PowerPoint Presentation

Company PresentationRailway Business01.2015

In 2010, MCG set out a strategy seeking diversification and sustainable growth, focusing on products and services related with MetalMCG mind for metal1938Start of the activity

1978Foundation as private companyBuilding of new facilities1981Expansionof plant facilities(25.000 sqm) 1992FORD Quality Prize1994ISO 90011998QS 90002014 2015 +11,000 m2 shop floor expansionGM Excellence Award2013 Start of MCG TransportationNew tooling shopISO/TS 1694920032010Strategic ReviewStart of MCG Automotive, MCG Tooling, MCG Laser & MCG Solar 2012New building and new 3.300T PressMCG is a family-owned business founded in 1938 by Manuel Conceio Graa

Dividir em 2 slides: um com info sobre facts/dates outro sobre figures. Referir R&D. Fazer linha de tempo

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Company FactsMCG is located in Carregado, 25 km north of Lisbon airport

Five divisions:AutomotiveToolingLaser (Industrial)SolarTransportation

Competence Center for Sales, Marketing and R&D

Production area: 38,000 m2

Turnover: 40Mi eur

Employees: 400

50Mi items supplied last year

120+ customers world wide

3Main Customers

Sample Products

CPC Solar Pannel

Continuous InnovationContinuous improvement

Automotive based management techniques are used in order to ensure compliance with deadlines and zero defects quality level:TPM5SKanbanIT

Continuous technological evolution

MCG invested more than 10 Mi euros in the past three years in new machinery and new processes proving to be one of the most solid and competitive companies in the metal working sector in Southern Europe, ex:3300 tons , 8x2.7 m bed, hydraulic pressAutomatic bending machineAssembly lines

Certifications:ISO 9001ISO TS 16949In progress ISO 14001Engenharia6Mechanical Stamping PressesHydraulic Stamping PressesMig-Mag Welding RobotsResistance Welding RobotsTox Crimping Epoxy Painting LineCataphoresis Painting LineDegreasing LineAluminum Annealing Line2D Laser CuttingBending MachinePunch & Bend Automatic LineAssembly LinesTube Forming LineSPIFMachining Centers 3 and 5 axisCNC LathesElectro erosion3D Measuring Salt Spray Test--------------------------------------------EN ISO 9606-1 Welding Operators (EN ISO 287-1)

Metal Manufacturing Processes

In house metal fabrication processesProduct and Process Engineering

Design ToolingSystem ApproachSimulation (FEM)TestingProcess Development & Industrialization

3% of turnover invested in R&D every year

Current projects under development:

System Competence

0New high efficiency solar collector for medium/large sized solar thermal systemsNew hybrid automotive head rest (steel/carbon fibre reinforced thermoplastic)

New modular railway floor system, heated/non heated

Railway ComponentsMCG started in the railway sector in 2012 by supplying services and components for the refurbishing of Portuguese rolling stock.

MCG is capable of producing a vast range of metal components in small, medium or large batches, and for different subsystems:

HVAC boxesWater depositsMetallic electronics enclosuresBattery boxesSkirts

Certifications currently being prepared:

DIN 6701-2 for adhesive bonding processesEN 15085-2 for welding of railway components IRIS

9MCG build its first composite flooring system in 2013 for a small refurbishing project (drivers compartment). The project introduced the sandwich construction technology and the rail interiors application at MCG.

Core materials + Aluminium cover sheetsMechanical stiffness Thermal insulation Acoustic insulationPressure resistance Fire resistance Energy absorption

Manufacturing partner for the Alucork floor system:

Railway Floor systems

2011-2013: Siemens Inspiro Warsaw2015-2018: Siemens Inspiro Ryadh2015-2017: Refurbishing of CPs intercity fleet

Weight savings:

Up to 4 kg/m (1 lb/ft) 200 kg per car (42 m)

Renewable raw material (cork core)

Recyclable materials (core, skins and profiles)13,0 kg/m (2,6 lb/ft)9,9 kg/m (2,0 lb/ft)8,6 kg/m (1,7 lb/ft)AlucorkTM by MCGLightweightAlucorkTM by MCGBending stiffness

The Alucork panel presents a low deflection under distributed load. Tests performed on a 20 mm thick panel using a 540mm span and considering a maximum load 1.000Kg/m

2Noise Reduction

The combination of a multi-phase visco-elastic core material and strong aluminum skins deliver:

The best dB/kg ratio maintaining structural strength and thermal efficiency 31 - 36 dB Airborne Sound Insulationdepending of panel thickness

Airborne sound insulation (EN ISO140)Alucork 2031Alucork 3036AlucorkTM by MCG

The Alucork floor systems takes advantage of the low density core material:(k=0,040 W/mC)

Depending of the thermal insulation requirements of the project, the floating floor system alone may be enough!

ex: For a target U-value of 1,5 W/m C theres no need for additional insulation layer:

lower material costs long term thermal efficiency lower overall floor thicknessAlucorkTM by MCGThermal InsulationLong term durability:

High strength impact resistant AW 5754 alloy protected against corrosion with a primerEdge profiles to protect panel from intrusive moisture or substances

Testing:

Point load, impact and vibration agingFatigue cycles with no loss of bending stiffness: after 1,2 million loading cycles after 3,0 million loading cycles (450 kg/m load)

AlucorkTM by MCGDurabilityDurability

Water absorption/Thick.change @ RT, exposed edgesLong term durability:

No mold growth: Long term testing at +80C and 100% HR, exposed edges

No structural failure after: 2-wk heat/cold/humidity cycles (+80/-20C/100% HR)

Low creep ratio:After 1 million compression cycles the reaction force of the panel is above the design load of 750 N

Retained reaction force after fatigueAlucorkTM by MCGAlucorkTM by MCGFire, smoke & toxicity

Built-in profiles for seat/hand poles installationLarge standard panels: (4,6 m x 2,4 m)

AlucorkTM by MCGModular systemThe correct fit, alignment, and mechanical assembly between different parts of the complete railcar floor is made by interconnection profiles inserted into the edges of each floor panel.

These profiles, which are typically designed specifically for each project allow multiple types of assembly: lock&bond, fastening, simple positioning.

Extruded profiles will be designed to provide interface between the horizontal and the vertical parts of the floor.

Depending of the project, the floor may be a floating floor (decoupled by elastomeric strips underneath, or fixed to the car by means of bonding or fastening

In the manufacturing phase of the floor panel:

Much lower use of fossil resources Reduced impacts in all ecological footprint itemsIn the use phase a reduction of 200 kg (440 lb) in a rail car can save:

Co emissions:800 kg (1680 lb)/yearEnergy consumption:2,8 MWh/yearAlucorkTM by MCGEnvironmental footprint

AlucorkTM by MCGPanel manufacturing

AlucorkTM by MCGFloor assemblymind for metal