ZKM forging acquiring aerospace credentials and orders

Citation

(2008), "ZKM forging acquiring aerospace credentials and orders", Aircraft Engineering and Aerospace Technology, Vol. 80 No. 5. https://doi.org/10.1108/aeat.2008.12780eaf.001

ZKM forging acquiring aerospace credentials and orders

Article Type: Features From: Aircraft Engineering and Aerospace Technology: An International Journal, Volume 80, Issue 5

At the time of its acquisition by Ladish Co., Inc. in 2005, ZKM Forging, one of Poland’s largest and best-known general industrial forge shops, had no aerospace business. Within three years, Ladish successfully installed an array of high-tech business systems and sophisticated capabilities designed to satisfy the standards of demanding aerospace customers. This investment opened the door to involvement with European-based aerospace supply chains and quickly added aerospace-structural components to ZKM’s list forging manufactures.

In the beginning, engineering upgrades

ZKM made a commitment at the time of acquisition to develop and maintain the technologies, systems and training necessary to design dies and forgings based on aerospace-customer models. ZKM trained its design engineers to use CAD/CAM software, such as CATIA, and began working with first-tier suppliers as well as international systems integrators within the global aerospace community to acquire aerospace business.

Upon “going live” with a plant-wide IT system in January of 2007, ZKM was able to demonstrate to potential customers that the forge shop had achieved a seamless and paperless flow of information from its die- and forging-design departments through the entire factory. ZKM’s IT system is a clone of the IT systems used throughout its parent company’s US business units. This system provides accuracy and accountability of data from the first steps of the forging process to the last. The company’s enterprise-wide IT system now enables any Ladish business unit to perform as a supplier to aerospace supply chains - serving any customer, in any part of the world.

This IT capability also helps ensure that every detail of a customer’s order is executed exactly to specifications and that these new, customer-specific steps are embedded in the forging processes for future orders from that customer. Moreover, this system assists in achieving optimal levels of efficiency in operational management, including cost planning, control of processes, raw material acquisition, parts flow and forging, heat treating and machining.

Material preparation Is also upgraded

The raw-material-stores operation also became a target for improvement. The objective was to increase the synchronization of workflow within the production process and minimise queue-and-wait time. For more than a decade, ZKM had been implementing lean techniques to serve their traditional business segments, but now management’s intent was to expand and upgrade this ability for aerospace materials arriving at the shop.

By installing new cutting equipment in the raw-material-stores department, ZKM could meet the requirements for bidding on certain types aerospace work, while simultaneously improving material flow for existing general industrial forging customers. Recently, the new band-saws prepare all material used in the plant’s forging process. These saws provide faster cutting and greater precision. This capability helps ZKM maximize raw material utilisation, successfully execute throughput-improvement initiatives, and reduce workflow disruptions throughout the plant. The new saws give ZKM the ability to cut materials up to 400 mm in-house and to meet a variety of aerospace customer standards.

Die manufacturing expanded

ZKM has reengineered significant areas of its factory to achieve rapid manufacturing turn times while meeting aerospace quality levels. To help meet those objectives, ZKM reorganized its 8,000 m² die manufacturing area to enable seamless work-in-process flow (Figure 1). By installing new CNC machine tools, ZKM expanded its die-making capabilities and simultaneously was able to improve die-manufacturing lead times while reducing opportunities for human error (Figure 2). A new coordinate measuring machine (CMM) and optical equipment were acquired to perform dimensional inspections on each die produced. This innovation supports the departmental vision of making sure every die-making step is performed correctly the first time.

Figure 1 In-house forgoing and die desing enhance ZKM's ability to optimize materials and process capablities

Figure 2 Extebsive, in-house die-making facilities help ZKM keep pace with customer demand for short manufacturing lead times

However, ZKM had to look beyond its die-manufacturing capabilities to maximise improvements. Production management also needed to perform die changeovers more quickly to achieve the additional objective of rapid manufacturing. To reach this goal, ZKM has dedicated 1,000 m² of plant space to a fully automated die-storage and die-retrieval area, which is the largest in Central Europe. Within this area stand more than 2,000 individual dies ready at a moment’s notice to be automatically rotated into service. Die setups and teardowns, retrievals and replacements are tightly synchronised with the manufacturing schedule to ensure timely delivery and return of dies.

This approach to die manufacturing and die management is vital, because the rate of die production is increasing rapidly. In 2007, ZKM produced 25 per cent more dies than in 2006 and the company expects to increase production by 33 per cent in 2008. To support this growth, ZKM purchased two new, fully automated CNC machines that entered production during the first quarter of 2008. ZKM now produces all dies and tooling in-house for all segments of business, including aerospace.

Forge press area receives investments

With a dozen presses ranging in capacity from 1,000 to 4,000 tons, ZKM offers customers a range of forging options, some of which are unavailable elsewhere in Central Europe. Furthermore, ZKM press capabilities exceed, in some cases, those available at Ladish’s flagship forge shop in Cudahy, WI, USA. For example, at ZKM, preforms are manufactured using the plant’s upset and roll-forming capability - offering an economical way to produce many types of aerospace materials.

ZKM’s Lasco Press is an exceptional resource. Unlike traditional hydraulic presses, it has a unique “hard-blow” capability which allows it to impart greater definition to pressed parts. This press was upgraded with new hydraulics in 2007, and can now handle weights ranging from 5 to 55 kg, lengths up to 1,000 mm and diameters up to 280 mm.

Thanks to additional investments in auxiliary equipment, such as new manipulators, ZKM can now move parts through the production process with greater speed than was possible in the past. These resources enhance the ability of the hammers and presses to provide more responsive manufacturing cycle times, which are often challenging due to time-compressed customer-build schedules. These improvements in the forge shop expand the capabilities of ZKM as a whole, because they accelerate the forging of parts for a variety of sizes, materials and shapes.

Forging hammers rebuilt

ZKM has ten single-acting hammers, rated from one to 10 metric tons, as well as a Beche counter-blow hammer rated at 50,000 mkg (Figure 3). Two of the larger hammers were recently rebuilt and equipped with new rams. ZKM’s hammers can handle weights up to 300 kg, diameters up to 450 mm and lengths up to 1,200 mm.

Figure 3 The 11 hammers at ZKM are rated from one to ten tons, including a counter-blow hammer rated at 50,000 mkg

Drawing on its rotary- and box-furnace resources, ZKM can satisfy all heating requirements for aerospace forging. Nevertheless, ZKM plans to upgrade the combustion systems for a number of these furnaces before the end of 2008, in order to improve efficiency. ZKM is also adding new furnaces designed to better accommodate the smaller quantities common with aerospace orders. These upgrades to internal equipment help ZKM streamline processes, increase efficiency, and improve manufacturing reliability.

Nondestructive evaluation certification awarded

To become an aerospace supplier, a shop must have first-rate nondestructive evaluation (NDE) capabilities. To offer customers this testing service, ZKM expanded its existing magnetic particle inspection (MPI) capability for general industrial forging to meet the standards for performing the post-forging evaluation of aerospace parts. To meet aerospace standards, the company needed to have an operator who met not only Level III Certification for general industrial production, but for aerospace production as well. In June of 2007, ZKM’s inspector completed this training, qualifying the shop as meeting EN4179 and NAS410 standards. In January 2008, ZKM received Nadcap approval for MPI (Figure 4).

Figure 4 ZKM's forging operation meets the most global standards for heat treating and inspecting aerospace components

Ensuring that parts meet dimensional requirements is a critical NDE activity. Aerospace NDE calls for capabilities that can only be achieved using certain types of equipment. The new CMM station ZKM has acquired is an example of this type of equipment (Figure 5). This unit is portable and can be easily moved to every corner of the plant. It is now used to satisfy aerospace NDE inspection requirements. In addition, it performs dimensional inspections of general industrial components, as well as dimensional inspection of dies produced in the company’s die-manufacturing department.

Figure 5 ZKM forging maintains a variety of inspection tools, such as this CMM unit, to insure the dimensional accuracy of parts

ZKM has also acquired a new grit-blast machine to complement its existing shot-blasting capability. The grit-blasting capability is necessary for preparing the surface of aerospace components for MPI inspection. With the acquisition of this piece of equipment, ZKM now has the hardware resources to conduct aerospace-quality NDE.

However, hardware is only as good as the people who use it. Executing ZKM’s aerospace business strategy also depends on a population of highly trained professionals skilled in following the aerospace quality system. Therefore, ZKM’s investments in hardware and quality systems are accompanied by complementary investments to train the employees who use the new equipment.

Future investments in the area of NDE, now in the process of being installed, include the construction of ultrasonic, fluorescent-penetrant and etch inspection stations.

New controls and certifications for heat treating

ZKM has upgraded many of its furnace and process controls during the last two years. These upgrades demonstrate that ZKM can meet and maintain standards necessary for aerospace heat-treating. Currently, the company has four electric heat-treat lines that supply continuous processing through all of the high- and low-temperature heat-treat cycles need for successfully processing aerospace alloys. ZKM has acquired Aerospace AMS2750 approval and its heat-treating department has been approved by a number of aerospace customers. Furthermore, the department is in the process of acquiring Nadcap approval for heat treating. In step with the pursuit of Nadcap heat-treating approval, upgrades are now being installed on four electric-box furnaces that provide oil and water quenching for aerospace components. When installation is complete, ZKM’s heat-treat capabilities will meet all technical requirements for steel, titanium and other aerospace alloys. Upon receipt of Nadcap heat-treating approvals, expected during the fourth quarter of 2008, ZKM will have established itself as one of Europe’s top-tier aerospace forge shops.

Met Lab upgrades in process

ZKM performs a variety of tests in its metallurgical laboratory, including: chemical, micro- and macro-structural analysis, room-temperature-tensile and impact-strength tests, and other types of mechanical, destructive and nondestructive testing (Figure 6). The lab has long met standards for general-industrial-forging testing, but currently subcontracts some aerospace testing. However, with the purchase of a new tensile-test machine, the upgrade to ZKM’s met lab is almost complete and soon the vast majority of aerospace testing will be performed in-house. For any customer requiring Nadcap certification of the met lab, ZKM will be able to obtain that certification by early 2009.

Figure 6 Microstructural analysis is one of the many destructive and non-destructive tests offered by ZKM's in-house metallurgical laboratory

Basic quality capabilities are in place

ZKM maintains numerous quality certifications, including: QS 9000, ISO9001:2000, ISO/TS 16494:2002, and AS9100:2004. As noted, these certifications have recently been supplemented by Nadcap approvals in the areas of nondestructive testing. The company has a number of customer approvals and also has multiple quality-related initiatives underway that will be completed in 2008 and early 2009.

Finish machining

Finish machining, like nondestructive testing, is a value-added service many customers demand. ZKM recognises these capabilities are essential for supporting future work from first-tier suppliers and leading aerospace OEMs. In August 2007, parent company Ladish announced an expansion of ZKM’s finish-machining capabilities in a facility adjacent to ZKM’s plant in Stalowa Wola, Poland. In addition to finish machining, ZKM is also in the process of installing an ultrasonic fluorescent-penetrant and etch inspection capabilities. By making a commitment to install the finishing and testing systems and support trained personnel in-house, ZKM will accelerate its transition into an operation that can fully meet requirements for manufacturing the most demanding aerospace components, including rotating parts.

ZKM Forging’s business plan calls for expanded participation in multiple segments of the aerospace market, no matter what specific demands may emerge for different types of components, materials and applications. The forge shop is on track to double the size of its aerospace customer base in 2008 and maintain steady growth in aerospace production. The company has designed an approach to investment and production that will allow it to move nimbly in whatever direction customers require. In short, ZKM is executing a long-term vision for its growing aerospace activity - enabling an integration of capabilities in an environment of continuous improvement that satisfies customers.

Jack FranczakQuality and Technology, European Operations Ladish Co., Inc.