Visions meet solutions take a look inside and experience
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We design customized manufacturing... improving your cost efficiency Primary process steps
Preparation services
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• R&D and production of fixtures • Customer specific manufacturing • Continuous improvements • Quality standards such as PPAP, P-FMEA, ISIR, etc.
Advanced High-tech manufacturing • FMS, JET and Combi Cells • Experience and know-how • Advanced cutting tools • High flexibility for small and large series
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Internal added value services
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• Deburring without limitations • Ultrasonic and high-pressure cleaning • Honing • Grinding • Assembly
combining it all
Quality management • DS/EN9001:2008 • QDA software
• CNC measured process control • System and documentation
• Measuring laboratories • Quality guidelines
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• Large purchasing volume • Directly to assembly line
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Supply chain • Global sourcing • Large network of suppliers
• Kanban or consignment stocks • Vendor Managed Inventory (VMI)
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Precision - a lifestyle
our experience, your potential As a CNC machining sub-supplier within the metal industry we have taken up the challenge from low-wage countries and created one of Europe’s most automated process factories. Our customer group ranges from large, global industrial players to small businesses around the world. We supply machining operations for a variety of industries and cooperate with a number of foundries. Furthermore, our focus on continuous product and process development allows us to meet the needs of customers with special requirements. KP combines its many years of experience with the best technologies on the market to provide its customers with competitively priced products. We have the most advanced technologies at our disposal, which in addition to precision and quality enables us to supply products with a unique degree of complexity. This type of production demands a highly educated staff, which we have successfully employed and upgraded in line with the technological development in our company. We are proud of this integration. This increases our know-how and allows us to successfully act as a sparring partner for our customers during their phases of development and production.
In our organization flexibility is a core area. We have considerable experience in developing logistical solutions, tailored to meet the demands of our customers. We offer to keep stock and be a just-in-time supplier, a service that is economically beneficial to our customers and enhances reliability of supply. In a globalised world, proximity has become another significant parameter, not only with regards to delivery times but also when it comes to product development. In that sense we are “just around the corner� - enabling us to act promptly in the essential dialogue with our customers. At KP, we want you to benefit from our experience. Globally KP has more than 250 employees with a production running in three shifts. More than 125 high-tech CNC machining centres and CNC lathes are installed in our production facilities, which cover an area of over 21,500 m2 (231,424 sq ft).
Martin Krogh Pedersen Managing Director (CEO)
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Preparation services
the key to success lies in the preparations
The preparation process for a qualified quote and subsequent successful production start-up is very important to us and a process in which we invest a lot of resources.
KP works according to many different quality standards and work-flows to ensure an optimum and flawless production start-up.
The development of customer specific manufacturing systems and fixtures begins early. Both during the quotation process, as well as running in and initial serial production. The systems and procedures used in this careful process, automatically loop back and evaluate all collected data.
• Production Part Approval Process (PPAP) • Potential Failure Mode and Effect Analysis Process (P-FMEA) • Control Plan Requirements • Initial Sample Inspection Report (ISIR) • Gage Repeatability and Reproducibility (Gage R&R) • Capability Study • 8D Problem Solving • Continuous improvements
This loop back not only ensures that new projects will be based on best practices, but also that current projects are adjusted based on experiences and knowledge from preceding processes.
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APQP process advanced product quality planning
Time study latest technology and know-how
When receiving a request from a customer we begin a thorough process, based on an internal APQP procedure.
By combining our know-how with our preferred partners within machinery and cutting tools, we can perform optimal time studies for specific parts.
During this step we analyze all available information of the components and store it. All necessary information is analyzed and similar components or processes are considered and documented. All the information stored can be retained and supplemented during the manufacturing process.
Due to this close partnership, we always have access to the latest technology and know-how, which allows us to calculate the best production time and efficiency of the manufacturing process.
Deciding the best method competitive edge
Work-flow reevaluation of the process
In order to make a qualified and solid quote, we spend valuable time deciding on the most efficient and cost-effective method for the manufacturing process. By doing so, we ensure competitive pricing both now and in the long run.
The entire work-flow of a component is designed by following the previous mentioned steps.
In many cases, this step lets us develop groundbreaking methods that gives us a competitive edge.
Clamping systems high and stable quality We develop, design and produce our own clamping systems and we often produce a unique clamping system for each component. In order to maintain high quality we take advantage of the clamping forces to machine the component to its limits. Intelligent clamping systems, which allow for automation, are produced when a certain volume is required. The system can provide feedback and communicate with the robot and machine in a fully automated manufacturing cell. This ensures that the components are clamped correctly for the machining process.
The work-flow is reevaluated and determined just before beginning the manufacturing process. This ensures that we always use the newest available technology for the project in question.
Documentation customized according to specifications Prototyping, 0-series and serial production processes often end with a complete documentation package. Our documentation is almost always based on the PPAP standard, but can be customized depending on needs and specifications. The final documentation package is based on our experiences, evaluations and decisions gathered during the process between initial quote and manufacturing start-up.
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Advanced high-tech manufacturing cost efficient and flexible Our robot automated manufacturing systems allow a direct salary cost down to three percent per component. This facilitates an extremely low production cost per unit and makes KP competitive with any global subcontractor.
Our normal manufacturing tolerances fall within 20 microns and some of our Combi Cells can machine surfaces within tolerances of two microns. The honing department subsequently work hole tolerances down to one micron.
In production we work with deviation levels down to 400500 PPM. Tolerances in straightness and roundness fall within two microns.
We constantly develop production methods and offer a multitude of solutions to meet any customer specific needs.
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Jet-cells high efficient output We have numerous fully automated Jet-Cells. Each Jet-Cell consists of four or five identical MAZAK CNC-centres that are all equipped with fully automated hydraulic fixtures and each operated by a horizontal working robot. We have optimized our Jet-Cells to serial produce high quantities of one identical component or to serial produce many variants. The Jet-Cells are constructed with a high level of flexibility, which means that one or more machines can be operated manually, while the robot still operates the remaining machines. These Jet-Cells run an optimal production down to 50 units per variant.
Combi cells highly customized As an example, one of our many Combi Cells link together two 2-spindle MORISEIKI CNC-lathes along with one MAZAK CNC-centre with hydraulic fixtures as well as a 6 axis stationary robot that takes care of the part handling. The robot even manages the cleaning and packing of the machined parts in our customers own packaging. We have designed these Combi Cells to machine one or several customer specific components to be manufactured in large quantities.
FMS-cells flexible and cost-effective Our FMS-cells (Flexible Manufacturing System) consist of up to seven identical MAZAK CNC-centres with a complete pallet system that replaces pallets with fixtures in each centre. These FMS-lines are especially suitable for simultaneous manufacturing of many different complex components and at the same time provide a high output. The lowest number for optimal production on an FMS-line is about 50 components of each variant. The lines are equipped with cleaning units, which allow instant shipping of the machined parts - directly to the customer’s assembly line.
Stand-alone optimized time consumption To secure lowest possible costs, we typically place our stand-alone CNC-centres in smaller groups, manned by a single employee. These machines can handle everything from small components, up to larger parts, measuring more than one meter in diameter. Usually our centers load automatically, either by robots or a magnetic loading setup. We can also load manually if you require visual control or if producing small series.
Horizontal and vertical solid know-how With more than 70 horizontal machining centres (including high-speed machines) and a number of vertical CNC centres for processing large parts that need machining on multiple sides, we are well equipped to handle any needs. When setting up our milling machines in the FMS-Cells, self-invented Jet-Cells, or other high-tech systems, we ensure a highly flexible serial production.
Turning considerable and versatile capacity Our range of more than 30 turning machines includes: 1-spindle machines for small and medium production series. Max. 600 kg (1323 lbs) / Ă˜1000 x 2000 mm 1-spindle machines with sub-axis for complex turning/drilling/milling jobs. Max. 600 kg (1323 lbs) / Ă˜1000 mm 2-spindle machines with automatic loading and unloading equipment for small and medium production series.
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Internal value added processes
components ready for your assembly lines We believe in being a One-stop supplier to our customers. That is why we go beyond the traditional machining and offer internal Value Added Processes. Our experience as a turnkey supplier includes various types of surface treatment, gear cutting, grinding, polishing, welding, thermal deburring, etc. We also offer a number of part-assembly jobs, so products can be delivered directly to the customer’s assembly line. We are often involved as a sparring partner in the product
development phase, in order to ensure the best possible result with regards to production costs and expenses. We have invested heavily in large-scale production and a very high degree of automation improves cost competitiveness. We handle large-scale production with our turning machines, CNC machining centres and in cells consisting of both turning machines and CNC machining centres. We run series ranging from a few hundred up to several hundred thousand parts per year.
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Thermal deburring efficient removal of burrs internally and externally
Ultrasonic cleaning intensive cleaning for high quality standards
Thermal Deburring (Thermal Energy Machining - TEM) is an economical and beneficial method for deburring a wide range of products, including those for hydraulic industry and those with large areas of burrs or sharp, processed surfaces.
Hydraulic parts and other metal components often require an intensive cleaning process to meet high quality standards for cleanliness of parts. Furthermore, parts that have been thermally deburred also require a cleaning process to remove stains and oxidation.
Thermal deburring can be carried out on all types of materials such as steel, casted and grey iron, stainless steel and aluminium.
The cleaning method combines a high-flow spray of the cleaning liquid with ultrasonic rays and a vacuum-drying process. This way, we ensure that parts are always 100 % clean using an environmentally friendly process.
Items with a diameter of max. Ø320 mm and a height of max. 300 mm can be thermally deburred. We can handle even larger items through our sub-contractors.
High-pressure cleaning and Deburring precise control and high accuracy With high-pressure blast cleaning, the hard water jet loosens the burrs. This process also has a cleaning effect on the components. The high-pressure water jet is controlled precisely against the point of the subject to be machined. This accuracy ensures that even hard-to-access areas are reached. The high kinetic energy of the water jet not only removes the burrs, but also shavings and anything else left on the object.
Assembly the ideal one-stop supplier We perform simple assembly processes today, but we are keen on further exploiting this area. Our goal is to be able to perform part assembly for the benefit of our customers, hereby strengthening our One-stop concept.
Honing when precise bores are essential The honing process is typically used in hydraulic parts such as valve housings and valve blocks, or parts with special bores with tight tolerances. Honing offers significant dimensional and surface improvements as well as geometrical corrections that cannot be economically achieved by any other process. Diameter Length Straightness Roundness
min. Ø8 mm / max. Ø45 mm max. 350 mm within 2 µm 1, 5 µm
Grinding tight form and surface tolerances The objective of grinding is the general improvement of shape, size and surface of a part. Especially in the hydraulics industry but also in general engineering grinding is becoming more common to achieve tight form and surface tolerances. Roundness Flatness Surface roughness Diameter Length Work piece weight
0,001 mm 0,002 mm / 100 mm > Ra 0,1 Ø250 mm 1000 mm 120 kg
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Quality management
high quality and environmental standards We have a very high focus on quality and productivity. Our quality management system is certified according to DS/EN9001:2008. We aim to offer products and services that meet the demands of our customers. It is essential to us that our customers experience a high degree of satisfaction with regards to quality, price and delivery time. This objective must be met in an environmentally responsible way, now - and in the future. Our quality management system includes procedures for incoming goods inspection, process control, and final inspec-
tion. Sample documentation is carried out for all new parts and set-ups. The documentation is prepared in our electronic quality management system (QDA), and in accordance with our customer’s demands. At a minimum, the documentation consists of one measurement (in a 3D CNC measuring machine) of the part as supplied. Upon request, our sample documentation can also include Flowcharts, PFMEA, Control Plans, ISIR, Gage R&R, Capability tests (Cp - Cpk) and more. We use electronic control plans, generated in QDA, in on-going production to gather all measured data, which offers the possibility of providing SPC data to our customers.
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Measuring equipment quality is our top priority
Quality approach internal guidelines and priorities
All our products are subject to a continuous sampling control. Also new work pieces and single item products can be subjected to a complete measurement, recording all results.
In addition to our quality systems, our employees perform their duties according to internal guidelines and priorities:
In-house calibration of all measuring tools is continuously carried out according to international quality standards. We use the following measuring equipment: ZEISS 3D, ZEISS RONDCOM 60S, ZEISS SURFCOM 1900, ZEISS SURFCOM FLEX, MITUTOYO 3D, WENZEL 3D, ZOLLER as well as a large number of mechanical and electronic measuring instruments for use in current production.
Quality data analysis software automatic data recording QDA is a software with automatic data recording enabling electronic manufacturing and monitoring of measurement plans and measurement data. QDA provides us with a variety of options to interact with other systems.
Safety: All work shall be carried out in a way that avoids any risk of accidents to the staff, machines or tools. Quality: The quality of the product and the related documentation must comply with the requested specifications. Customer service: All inquiries are answered immediately. In-house routines: We have numerous in-house routines to ensure the highest quality of the finished product and prevent any errors.
Quality assurance solid know-how in manufacturing We have a number of internal guidelines to ensure the proper quality of our products. These guidelines are widely implemented in the company and represent the backbone of our quality focus.
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Supply chain
we are an attractive business partner Our supply chain allows our customers to benefit from our extensive know-how and experience. Through global sourcing of materials, additional services, dedicated production planning and just-in-time delivery, we meet our customer’s expectations for a One-stop supplier.
Our large purchasing volume gives us extra bargaining power and a preferred customer status with many of our suppliers. This enables us to offer solid solutions for our customers and lets us adjust our offerings to best fit their needs.
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Procurement high priority partner We have a large procurement organisation that handles both sourcing of raw materials and external services. We act globally from a sourcing perspective and can thus transform the benefits of a large purchasing volume directly into advantages for our customers through competitive raw material prices, fast delivery and high quality. Due to our size, our customers also benefit from our large network of excellent suppliers, who contribute with their know-how, expertise and best-in-class materials. All-in-all this enables us to constantly come up with the latest and most innovative solutions for our customers, which often trigger large competitive advantages for our customers in their respective market segments. We handle more than 30.000 tons (33.070 US short ton) of raw materials annually (various grades of castings, steel and aluminium), which ranks us as a high priority partner.
Logistics minimizing total cost
Just-in-time delivery for your convenience With a continuous focus on offering our customers the best possible delivery performance - even for components with normally long lead time - we have established a number of different logistical solutions. This is done through VMI (Vendor Managed Inventory), consignments stock and Kanban agreements. We can stock the manufactured components in different ways, which can vary from customer to customer. We can also offer to stock the original raw material. These consignments reduce the tie-up in storage capacity and costs for our customers, offering a short delivery time.
External Value-add services additional services Through a strong cooperation with carefully selected and audited partners, we can offer additional services such as: Hardening processes: Corr-i-durr processing, nitro carburetting, induction hardening, etc.
With many of our customers we exchange data electronically via EDI systems. This electronic data interchange saves valuable resources on both sides and ease the day-to-day cooperation.
Surface treatments: Metalizing, grinding, hardening, hot dip galvanizing (HDG), electro galvanizing, thermal spray metalizing (TSM), achromatizing, anodizing, painting, etc.
Being able to handle these often specific customer systems, makes it easy for us to track orders and shipments.
Special processes: Balancing, toothing, welding, gear cutting, etc.
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Business areas a strong foundation
We target a number of different business segments - both to utilize our competencies for future potential customers and also to have a much stronger foundation for our overall business. We have organized our global customers into five different segments, all covered by our unique experience and competencies. The skills we offer are wide ranging and as a result of this, we have customers that do not fit ideally into one of our cus-
tomer segments. Therefore we have a sixth segment, which we call Special Areas. More than 50 % of our direct turnover and more than 90 % of our indirect turnover is generated outside of Denmark. We constantly monitor new business opportunities within other segments and are open to new business areas that are not currently our primary focus.
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Hydraulics
Offshore
We deliver parts for both mobile and industrial hydraulics. From sourcing the raw material to delivering a part ready for assembly, we handle and control all necessary processes with unique perfection.
We deliver to a mix of different companies. The common denominator is that the parts typically are manufactured from high-alloy steels or other special raw materials, including special casted variants.
Our main competitive advantages in the production of hydraulic parts are our technical skills and know-how. We work with a variety of processes in a highly automated setup, offering the best of latest technology. As a result, we can meet the constantly increasing demands for end product quality - at a globally competitive level.
For this segment, we supply mainly items for offshore installations, as well as oil, gas and harbour installations, typically in small runs with very high demands in the complexity and general specifications, gapless traceability and often very small tolerances.
Energy Within the energy segment we mainly supply parts to the wind turbine industry. We supply directly to a number of global wind turbine manufacturers and to “Tier 1” suppliers. There is some overlap between the energy and hydraulic segments, since we deliver a large amount of manifolds and housings to the “Tier 1” suppliers of hydraulic systems for wind turbines. Our competitive advantage is the ability to purchase on a global scale and to offer highly efficient manufacturing systems for these semi-complex parts. Our ability to handle many different processes for medium sized series at a hightech level contributes to this. Even in a very competitive segment like this, we are able to compete with suppliers from traditional “low cost” countries.
Marine This segment consists of customers, who are subcontractors to the shipping industry. We provide a variety of products, such as parts for ship engines and sonar systems, made of everything from cast iron to aluminum and high alloyed steels.
Within this business segment, our ability to handle machining of these very complex materials on a competitive platform is our greatest strength.
Process control The Process Control segment targets the food, beverage and processing industry on a broad level. The use of highalloy steels and other special raw materials is common. The business is mainly focused on smaller parts and components used in processing applications and complete processing systems - typically in small to medium series with high complexity and small tolerances. For this business segment, our ability to handle machining of these very complex materials on a competitive platform is our main strength.
Special areas In this segment, we bring together products and/or customers, who do not clearly fit into the other segments. We are talking about customers, who are interesting for our overall business - now and in the long term - and who we would like to pay special attention to.
Here are small to medium runs with high demands on the complexity and specifications, and often small tolerances.
We produce most items typically in small and medium series, with high complexity and small tolerances, for example for the use in motor and clutch systems for locomotives.
For this business segment, our ability to handle machining of these very complex materials on a competitive platform is our main strength.
For this business segment, our ability to handle machining of these very complex materials on a competitive platform is our main strength.
Š KP 03.2014 - 0036_PM_DK_ML
Find us in Denmark KP Komponenter A/S Birkevej 2 DK-6971 Spjald
Find us in the US KP Components Inc. 117 Sheriff Mill Road Easley, SC 29642 - USA
Phone: +45 97 38 16 11
Phone: +1 864 644 8522
sales@kp-components.com www.kp-components.com