Die neue Fabrik in Yangzhou übertrifft die Kapazitäten des alten Standorts bei Weitem.
Everything from a single source
A new machining center at the GF Casting Solutions location in Leipzig (Germany) ensures customer satisfaction and a boom in growth.
Now more than ever, companies subscribe to the mindset of “the faster, the better.” That’s because they need to offer shorter times for product development and manufacturing. Against the backdrop of growing competition, this is the only way they can convince customers and acquire new orders. One of the two GF iron foundries worldwide is situated at the GF Casting Solutions location in Leipzig (Germany). It produces large cast components for off-highway vehicles such as wheel loaders, tractors, farm machinery and construction vehicles. Prototypes and series produced models can be manufactured relatively quickly, and customers’ individual requirements can be met in the automated molding line at the location, the largest in Europe and the Americas. “More and more, our customers want ‘no-worries’ full-service packages,” says Matthias Heinrich, Managing Director of the location.
In-house ready-to-install parts – at long last
Cast components could not be machined at the Leipzig location until now. In the past, the company required the services of an external provider. This poses a problem for GF, especially with regard to prototypes. “We can hardly find companies anymore that can machine our cast components quickly enough to satisfy our customers in terms of the final timing,” explains Matthias.
© Michael Bader
© Michael BaderFor this reason, GF Casting Solutions made the decision to invest in its own machining center. Now, two employees work on a lathe and milling machine to produce the ready-to-install cast components. “As we look to the future, we want to invest in more machining equipment, with three-shift operation,” says Matthias. A new campaign sums up the Leipzig location’s single-source concept with the slogan, “Our hands shape your success.” There are many inquiries from new customers and many orders already coming in, also for the still nascent Robotics division.
Robots for the US
GF Casting Solutions recently secured an order from the US. A customer is planning to introduce an autonomous robot for loading and unloading containers. The robot’s housing requires a heavy and stable iron cast component that can accommodate the battery and wheels. “We developed the component together with the customer and simulated the casting process on the computer. The first test molds for the prototypes were created using our sand 3D printer,” Matthias explains. 3D sand printing is also proving useful for the internal parts of hydraulic systems (oil ducts). “It is another way to ensure growth at our location,” says Matthias. GF Casting Solutions in Leipzig won the company award in the Value category in 2021. The reason for this decision: “The location exemplifies the GF Purpose ‘Becoming better every day’ and leads the way in this regard. The colleagues have found their own way to optimize processes sustainably and serve as role models for other locations.”
© Michael BaderMatthias Heinrich
Position: Managing Director
Division: GF Casting Solutions
Location: Leipzig (Germany)
Joined GF in: 1995
© Michael BaderCustomers want lighter parts
GF Casting Solutions has recently modernized other workflows to facilitate quick reaction times. “In addition to the sand 3D printer, we acquired five cleaning robots, for example, which we have been using successfully for two years,” the managing director notes. It is a very difficult job to grind cast components. Artificial intelligence (AI) has been leveraged to automate this work step, meaning that employees do not need to grind them by hand as often. There are also plans to purchase a second sand 3D printer. The location’s strategy includes a view to sustainability. “The new generation of off-highway vehicles increasingly relies on alternative powertrains,” Matthias explains. “Manufacturers also expect us to point out on where they can save on materials – without sacrificing strength, of course – so they can increase the fuel economy of diesel engines.” The axle on a dump truck – that is, a front loader capable of operating on large construction sites – weighs up to 700 kilograms. GF Casting Solutions is working on lighter solutions that employ bionic lightweight design techniques, for example. Matthias stresses that “the recyclability of our materials plays a substantial role in climate protection, as well.” “Stamping waste from the manufacture of the body & structure in the automotive industry already accounts for the lion’s share in our manufacturing process. What’s more, our cast components, in their entirety, can also be recycled at a later point in time.”
Further impressions:
© Michael Bader
© Michael Bader
© Michael Bader
© Michael Bader
© Michael Bader
© Michael Bader