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2009KORAM ZZM2 COMPANY OVERVIEW Company foundation April 1983 Board Members The president: Ewa Czajka Members: Mirosław Cendrowski, Arkadiusz Plewka Lokalisation Białołęka District, Warsaw Share capital 102 040 482,95 PLN Annual turnover 63 000 000 PLN Number of permanent employees 215 people The size 36 528 m 2 area 22 347 m 2 building Type of activity manufacture (injection moulding) and painting of the plastic parts, manufacture of single and double hardness PUR profiles, parts assembly
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2009KORAM ZZM3 WE COOPERATE WITHIN A GROUP KOŻUCHÓW 480 km ELBLĄG 295 km POMATICS Sp. z o.o. ŻUROMIN 145 km CIECHANÓW WARSZAWA FSO S.A. 105 km EŁK 235 km PUŁTUSK 60 km SIEDLCE 88 km GRÓJEC 60 km ZEM Ełk Sp. z o.o.
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2009KORAM ZZM4 HISTORY 1983 - the establishment of the company under the ZZM FSO name - the start with drive units assembly and equipment os short series of POLONEZ cars 1985 - the modern line of seat profiles production for motor vehicles industry setting 1991 - large plastic elements for POLONEZ car manufacture setting 1998 - setting of production of large-size plastic elements (bumpers, instrument panels, door trims) for Deawoo Lanos on the newJapanese machines 2000 - production development of parts for Deawoo Matiz 2005 - start of cooperation in the range of suppliers for Avto Zaz Ukraine 2007 - getting the certificate of Quality Management System that complies with ISO/TS 14001 2008 - start of cooperation with GM (production of PUR profiles and plastic elements for bumpers, painting and assembeling of bumpers, painting of spoilers and rocker panel moulding)
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2009KORAM ZZM5 MISSION AND VISION Our Mission: The clients are our major goods and fulfilling their needs and expectations is our major purpose Our Vision: We want to be the best partner for leading producers of different branches: automotive, RTV and AGD, furniture and others. Values: Professional approach to the customer service Honesty and reliability Care for natural environment Respect for the employees Constant improvement
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2009KORAM ZZM6 SHAREHOLDERS MEETING THE PRESIDENT OF BOARD AUTHORIZED AGENT FOR QUALITY MANAGEMENT SYSTEMS SECURITY, OC, SAFETY AND HEALTH,FIRE PREVENTION SPECIALIST LOGISTICS DEPT. IT DEPT. SALES AND NEW STARTS UP DEPT. PURCHASING DEPT. COMMERCIAL AND PRODUCTION TECHNOLOGY DIVISION FINANCE AND ACCOUNTANCY DEPT. ADMINISTRATION AND HUMAN RESOURCES DEPT. CONTROLLING FINANCIAL DIVISION FSO DEPT. MAINTENANCE DEPT. QUALITY INSPECTION DEPT PUR PROFILES DEPT. INJ. MOULDING AND ASSEMBLY DEPT. PAINT SHOP DEPT. PRODUCTION PLANNING DEPT. PRODUCTION ENGINEERING DEPT. QUALITY DIVISION ORGANIZATION CHART
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2009KORAM ZZM7 OUR CUSTOMERS
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2009KORAM ZZM8 MAIN PROJECTS PART NAMELanos T100 Matiz M104 AviaPolonezAveo T25X Volvo V50 Volvo V 70 Lublin Bumper Instrument panel Door trim Seat foams Small plastic parts Radiator grille Rails Covers
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2009KORAM ZZM9 SALES IN 2004 - 2008
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2009KORAM ZZM10 ALL DATA IS BASED ON ANNUAL BASIS EMPLOYMENT STRUCTURE
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2009KORAM ZZM11 Fire Prevent. Tanks Building no.2 - 4.720 m 2 - PUR Foams Production Building no.8 - 234 m 2 - Chemical materials warehouse Building no.3 - 641 m 2 -Maintains Dept. Building no.1A - 3.590 m 2 - Offices Building no.1 – 10.580 m 2 - Injection moulding - Paint shop - Assembly Lines Annopol Street Building no.7 2.304 m 2 Warehouses Building no.6 - 224 m 2 Total area: 36 528 m 2 - Retention Tank Parking Building no.4 - 54 m 2 - Reception COMPANY LAYOUT
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2009KORAM ZZM12 PARAMETERS OF THE MACHINES NoTechnical data UBE UBEMAX 3500 UBE UBEMAX 2500 Battenfeld BA-D 2200 Sandretto 650 Battenfeld BK-T 570 LS 300 Battenfeld BK-T 130 Battenfeld BA 80 1Max.locking force3500 T2500T2200T650T570T300T130T80T 2 Size of clamping plates 3000x26802460x22602700x23001260x12601280x1280 960x96 0 700x700590x590 3Max.opening gap2700 mm 1400 mm920 mm850 mm 800 mm 420 mm425mm 4 Distance between columns 2164x17001830x1500 1800x1400 /1360 820x820900x900 660x66 0 470x470370x370 5 Theoret.injection volume 12930 cm310838 cm312868 cm32860 cm33338 cm3 736 cm3 286 cm3201cm3 6 Working injection pressure 1760 bar1722 bar1920 bar1540 bar1344 bar 1860 bar 1746 bar1575 bar 7Max.weight11896 g9970 g11710 g2775 g3038 g677 g260 g183 g 8 Min.-max. of mould heigh 1000-1900 mm 900-1700 mm 1500-2000 mm 250-900 mm 375-850 mm 300 - 800 mm 200-450 mm200-425 mm 9 Processed materials Polypropylene (PP), copolymer (PP), Polyethylene (PE), Polystyrene (PS), Polyamide (PA), styrene copolymer (ABS, SAN) and POM, PC, PBT 10 Alignment rings diameter (female mould) --- 250/40 200/40 - 125/35 11 Alignment rings diameter (male mould) --- 115/50 200/50 - 125/40
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2009KORAM ZZM13 PAINT SHOP Paint shop features Working hoursDepends on the parts size and volumen Number of suspensions 130 trolleys (260 suspensions) Capacity60 trolleys/hour Size of elementMax.lenght of 220 cm Used paintsSolvent Type of paintingAutomatic spray CabinesFull climatization
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2009KORAM ZZM14 PAINT SHOP Control Panel Range of temperature between 20°C-23°C Range of wetness 60%-70% Boost Catalytic Friendliness Environmental (95% of combustion solid particles)
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2009KORAM ZZM15 PAINT SHOP 7 FANUC robots: One to overburned One to cushined Three based Two colorless Three catalytic robots are friendly for environment
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PRODUCTION CAPACITY OF THE PAINT SHOP BASED ON BUMPER EXAMPLE* over 700 000 parts/annually over 58 000 parts/monthly over 2 700 parts/daily QUALITY INSPECTION THE FLOOR CONVEYOR DRIVING UNIT RELOADING ZONE LOADING ZONE FRONT SLUICE UNLOADING ZONE PIEC SUSZĄCY BASE COAT BOOTH WASTE WATER TREATMENT PAINT MIXING ROOM AIR CONDITIONING CABINS PRIME COAT BOOTH CLEAR COAT BOOTH DRYING FURNANCE OMIAOMIA DRIVING UNIT WASHING * III shifts working AIR BOOTH PAINT SHOP
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2009KORAM ZZM17 PUR FOAMS LINE PUR foams line features The number of cassettes 34 (number of moulds in the cassette depends on the size of the element) Capacity204 cassettes/hour Size of the elementmax.1340x660x250 mm Used materialsDouble-hardness MDI components Load capacityFrom 80 to 350 N accordingly to EDS-T-76 DensityFrom 45 to 65 kg/m 3
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CANNON AFROS LINE PRODUCTION CAPACITY OF PUR FOAMS LINE * over 2 150 000 parts/annually over 179 000 parts/monthly over 8 500 parts/daily * III shifts working - back foam example CONVEYORS UNIT POURING HEADS AIR-BUBBLES TEARING COMPONENTS’ TANKS SEASONING CONVEYOR TOOLING CARRIER LINE
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2009KORAM ZZM19 CERTIFICATES CERTIFICATE OF CLEAN PRODUCTION– awarded in 1996 ISO 9002 CERTIFICATE - November of 1997 DF 100 Q PROGRAM 100 PPM SUPPLIER – April of 2000 ISO 9001:2000 CERTIFICATE - October of 2003
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2009KORAM ZZM20 ISO/TS 16949
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2009KORAM ZZM21 ISO/TS 14001
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2009KORAM ZZM22 PICTURES GALLERY INJECTION MOULDING MACHINES PAINT SHOP PUR FOAMS LINE PUR FOAMS LINE ASSEMBLY
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2009KORAM ZZM23 THE ADDRESS ul. Annopol 4, 03-236 Warsaw Tel. (+48 22) 811 54 80; (+48 22) 811 21 70 E-mail: koram@koram-zzm.com.pl Web: www.koram-zzm.com.pl
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THANK YOU! WE ARE LOOKING FORWARD TO COOPERATION WITH YOU. THE BOARD AND THE EMPLOYEES OF KORAM ZZM POLAND Sp. z o.o.
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