Ulus Metal. 9-Apr-14

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Ulus Metal

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History :

• 1970 Production of stamped metal parts for automotive industry

• 2007 Moved to a new plant in Gebze Industrial zone on a 8000 m2_{closed area.}

• 2009 First non-automotive business started

• Total Number of employees : 125 • Number of shifts : 1 shift

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Ulus Metal

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Ulus Metal

Worldwide Customer Portfolio

KYB Suspension Europe S.A. Spain

TENNECO AUTOMOTIVE Spain, Belgium, Germany, Czech, Poland, USA

THYSSENKRUPP BILSTEIN Germany, Romania, USA ZF SACHS

Turkey, Germany, Slovakia, Spain MAYSAN MANDO Turkey ISUZU Turkey MAGNETI MARELLI Poland WABCO

Germany, Poland, USA, Brasil, China, India EMERSON Climate Technologies

Northern Ireland, Czech Republic, USA, Belgium, China KNORR BREMSE – Hasse&Wrede Germany AL-KO Spain KONI Holland, Czech RECORD France GABRIEL Europe France BWI (DELPHI) Poland 3 9-Apr-14

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4 4 Caps Bracket Assemblies Spring Seats Stabbar Brackets Rolled Rings

Truck and LCV Chassis brackets Shock Absorber Parts

Eyering

Assemblies Washers Holders

Ulus Metal

Overview Product Families

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Cooling Compressor Components Brake System Components

Ulus Metal

Overview Product Families

Machined Parts

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Ulus Metal

Main OEM automotive projects 1/4

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ZF Sachs – Slovakia

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Fiat 330 Idea & Lancia & • Grande Punto Alfa 955 (Mito) Y413 – XC60

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ZF Sachs - Germany

W212 MFA EVO

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Magneti Marelli

Fiat Fiorino 330

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Ulus Metal

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ZF Sachs - Turkey

Fiat Doblo & New Doblo 263 & Fiat Palio & Fiat Albea

Renault L38 / Fluence

Ford Transit V184/V347 Ford Connect V227 New Transit V36X

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Ulus Metal

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Maysan Mando - Turkey

Hyundai MC Renault Clio

Hyundai IA Symbol

• Tenneco (Monroe) – Germany & Belgium

BR172 SLK

Renault Clio 4 (X98) Renault Trafic (X82)

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Ulus Metal

Main OEM Automotive projects 4/4

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ThyssenKrupp Bilstein - Romania & Germany

X90 911

NPR Trucks and NKR Light Duty Trucks Buses

Supplier for chassis parts. • ISUZU - Turkey

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• Experienced Project Management Team

• In house stamping die design and manufacturing

• Production flexibility for AM and OEM Projects

• Fast Prototype sampling

Ulus Metal

Project Management

•Reverse engineering for AM projects

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Ulus Metal

Toolshop

CAD systems : Siemens NX, Mastercam, EzCam Capabilities : Wire EDM CNC vertical machining CNC turning Surface grinding

Conventional turning and milling machines

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Transfer lines (600t-250t)

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Ulus Metal

Production Shopfloor

• Mainly for high volume

projects

• Transfer presses with 3D

transfer arms (X-Y-Z axis)

• 600 Tons

• 400 Tons

• 350 Tons

• 250 Tons

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•Transfer tool design and manufacture

Movie: Spring Seat Movie: Outer Bracket

Ulus Metal

Production Shopfloor – Transfer Press

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Progressive lines

• Progressive tools for higher

volume parts

• Tool capability of on one shot

1 – 2 or 4 parts production

• 100 Tons

• 250 Tons

• 300 Tons

• 350 Tons

• 400 Tons

• 500 Tons

Ulus Metal

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•Progressive tool design and manufacture

Movie: Inner Bracket

Steel band view of stabiliser bracket Progressive tool for stabiliser bracket

Ulus Metal

Production Shopfloor –Progressive Press

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Ulus Metal

Hydraulic Press - Deep Drawing

• Hydraulic presses with hydraulic hole punching machines • 600 Tons

• 250 Tons x 2 • 330 Tons

Movie : Production of deep drawn shell (2nd Operation)

Depth : 500 mm Diameter : 275 mm 9-Apr-14

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Manual tandem stamping (400t-30t)

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Ulus Metal

• Wide range of presses for less volume productions

• 40 presses from 30 Tons up to 400 Tons

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Ulus Metal

- CNC Machining

Movie : Production of muffler plate assembly

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Ulus Metal

Shock Absorber Body Welding Line

• Machines for producing Shock Absorber Body Assembly

(Automated Welding Line, welding fixtures, press-fitting presses, leakage test units, punching presses, control fixtures)

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•Mag Welding Line

•100% parameter controlled Cloos Welding Machines

•500A welding power source

•Servo controlled rotating movement torch

•MAG welding on upper mount assemblies

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•Spot Welding Line

•Projection welding – inner&outer knuckle brackets, hose holders, ABS cable holders

•Welding tools manufactured in-house

•Welding power 300-400-600 kVA

Ulus Metal

Production - Welding

Poka Yoke System for Renault Bracket Assy

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Ulus Metal

Auxiliary Operations

IN-HOUSE : • Deburring • Thread cutting • Riveting • Chamfering OUTSOURCED :

• Surface treatment (Zn-Fe coating, Zn-Ni coating, KTL painting) • Heat Treatment

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Ulus Metal

Raw Materials Used

MATERIAL TYPES

• Hot & Cold Rolled Steel

(DD11, DD12, DD13, S315MC, S355MC, S420MC, DC01, DC03, DC04) • Profile material for rolled rings

• Stainless Steel AISI 304 (1.4301)

MATERIAL THICKNESSES From 0,5 mm up to 6 mm

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Ulus Metal

Measurement Capabilities

Laboratory capabilities

• CMM DEA with PCDMIS-CAD ++ software with rotating and scaning probe

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• Shadow projector device

• Pull-out test device (5t capacity) • Flatness measurement device • Welding strength test and penetration test devices

CMM Table Size : 1200x1500x1000 CMM Table Size : 2700x1000x6660

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Ulus Metal

Quality system certifications

Certified by SGS for

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ISO TS 16949 ISO 9001: 2008 ISO 14001 OHSAS 18001

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Ulus Metal

New Investments

• 800 tons Mechanical Transfer Press (Delivery in August) • CNC Milling Machine

• Spot Welding Machine (750 kVa) • Coil Feeders

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ULUS METAL

Contact information:

Company Name : Ulus Metal Sanayi ve Ticaret Limited Şirketi

Address : Gebze Organize Sanayi Bölgesi

1000. Sokak No. 1039 Gebze-Kocaeli/ Turkey

Telephone no. : +90 262 677 10 21 – 5 lines

Fax no. : +90 262 677 10 26

Email _:_{[email protected]}

Web site _:_{www.ulusmetal.com.tr}

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Thank you for your attention…

ULUS METAL

www.ulusmetal.com.tr