Company presentation 2015
Company presentation
2015
MCG site
Manuel Conceição Graça, Lda.
Family Owned Private Company
Located in Carregado, PORTUGAL
Over 60 years experience
Steel parts and assemblies, tool an die development and manufacturing
MCG plants
Total area= 96.000 m²Covered = 34.000 m²
Metal1 – Stamping, welding, assembling, surface treatment
Metal 2 – Tool shop, machining
Metal 3 – Laser, bending, welding
Metal 4 – Stamping
Metal 5 – Assembling
Employees MCG
Business Areas
Prototyping and rapid manufacturingDesign, production and assembly of metal assemblies Metal assemblies
and components for the automotive industry
Development and manufacturing of stamping tools & dies for the automotive industry
R&D projects
Turnover
Destinations / Shipments
2014
• 46.000.000 shipped parts
• 30.000 shipments
• 130 clients/destinations all business units
MCG @ GM
General Motors' Supplier
Quality Excellence Award
2013/2014
Opel’s Live Auditorium
Rüsselsheim, Germany
September 30, 2014.
MCG ToolingBusiness Unit
MCG tooling supplies automotive industry tier 1 suppliers and OEMs that manage large scale outsourcing programs for stamping tools (progressive and automatic transfer tools) in order to achieve simple and competitive solutions for complex situations, succeeding
in their industrialization programs.Unlike low-cost, unqualified companies and with little or none
experience in analyzing and implementing serial production processes, MCG provides qualified and competitive personnel,
focused on optimizing customers total cost.With work based on its solid experience in stamped parts production, always under the highest automotive industry
standards (ISO9001, ISO/TS16949), MCG manages to get the best integrated solution (one stop shop), consisting in a reliable and
flexible partner as shown by several implemented programs with costumers like GM/Opel and VW (Body-in-White), Faurecia (Seat
Structures), CBI (DrumBreaks).
MCG Tooling Value Proposition
what we offer
MCG Tooling
our focus
MCG is a manufacturer for Stamping Tooling such as:
Progressive Stamping Tools up to 4500mm
Automatic Transfer Stamping Tools up to 6500mm
Tandem Transfer Stamping Tools
Hybrid (Progressive + Automatic Transfer) Stamping Tools
Checking Fixtures
Stamping tools with special features (in-die ops and automation)
MCG is equipped for Big Volume Tooling
MCG is able to validate in real conditions serial life conditions in most of the cases
MCG Tooling
project management driven
MCG is working on a project management logic
Periodic full detail reporting, conf calls
Centralized communication channels by the PM, or
Decentralized communication peer to peer according to clients needs
English as our official language
MCG Tooling Partners
MCG Tooling Partners
our partners for materials and heat treatments
Material and Heat Treatment from Thyssen:
Thyssen Steel Center at 2Km from MCG. Total flexibility.
The heat treatments are made by Thyssen in Marinha Grande
Material and Heat Treatment from Bohler:
Representative from Bohler in Portugal called UniversalAfir.
Material and Heat Treatment from Uddeholm:
Representative from Uddeholm in Portugal called Ramada.
MCG Tooling Partners
our partners for standard components
Standard Components from Fibro:
Representative from Fibro in Portugal called Ferrometal
Also direct contact to Fibro Germany
Volker Rupprecht – International Sales
Standard Components from Voestalpine:
Direct Contact to Germany
Frank Amede, Andreas Gayer – International Sales
Standard Components from Stack Normalien:
Direct Contact to Germany
Bernhard Reichl – International Sales
MCG Tooling Partners
our partners for coatings
Coatings from Oerlikon Balzers:
Experience with Balinit Lumena and Futura Nano
Direct supplying in Portugal, Leiria
Coatings from Prirev:
Portuguese Supplier
Experience with TiN, CrN, TiCN, ZrN, AITiN and WS2 solid lub
Coatings TEandM:
Portuguese Supplier
MCG Tooling Partners
our academic R&D partner
Since its creation in 1911, InstitutoSuperior Técnico is the largest and most reputed school of Engineering, Science and Technology and Architecture in Portugal.
It has three camps, all located in the Greater Lisbon area (Alameda in Lisbon, Taguspark in Oeiras and Tecnológico e Nuclear Campus in Loures),
http://tecnico.ulisboa.pt/en/
MCG Tooling Partners
our academic R&D partner
MCG works in cooperation with IST and PhD Paulo Martins on several projects that led to several paper publications and magazine covers
MCG Tooling Partners
MCG sponsors manufacturing labs at IST (NOF)
Tooling RelatedSoftware and
Personnel@ MCG
CAD/CAE/CAM UNIGRAPHICS-NX SIEMENS
CAD/CAE CATIA DASSAULT SYSTEMES
CAM TEBIS
CAD SOLIDEDGE SIEMENS
CAE AUTOFORM
CAQ PC-DMIS AND GEOMAGIC
LIQUID PLANNER
MCG Tooling
engineering and management software list
7 Tooling Engineers (up to 40 years in experience)
10 Assembly/Try-Out workers (up to 30 years in experience)
2 Project Managers + 2 Progress Monitors
5 Process Engineers/Machining Programmers
On tool shop we are able to work 3 shifts
MCG Tooling
engineering and management personnel list
Tooling RelatedNew Investments
@ MCG
MCG Tooling new investments
catia
MCG Tooling new investments
autoform
MCG Tooling new investments
tebis
MCG Tooling new investments
precision universal tester
Shimadzu | AG-Xplus Series 50 KN
MCG Tooling new investments
laser scanning arm
Quality reporting
Reverse Engineering
Tooling and Part checking
2,7m spherical working volume
Related softwares:
Cam 2
Polyworks Inspector
Geomagic
faro edge 2.7m
MCG Tooling new investments
5 axis machining center
DMG DMU 60 eVo linear
New Plant Metal 4 | New 3.300 ton press
Machineryfor Big Tooling
MCG Tooling
specific machinery for big tooling
Milling Machine 4500*2600*1000
MCG Tooling
specific machinery for big tooling
Laser Machine 4000*2000
MCG Tooling
specific machinery for big tooling
Small to medium machines for smaller components
MCG Tooling
specific machinery for big tooling
Transfer Mechanical Press 800Ton (4500*2100)
MCG Tooling
specific machinery for big tooling
Progressive Mechanical Press 800Ton (4500*2100)
MCG Tooling
specific machinery for big tooling
Mechanical Press 3300Ton (1500*2500 + 6400*2500)
Tooling RelatedR&D activities and projects
@ MCG
R&D Projects
TUBE FORMING
R&D Projects
Multi parts assembling and mechanical coupling systems
Challenge:To replace the welding
connections by others with the same mechanical characteristics
Conventional approachConventional welding
MCG Approach:Replacing conventional welding
by mechanical connection based on tube forming operations
SPIF
R&D Projects
SINGLE POINT INCREMENTAL FORMINGSmall batch production, prototypes and more diversity of productsPart production directly from the CAD design using CNC CNC machine with no need for stamping tools.
Challenge:Produce functional prototypes without
tooling investment.
Conventional approachProduction of conventional tools for
prototypes production.
MCG Approach:Depending on part geometry we have
the two options:SPIF and laser-cutSPIF, laser cutting and conventional stamping tools.
MouldCork
R&D Projects
Challenge:Optimize thermal, acoustic and
damping characteristics on structural metal components
Conventional approachUse of insulators and damping
materials applied after assembling operations
MCG Approach:Optimize a composite cork base
polymer for conventional stamping process, taking advantage of three characteristics associated with cork:
Low weightHigh acoustic and damping performanceHigh thermal performance
LaTch 1 | Lightweight Thermoplastic Composites
R&D Projects
ObjectiveDevelop and integrate new composite materials based on unidirectional thermoplastic and its processing techs.
ImplementationBuild a prototype of a structural automotive component taht is currently made out of steel
HowTest new materials and processes to try and reduce weight, matching the original strutural performance
CalendarStart - Jan 2014; End – Jul 2015
LaTch 2
R&D Projects
Project aiming to develop, build and test a hybrid automotive seat demonstrator (recliner and back/bottom sections only)The carbon reinforced polyamide part and additional metal inserts are then join together in a overmouldingprocess
Development of know-how on different hybrid joining processes (bonding, etc)
Improvement on tooling (LATCH 1) design and manufacturing; demo manufacturing on pre-industrialization environment.
MaxNesting
R&D ProjectsChallenge:Reduce raw material consumption to theTheoretical minimum with no additionalblanking operation.
Conventional approach:Reduce raw material consumption withblankingoperation
MCG Approach:MCG MaxNesting synthesizes blanking+ stamping in one operation
Customer Benefits:Lower piece cost
Raw material optimizationLess operationsOptimized machine occupation
Same industrialization cost
MCG Tooling
Tooling Case Studies
MCG Tooling – Case Studies
extrusions
3mm thick material, 18mm final extrusion
in-die tapping
push out force of more than 12 tons
in an m12 tap
85mm
18
MCG Tooling – Case Studies
stamping of big parts with material optimization
870 800
200
1.7mm thick sheet metal
1740mm*1000mm initial blank
special nesting and stamping position meant a real saving of 1kg per two parts, meaning more than 40.000€/year saving, when compared to similar
processes in same customer
MCG Tooling – Case Studies
safety products – drum brakes
highly precision and stable 3mm thick part
from prototyping to tooling development for tandem line presses.
550mm
275
MCG Tooling – Case Studies
safety products – hand break lever arm
high complexity parts, with high precision for final assembly.
550mm
280
MCG Tooling – Case Studies
safety products – motor housing
deep draw on aluminium, with high precision requirements
.
550mm
80mm
60mm (90º vertical)
3100mm
MCG Tooling – Case Studies
tooling in-die operations
Integrated processes allows us to meet capacity demands, still maintaining affordable and competitive prices
in-die tapping
in-die piercing
MCG Tooling – Case Studies
other products
450
copper parts
spring steel precision parts
hss steel parts
Portfolio MCG automotive
Portfolio MCG automotive
Portfolio MCG automotive
Portfolio MCG automotive
Portfolio MCG automotive
Portfolio MCG automotive
Portfolio MCG automotive
Portfolio MCG automotive
Portfolio MCG automotive
Portfolio MCG automotive
Portfolio MCG automotive
Portfolio MCG automotive
Portfolio MCG automotive
Teams & Plants
Quality Department
Quality Department
Recent acquisitions: FARO ARM
- 3D measurement anywhere;- Quick check when it comes to tools;- 100% comparison to a 3D Model.
Project Management
Stamping
Auto-Transfer max 8 m | 3.300 ton
Progressive max 4.5 m | 800 ton
Transfer max5.0 m | 1250 ton
Materials:
Mild steel & HSS steel
Aluminium
Stainless Steel
fully automated conveyors for scrap recovery with steel/aluminium segregation
Plant | Metal 1+4
Stamping
Plant | Metal 1+4
Welding, assembling, surface treatment
Welding and Joining capabilities
Robot & Manual welding
Arc Welding
Resistance / Drawn Arc
Tapping / Riveting / Clinching (in die & stand alone)
Materials: Sheet Metal & Tube, Bolts / Nuts / Rivets / Studs, Springs
Surface treatment
KTL Line
Epoxy Line
Annealing Line
Degrease/Washing
Capable to manage large scale programs for stamping tools (progressive and automatic transfer tools), up to 4,5 M€/year
Stamping Tooling such as:
Progressive Stamping Tools up to 4500mmAutomatic Transfer Stamping Tools up to 6500mmTandem Transfer Stamping ToolsHybrid (Progressive + Automatic Transfer) Stamping ToolsChecking FixturesStamping tools with special features (in-die ops and automation)
Able to validate in real conditions serial life conditionsin most of the cases
CAD/CAE/CAM UNIGRAPHICS-NX SIEMENSCAD/CAE CATIA DASSAULT SYSTEMESCAM TEBISCAD SOLIDEDGE SIEMENSCAE AUTOFORMCAQ PC-DMIS AND GEOMAGIC
Plant | Metal 2
Tool shop
Plant | Metal 2
Tool shop
Project management driven
Experienced team
7 Tooling Engineers (up to 40 years in experience)
10 Assembly/Try-Out workers (up to 30 years in experience)
2 Project Managers + 2 Progress Monitors
5 Process Engineers/Machining Programmers
On tool shop we are able to work 3 shifts
Production
Machining Centers
CNC Milling Machines
Turning Centre and Lathes
Grinding Machines
Wire Erosion Machines
Spark Erosion Machines
Try-Out Hydraulic Press
3D CMM machine
max 1000 x 500 x 500
max 4500 x 2500 x 950
max Diam 300
max 1000 x 500
max 700 x 500
max 700 x 500
1000 Ton
max 1000 x 800
Plant | Metal 3Prototype and
rapid manufacturing
Laser cutting equipment |Trumpf
Work area: 4000 x 2000 mm
Cutting speed (max): 300 m/min
Laser Power (max): 6000 w (Truflow6000)
Maximum sheet thickness:
Mild steel: 25mm, Stainless steel: 25 mm, Aluminium: 15 mm
Together with a bending equipment, also Trumpf, MCG offers a complete solution for prototyping and low series production
Plant | Metal 5
Assembling area
New investment (2015)
12.000 m2
Area dedicated to
assembly operations