in ATEX portfolio; employment 90 people,

implementation of a new cutting laser Introduced new business management system „GRAFFITI.ERP”

ISO 9001:2000 certificate; provide a laser cutting machine

2003 buying the first CNC machine, employment 54 people 2000 ATEX brand was created; first job for Solaris granted 1998 manufacturing silencers – western makes; employment 38 people

1996 manufacturing fuel tanks for trucks – east European makes 1991 manufacturing silencers for trucks – east European makes 1986 manufacturing exhaust systems for Fiat 126p

1980 ART- MOT established, employment – 5 people

About us We are aiming at perfection in every single detail so that our customers are more than just satisfied with their choice of our products. We are a leading manufacturer of exhaust systems, fuel tanks and other components for trucks, special purpose vehicles, power generators and buses. We have been on the market for nearly 30 years developing our competencies. Our experience, latest modern technology and constant improvement make it possible for us to develop even more and offer our customers outstanding solutions. Since 2005 we have had a Quality Management Certificate ISO 9001:2000 granted by TUV RHEINLAND for design, exhaust systems production, fuel tanks and parts for trucks, buses and other machines as well as sheet metal working.

ATEX Organization chart

Design Engineer Adam Walczak

Our mission

Being at the forefront of producing exhaust systems and fuel tanks for buses on the OE market in Europe and participate in the production of components or complete exhaust systems, water and air charge pipes.

Create, produce and sell products of the highest quality and always on time

Our vision

ATEX CERTIFICATES – ISO 9001 since 2005

Sales in EURO

€4 000 0.00 €3 500 0.00 €3 000 0.00 €2 500 0.00 €2 000 0.00 €1 500 0.00 €1 000 0.00 €500 0.00 €0.00 2008

2009

Export

2010

Poland

2011

2012

Total

ATEX – market segmentation by industry Exhaust systems, pipe

Oem trailers

Tanks

Sheet metal parts

11% 12% 6%

71%

ATEX – sales division: country / export POLAND

UE/EXPORT

48% 52%

ATEX Market share – OEM / AEM

2008 Number of part numbers manufactured (silencers only) number of silencers manufactured Number of silencers manufactured - by weight

2 009

2008

21-30 kg 31-40 kg 41-50 kg

461

15 800

18 111

21 467

2009

2010

2011

880

1 018

2 675

6 715

5 697

6 670

7 051

3 869

5 183

6 445

7 266

4 089

2 862

2 737

2 470

2 366

1 148

1 181

1 869

51-60 kg 61-70 kg more 2008 Number of projects open for the Design Dept. Tons of sheet metal used

393

939

1-10 kg 11-20 kg

2011

320

309 18 083

2010

2009

2010

Production Capabilities – Exhaust systems • All the growth within one shift system a lot of production capabilities to be used • ATEX is a perfect partner for production series of 1-5000 pcs a year

2011

247

301

1 150

900

915

1 014

Strategy for the years 2012-2015 Customers

Technology

Cost Control

Employees

Society

 Diversification of customer base

 Development through innovative technologies

 Effective management of production and purchasing

 Appropriate selection and motivation of employees

 Social Responsibility

 Extending cooperation with existing customers  The highest level of customer service

 Fixed cost reduction  Striving for – "Zero defects”

ATEX products – examples – exhaust systems

SILENCERS

ATEX products – examples – exhaust systems

RETROFIT / NEW EMISSION

ATEX products - examples

CLAMPS / ACCESSORIES

ATEX products - examples

BAFFLE

ATEX products – Silencers with DOC’s and DPF’s ATEX is a subcontractor producing baffles, end caps, boxes and pipes for companies selling stainless steel silencers with DPFs or DOCs. The silencers are sold all over Europe, mainly in Germany and Great Britain.

ATEX Production of fuel tanks

Aftermarket Brands of vehicles from Central and Eastern Europe

Brands of vehicles From Western Europe

> KAMAZ > JELCZ > STAR > AUTOSAN > TATRA > LIAZ > IFA > IKARUS > BERLIET

> MAN > VOLVO > SCANIA > DAF > MERCEDES > RENAULT > IVECO

Based on customer drawings we produce custom fuel tanks. Examples on following pages of presentation. The choice of fuel tanks is available on the www.atexweb.pl Copyright ÂŠ2012 Atex Sp. z o.o. |All Rights Reserved

ATEX Aftermarket fuel tanks

ATEX Production of tanks

Division of tanks according to adaptation Hydraulic tanks for construction equipment

Fuel tanks for buses

Fuel tanks for trucks

Fuel tanks made of aluminium

Fuel tanks made of acid resistant steel 1.4301

Fuel tanks made of stainless steel 1.4016, 1.4003

Fuel tanks made of steel

Combo tanks (fuel and hydraulic)

Tank made of acid resistant steel for water

Fuel tanks for boats

Fuel tanks for fire trucks

Fuel tanks for special purpose vehicles

Fuel tanks for hydraulics

Acid resistant tanks for AdBlue systems

Fuel tanks for army vehicles

Fuel tanks with steps

Fuel tanks for rail vehicles

Fuel tanks for construction equipment Double-jacketed steel tanks for Fire Service

Tanks for ethanol

ATEX products – examples – aluminium fuel tank

ATEX products - examples

ATEX – Accessories

Accessories for tanks Fuel, AdBlue sensors

ATEX anti-theft cladding

sets of fittings for tanks

Fuel caps

ATEX – Cooling pipes - water, air, exhaust ATEX produce various types of cooling pipes. It could be water, or air pipes. All types of pipes are producing with using CNC bending machines in regards to customer’s specification and common arrangements to reduce production cost. Why choose co-operation with ATEX? Because we know: - how to clean pipes inside, that no impurities do not enter the cooling system, - how to protect pipes during transport to avoid impurities inside. Because we have: - rich resource of bending tools without external cooperation (see table below) - specific machine park to produce as soon as possible small series, - vast experience in the production of pipes for cooling systems - we always aim to avoid welding - knowledge how to make ends, according to standards contained in DIN 71 550 (80% without welding) In case of different demands, please contact with our R&D department, to establish such requirements as: - brackets on the pipe - flanges to the engine, - pipe endings. Raw-material: - Aluminium pipe DX54+120AS - available - stainless steel pipes 1.4509 - on request - acid resistant pipes 1.4301 - on request The possibility of surface: - Powder coating - Wet painting - Cromodizing: blue, yellow, black - Other specification required by the customer

Średnica zewn.

Gr. Ścianki

Promień do osi rury CLR

45 50 55 60 65

1,5 1,5 1,5 1,5 1,5

70 74,5 80 90 101,5

Min. odcinek prosty między gięciami 45 60 55 70 70

65 70 76,1 76,1 80 83 88,9 101,6 110 114,3 120 127 127 152,4

1,5 1,5 1,5 1,5 1,5 2,0 2,0 2,0 2,0 2,0 2,0 2,0 2,0 2,0

150 100 132 154 125 165 135 153 158 200 200 162,5 200 225

70 100 73 73 110 130 110 98 130 170 160 250 200 250

ATEX – Cooling pipes - air, exhaust - exmaples

ATEX – Wheel chocks– compact desing

R&D department The prototype design is created using the 3D CAD tool SolidWorks, which enables the designers to make 3D models of parts and complete system assemblies. The input to the design from customerâ&#x20AC;&#x2122;s side is preferred to be the following formats: Drawings: DXF DWG PDF SolidWorks file

3D Models: STEP IGES Pro E files SolidWorks files

The output files to customers and simulation tools are listed below and a complete list of possible import and export options can be found on the SolidWorks web page: STL STEP IGES Parasolid We have: 2D CAD (AUTOCAD) - 1 station 3D CAD (SOLIDWORKS 2012) - 4 station CAM (PN4000) - 1 station CAM (BYSOFT) - 1 station CAM (EDGECAM) - 1 station

ATEX examples of projects

ATEX Production and processing capabilities Automatic welding process Automatic welding robot MOTOMAN EA 1900N Data sheet • sixaxis robot • Positioning precisely +/- 0,08 mm • max reach P-Point R = 1904 mm Robotic positioner RM 2-250 Data sheet: • moment: 1050 Nm • rotation speed: 0 – 16,8 rpm • positioning time: 4 sek. • lenght between plates: 2 000 mm • diameter: 1 170 mm

ATEX Production and processing capabilities Welding process Welding TiG, MiG/MAG We are welding with such method as: MiG/MAG, TiG, •carbon steel with aluminium-silicon, •heatprof steel, •stainless steel •aluminium. We owns welding machines: • KEMPII, PRO EVOLUTION 5200 • LINCOLN ELECTRIC, MASTER TIG • BESTER Atex company is hiring about 40 welders

ATEX Production and processing capabilities Laser cutting Laser cutting machine BYSTRONIC model BYVENTION 3015 year of production: 2008 Table format: 3000 mm x 1500 mm. • Steel sheet

12 mm

• Stainless steel

8 mm

• Aluminium

6 mm

ATEX Production and processing capabilities CNC press brake AMADA HFBO 170 / 4 CNC PRESS BRAKE •

• • • • • • •

8 axles control: -X1, X2 -Y1, Y2 -Z1, Z2 -R1, R2 Max. folding force: Max. bench length: Clearance between folding bars: Clearance between cylinders: Max. speed of stamp travel: Max speed when pressing: Speed of stamp return:

170 tones 4000 mm 450 mm 3760 mm 100 mm/sec 1-8 mm/sec 1-80 mm/sec

ATEX Production and processing capabilities CNC punching machine Punching machine AMADA AC-255 NT Data sheet: • year of production: • max stroke power: • max steel thickness: • axes lenght (x,y): • max steel dimensions: • axis x positioning speed: • axis y positioning speed: • stroke speed: • stroke speed: • marking speed: • cutting precisely: possibilities • amount of tools in revolver: • max cutting diameter:

2008 200 kN 6,4 mm 1270 x 1270 1270 x 2540 80 m/min 60 m/min 480/min 370/min 900/min +/- 0,1 mm +/- 0,8 mm 51 stations 88,9 mm

ATEX Production and processing capabilities CNC plate bending machine â&#x20AC;&#x201C; 2 station 4-rool CNC plate bending machine 176P bending various shapes e.g. round, trapeze, square, cone min. diameter of tube rolled: 92,5 mm at max. plate thickness of 2 mm The machine is very useful for rolling regular and perforated tubes

ATEX Production and processing capabilities CNC guillotine cutting CNC guillotine cutting BAYKAL model: HGL 4000 / 6 Data sheet: • •

cutting line: 4000 mm cutting metal sheets S235: 6 mm

ATEX Production and processing capabilities Cutting pipe profile – 3 station Cross-cutting belt machine Cross-cutting belt machine with a cutting diameter up to 230 mm. Cutting angle of R/L 45 - 0 - 45 - 60 Data Sheet: • • • •

Min. diameter of cutting: 5 mm Min. length of the material in the vise: 20 mm Distance between the vise plate and ground: 760 mm Cutting strip size: 2720 * 27 * 0.9 mm

ATEX Production and processing capabilities CNC Lathe CNC lathe - TRAUB TND 360 - TX8 Data sheet: • • • •

very highly precision ( up to 0,001u) , in components turning 8 mounting places for tools in revolver 4500 Rpm turning length - 800 mm turning diameter - 250 mm

ATEX Production and processing capabilities CNC vertical milling machine CNC vertical milling machine LEADWELL VMC 25 Data sheet: •

• • • •

working area:

- X: 650 mm - Y: 410 mm - Z: 410 mm Basic table dimension: 850 mm x 410 mm Max. Table load: 300 kg Speed: X,Y,Z: 15 m/min Range of speeds for rotating head: 80 - 6000 rpm

ATEX Production and processing capabilities CNC milling machine CNC milling machine OERLIKON FBO TCA 10 Data sheet:

Table size Control Taper Speeds

X – 1100 mm Y – 620 mm Z – 560 mm 1600 x 630 Heidenhain TNC 415B ISO 5 0-4000 RPM

ATEX Production and processing capabilities CNC Pipe bending machine ADDISON MCKEE DB100ST Number of stock: year of production: Max Outside Diameter: Max Wall Thickness Max Centreline Radius

3 1993 127 mm 2 mm 300 mm

Max Bend Arm Movement Max Lenght Over Mandrel

193° 6000 mm

ATEX Production and processing capabilities Deep pressing Hydraulic press hydraulico 630/150 mp Data sheet • punchholder pressure: max 630 mp, • adjustable down • blankholder pressure: max 150 mp, • adjustable down to 2 mp • press clearance : 1200 mm • punchholder stroke: 750 mm • blankholder stroke: 350 mm • return speed of upper platen: 180 mm/s • return speed of blankholder platen: 70 mm/s

ATEX Production and processing capabilities Hydraulic and eccentric presse Hydraulic presses 1. Hydraulic presses 2. Hydraulic presses 3. Hydraulic presses 4. Hydraulic presses 5. Hydraulic presses 6. Hydraulic presses 7. Hydraulic presses

QTY 1 2 2 1 1 1 1

Open gap eccentric pres QTY 1. Open gap eccentric press 2. Open gap eccentric press 3. Open gap eccentric press 4. Open gap eccentric press 5. Open gap eccentric press

1 1 1 1 1

Pressure 15 15 40 80 100 200 650 Pressure 25 40 63 100 160

working space (lxw) 400x500 380x550 600x900 760x1140 650x650 730x1000 1700x2200 working space (lxw) 370x560 450x630 560x800 630x900 760x1210

ATEX Production and processing capabilities Surface treatment – blasting, painting Surface treatment, blasting, painting. Company owns: - Blasting machine - Cleaner spray - Heating stove Our capacity for surface protection apply to: - Security welds in the exhaust systems made of aluminized steel - Products being washed after expression In the works where the paint surface inspection and warranty certificate is required we use external paint shop located outside ATEX Company - 30 km ALUCORM - MIDROC – company- http://www.alucrom.pl

ATEX Quality control In order to ensure the highest quality of delivered products, company have their own measurement chamber equipped with a measuring arm provided by American Company FARO - Platinum model. The laboratory is also equipped with various types of measuring and control devices needed for the manufacture of exhaust systems and other goods. With advanced software to compare the spatial, we can very precisely confront the parameters obtained with model assumptions products. TRACEABILITY By introducing GRAFFITI.ERP SYSTEM Company is able to track the process from purchasing stage until the final product is made. Each finished product has its unique order number. Order number is extruded on the final product.

Positive external audits: -HJS -BOSAL -LIUGONG -BOMAG

ATEX – GRAFFITI.ERP System

Finance and Accounting Production

Human Resources and Payroll

SML

CRM

Purchase

Projects Management

Core of the system

Sale

Quality Control

Warehouse Management Logistic Tool Shop

Terminal Management (barcode readers) Logistic Management

ATEX sales

OEM customers

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