USA - China manufacturing facility - October 2012
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Transcript of USA - China manufacturing facility - October 2012
AVANTI Wind SystemsTower Internals, Made in China & USAOct 2013
Company Profile
AVANTI – a growing Company
Mission:
“Safe work in wind turbines.”
History:
AVANTI was established 1885 and have more then 100 years of experience with ladders.
AVANTI started off with production of wooden ladders and was a pioneer in the industry.Since then the product range has been extended to include ladders made of aluminiumand fibreglass.
Today the principal product range of AVANTI consists of internals for Wind Turbine Towersand Technical Services.
Company Profile
Sales:AVANTI is the market leader worldwide of products for safe work in Wind Turbines with sales and production activities throughout the world.
Head Office: DenmarkSales & Production: Denmark, Spain, Germany, China, USA, Canada, India, UK, Brazil & Australia.
Product Range Tower Internals
Tower InternalsA full line of tower internal per Your specification can be furnished competitively!
• Platforms
• Fences
• Support Beams
• Ladder Brackets
• Cable trays
• Brackets and weldments
• Manufactures, Supplied & labeled,
• Kitted per tower section or in bulk.
Tower Internals Experience with Tower Internals export
Full scope currently handled and quoted by AVANTI:
• Climbing Ladder w. Fall Protection (Manf.)• Cable Ladder (Manf.)• Ladder Accessories Scope (Manf.)• Service Lifts (Manf.)
• Structural Mechanical Platforms (Manf.)• Fences / Shielding (Manf.)• Other Mechanical parts and Three legs (Manf.)• Tower weldment’s / welding bosses (Manf.)
• Door and door hardware (Manf.)• Staircases (Manf.)• Hardware / Fasteners (Purchase & Kit)
• Grid Cable trays (Purchase & Kit)• Fan’s (Purchase & Kit) • Electrical cables (Purchase, Cut & Kit)• Roxtec cable gland components (Purchase & Kit)• Lighting (Purchase & Kit)• Tarpaulins (Purchase & Kit)• A4 Electrical Box (Purchase & Kit)
Example from a Tower Bill of Material: 500 line items in the top section 190 line items in the mid section324 line items in the base section
Tower Internals Experience with Tower Internals
Excluded from AVANTI scope:
• Flanges,
• Tower Plate Steel
• Tower Door frame
• Tower assembly / welding labor
• Paint
Product Range Tower Internals
Product Range Tower Internals
Product Range Tower Internals
Product Range Tower Internals
11
Tower Internals Experience with tower internals
Previous and current deliveries of tower internals kits to tower plants in USA:
• Ameron: 60 sets Q1 / Q2, 2010 (Full Scope)• Ameron: 44 sets Q2, 2010 (Full Scope)• Ameron: 34 sets Q2, 2011 (Full Scope)• Katana: 9 sets Q2, 2011 (Full Scope)• Katana: 73 sets Q3 / Q4, 2011 (Full Scope)• Katana: 68 sets, Q1, 2012 (Full Scope)• Ameron: 75 sets, Q1 / Q2, 2012 (Full scope)• Ameron: 10 sets, Q3, 2012 (Full scope)• BroadWind: 21 sets, Q2 / Q3, 2012 (Full Scope)• BroadWind 15 sets, Q3, 2012 (Full Scope)• Katana: 57 sets, Q2 / Q3, 2012 (Full Scope)• Katana: 89 sets, Q2 / Q3, 2012 (Full Scope)• Katana: 43 sets, Q2 / Q3, 2012 (Full Scope)• Martifer H: 25 sets, Q1, Q2 2012 (Full Scope) • DMI: 35 sets / 35 sets, Q1, Q2, Q3, 2012 (Partial Scope)• CS Wind: 30 sets, Q2 2011 (Partial Scope)• CS Wind: 17 sets. Q2 2011 (Partial Scope)
Tower Internals Areas of Success
• Supplies both Kit sets as well as bulk packaging
• The customer base likes our labeling
• All boxes and sub boxes have part numbers labeled cleanly
• Avanti is able to provide support to assist in plant startup and installation training
• Avanti is responsive to the customers. • We visit every customer on average every 4 weeks for tower internals projects• Weekly status calls with customer for tower internals projects
Tower InternalsEngineering Competences
• Avanti has gained great experience over the years, by integrating our different models of Service Lifts, Climb Assistance, Ladders and Fall Protection Systems in our customer´s Tower Internals concepts.
• Always looking for the best solution for our customers in terms of Safety, Cost and User Satisfaction, we have advised and proposed design modifications of tower internals, for a better integration in the Tower.
Tower InternalsEngineering Competences
• This great know-how is what give us the skills and capabilities to partnership with our customers in several ways, by producing internals, by generating all the production drawings from our customers 3D designs, or by leading the Complete Design of Tower Internals.
Product RangeAluminum Ladders
AVANTI LaddersAVANTI supplies over 500 km of ladders for wind turbine towers annually.
Ladders are approved for global use.
Ladders are independently tested and far exceed ANSI 14.3 requirements as well as EN 131.
A ladder deflection less than 0.01% provides high stability during the climb.
Nacelle ladders in different configurations are available.
”State of the art” ladder production in China, USA and Germany
Quality assuranceISO 9001
• One global Quality Policy in AVANTI • Same high level of quality through out
the world - for products and services • AVANTI provides a high level of safety
and ensure that local or global safety requirements always are fulfilled
• One common Quality, Environmental and Safety Management System in all AVANTI BU
• ISO 9001 - 2008 • ISO 14001 - 2004• OHS 18001 - 2007
• We focus on continually to make improvement of effectiveness of the QMS
Welding QualificationsEN ISO 9606-2
• All AVANTI welders are tested and qualified according to EN ISO 9606-2
• WPQ / WPQR’s are independently tested by SGS.
• Same high level of welding quality through out AVANTI Tower Internals Production Facilities.
• We focus on continuous improvements and training.
• Material and Weld certifications are available upon request.
Avanti Wind Systems- Tianjin, ChinaLocation
Avanti Wind Systems- Tianjin, China Location
Tianjin/Tianjin Economic-Technological Development Area (TEDA) keywords:
• 4th biggest port globally in terms of cargo tonnage throughput
• 10th biggest port globally in terms of TEU throughput
• Beijing Airport 180 km away, Tianjin Airport 38 km away
• Distance from TEDA to port: 5 km
• Tianjin-TEDA metro link
• Beijing-Tianjin high speed train link
• Connected to 9 major railroads
• Connected to 10 major expressways
• Population: 13 mio.
• Centrally located for Asian windmarket
Tower Internals, Made in ChinaAvanti Organization, BU China – Tianjin / Shanghai – Sept
2012
Shanghai, Sourcing / Quotation team:
Daniel Yang, David Wang, Vivian Chen.
Dedicated Tower Internals Staff
Above is in addition to our AVANTI Shanghai and Beijing organization consisting of 60 people
Rainbow ZhaoGeneral Manager
Sunny Jia + (1) NNEstimator
Kevin Shao Plant Manager
Jake ZhangQuality Engineer
Terry Zhao Finance Supervisor
Vincent Sun Manufacturing
Engineer
5 Welder2 Grinder1 Bending
1 Miller1 Warehouse keeper
12 Operators
Peter JingProduction Supervisor
LogisticsVanilla Cao
Lucy Zhang
Venus LiuPurchaser
Quality Inspectors(2)
Bill ChenQEHS Manager
Tricia ChaoCashier
Avanti Wind Systems- Tianjin, China Manufacturing Facility
The Manufacturing Facility
Avanti Wind Systems- Tianjin, China Manufacturing Facility
Building no. 31
- 8,000 m2
Avanti Wind Systems- Tianjin, China East Side of Building Entrance
Avanti Wind Systems- Tianjin, China South Side of Building
Avanti Wind Systems- Tianjin, China West Side of Building
Avanti Wind Systems- Tianjin, China North Side of Building
Avanti Wind Systems- Tianjin, China
Machine List and Capabilities
Tower Internals, Made in China Competencies
Manufacturing Processes implemented at AVANTI Tianjin:
• Bending
• Shearing
• Welding
• Milling
• Rolling
• Sawing
• Grinding
Capabilities already in place at AVANTI Shanghai / Tianjin:
• Safety & Quality
• Lift / Ladder production
• Assembly / Kitting
• Customer knowledge
• Engineering
• Logistics
• Project Management
• Training
• Field Service
Avanti Wind Systems- Tianjin, China
Yawei CNC Pressbrake
Bending Length- 5.1 MetersTonnage: 220 Tons
Max. Thickness Alu: 12mm
Max. Thickness Steel: 12mm
Current Tooling:
Radius 10 mm Radius 15 mmRadius 5mm
Avanti Wind Systems- Tianjin, China
Yawei CNC Shear Machine
Cutting Length- 4.05 Meters
Shear Thickness: 8mm Max.
Avanti Wind Systems- Tianjin, China
Rolling Machine
Rolling Thickness- Max.12mm
Max. Rolling Width: 2 Meters
Avanti Wind Systems- Tianjin, China
Rolling Machine
Rolling Thickness: Max. 12mm
Max. Rolling Width: 2.0 Meters
Avanti Wind Systems- Tianjin, China
Circular Saw Machine
Cutting Length- 700mm
Avanti Wind Systems- Tianjin, China
M6 Milling Machine
Table Size (mm): 305x1370
Travel X: 770Travel Y: 405Travel Z: 505
Spindle Speed (rpm): 70-5440
Avanti Wind Systems- Tianjin, China
M4 Milling Machine
Table Size (mm): 254x1270
Travel X: 760Travel Y: 405Travel Z: 400
Spindle Speed (rpm): 70-5440
Avanti Wind Systems- Tianjin, China
Lathe Machine
Model: CDS6136 DMTG
Range: Diameter 360 x 750
Avanti Wind Systems- Tianjin, China
Panasonic MIG Welding Machine
Model: YD-400GE with built in Cooling unit.
Push wire feed system.
Can be used for Steel and Aluminum
Avanti Wind Systems- Tianjin, China
Panasonic TIG Welding Machine
Model: YC-500GWX with Separate cooling unit
Can be used for Steel and Aluminum
Avanti Wind Systems- Tianjin, ChinaFixtures and Templates
Fixtures and Templates
Avanti Wind Systems- Tianjin, ChinaFixtures and Templates
Avanti Wind Systems- Tianjin, ChinaFixtures and Templates
Avanti Wind Systems- Tianjin, China
Inside the Avanti ManufacturingFacility
Present Day
Avanti Wind Systems- Tianjin, ChinaTianjin Facility Layout
Ladders
Avanti Wind Systems- Tianjin, ChinaShear, Bending, Rolling, Saw and Milling Area
Avanti Wind Systems- Tianjin, ChinaShear, Bending, Rolling, Saw and Milling Area
Avanti Wind Systems- Tianjin, ChinaWelding Room
Avanti Wind Systems- Tianjin, ChinaGrinding Room
Avanti Wind Systems- Tianjin, ChinaAssemby and Kitting Area
Avanti Wind Systems- Tianjin, ChinaAssemby and Kitting Area
Avanti Wind Systems- Tianjin, ChinaLadder Area
Tower Internals, Made in China Time plan
Time Plan:
• ISO 9001 Certifiation June 14, 2012
• ISO 14001 Certification August 10, 2012
• OHSAS 18001 Certification August 10, 2012
Continuous Improvements for Avanti Tianjiin Tower Plant :
• MIG Welding Machine WPQR Approval Completed - Sept.
• MIG Welding Welders Certifications (WPQ) Completed – Oct.
Tower Internals, Made in USA AVANTI Location in USA
Tower Internals, Made in USA AVANTI Wind Systems Inc., New Berlin, Wisconsin, USA
Tower Internals, Made in USAFacility - Avanti Wind Systems Inc.,
Tower Internals, Made in USA Facility
Tower InternalsProduction
Service Lift Production
80,000 sqf
Current tenant since Oct 2008
Service Lift Production: 2,300 sqmOffice Area: 300 sqm
2012 Expansion:Tower Internals Prod: 5,400 sqm
Total facility: 8,000 sqm
Ladder Production: 2,300 sqm(Separate building)
Location:
• Adjacent to Major Express way• 15 min from Gen. Mitchell International Airport• 30 min from Milwaukee Harbor• 1.5 hr. from Chicago, O’Hare Int. Airport
Tower Internals, Made in USA Capabilities
Manufacturing Processes being implemented at AVANTI USA, completion by Aug 2012:
• Bending
• Shearing
• Welding
• Milling
• Rolling
• Sawing
• Grinding
Capabilities already in place at AVANTI USA:
• Safety & Quality
• Lift / Ladder production
• Assembly / Kitting
• Customer knowledge
• Engineering
• Logistics
• Project Management
• Training
• Field Service
Tower InternalsAluminum Ladders – USA Production
Tower Internals, Made in USA
Press Brake
320 ton capacity
•6 mm Thick Mild Steel @ 14’ width
•9 mm Thick 5052 Aluminum @ 14’ width
•18” throat•16” stroke
Tower Internals, Made in USA
Rolling Machine
• 3/16” thick mild steel @ 5’ width
Tower Internals, Made in USA
Cutoff Saw
Tower Internals, Made in USA
Milling Machine
Tower Internals, Made in USA
Welding Area
• MIG (pulse)• TIG capabilities
Tower Internals, Made in USA
Fixture Tables
Tower Internals, Made in USA
Tower Internals Ware Housing
Tower Internals, Made in USA
Kitting Area
Tower Internals, Made in USA
Wire Measuring & Cutting Machine
Tower Internals, Made in USA
Runner Operations & Small Kitting Area
Tower Internals, Made in China & USAQuestions and Answers
Q & A
Thank you!