make in india @ konzert_atd_ptd_04_aug_2015

ISO 9001 – 2008 Certified

Technology Maestro | Timely Delivery | Functional Brilliance | Admired Quality

www.konzertgroup.com

Tool Room Tool Makers By

“KONZERT” - means “An Agreement in a design or plan with simultaneous Actions”.




2015 Installation of Vision Wide Double Column VMC of size 4200 x 2600 x 1200mm

Installation of 1000 Ton/ 4m Mechanical press exclusively for Trials

2014 Addition of 500T Mechanical press exclusively for trials

• Addition of 1600 x 1000mm Carl Zeiss CMM

• Addition of Ferromatic Milakron 80T & 150T Injection Moulding Machines.

• Addition of Agie Charmiles CNC EDM (Form 20)

• Addition of Vision Measuring System RAPID EYE

2013 : Additional 3600 sq.mt. Green field Tool room space (PLANT II) acquired with 15 / 5 MT

• (2 no’s) Over head cranes

• Addition of 200 & 400 Ton Mech. Press for Try-out ; 3 meters x 2 meters VMC

• Addition in Precision Tooling Division with Sodick CNC Wire-cut & Agie Charmiles CNC EDM (SP1U)

2012 : Formation of 2 new vertical Precision Tooling Division (PTD); For High precision Progressive Tools & Injection Molds & Konzert Automation and Robotics (KAR) ;for SPM’s Welding technologies.

2011 : Addition of 1200 sq. m. shop area (PLANT 1) & Registered with OEM's like Ashok Leyland, Mahindra, DICV etc

2009 : In 2 years Konzert already a player in the large Panel dies category with accreditation in ISO 9001: 2008

with in-house trial facilities on our own 500T Spotting Press.

2007 : Established Tool room in the First Auto Hub of the country (Pune)

Team Konzert History & Growth




• PANEL DIES

• TRANSFER DIES

• PROGRESSIVE DIES

• TANDEM DIES

• JIGS & FIXTURES

ASSEMBLY LANE CNC SHOP

Being in the first auto hub of India some basic locational advantages.

All tier 2 vendors in the form of

Heat treatment Support (Vacuum),

Standard Parts suppliers,

Conventional and CNC Machining outsourcing,

Logistical support,

Airport (15 km)

Housing & Lodging

All Within a 5 km radius




Konzert – ATD & PTD Core Strengths

MANUFACTURING

Reliable Material Source ( Local /Overseas)

Strict Quality Control ( ISO9002 )

High Quality Manufacturing Equipments

MARKETING

Broad Customer Base

Diverse Coverage of Different End Markets

Strategically Placed Local Service Support

MANAGEMENT

•Objective Oriented Management Policy

•Harmonious Worker-Management Policy

•Environment Friendly Development Policy

•Employee Development and Upgrading Policy

ENGINEERING

•Estimation

•Detailed process plans for every tool elements

Systematic approach for controlling manufacturing

process from material, Heat treatment, Machining

& assembly

DESIGN

In House-Design Capabilities high precision injection

moulds and high speed stamping dies

Progressive die design and injection mould design

validation

Standardized mould and tool design process

Detailed mould/progressive dies log documenting

insert tolerances

A complete Tooling Solution for plastic and sheet metal products - Designing and building high-quality production tools & molds are the core of our business . We are

recognized by our existing customers for our State-of-the-art technology which ensures exceptional precision, stability, and repeatability. Our reputation as the premium

tooling specialist in India is one that we do not take lightly. We consistently provide high capacity, fast turnaround fabrication of high precision production molds & high speed

stamping dies . Furthermore, our molds & tools are built to international standards, undergo stringent qualification runs, and are constructed under the at most confidentiality.

PROJECT MANAGEMENT

Separate CFT for major projects plans, execute & monitor each projects.

Single Window Communication System.

Effective Multi-Project scheduling & Resource Management, Critical Issue

Identification & Management.

Daily Monitoring of projects and resources & project updates to customer

on weekly basis

DEVELOPMENT

•Expansion of Manufacturing Capabilities

•Extensive Experience in high precision injection moulds

& high speed stamping dies.

•In-House Tooling development Capabilities




EXPERIENCED DESIGNERS FOR

• PANEL DIES

• TRANSFER DIES

• PROGRESSIVE DIES

• TANDEM DIES

• PRECISION INJECTION MOULDS

• JIGS & FIXTURES

• PART 3D DESIGN

• 2D DRAFTING

DESIGN




BFW – BMV 80 BFW – BMV 60 BFW – BMV 65 (2 nos.) Four star- MN 2132

Four Star

MN2132

BFW

BMV -80

BFW

BMV 65(2 Nos)

BFW

BMV 60

TRAVEL 3400x2200x1100 mm 2200x850x810mm 1500x710x710mm 1200x610x610mm

MAX LOAD 15000 kg 3000 kg 1500 kg 1200 kg

CONTROLLER Mitsubishi M720 Mitsubishi M720

Mitsubishi M720

Mitsubishi M720

FOR DELICATE PRECISION WORKS, WE ARE EQUIPPED WITH BFW FOR CNC PRECISION MILLING.

5 Nos.. CNC Machines (VMC)




6th CNC Machines (VMC)

NEW MACHINE UNDER INSTALLATION !!!!

Vision wide NF 4226

Bed Size: 4200 x 2600 x 1200 mm

16000kg Table load with

Mitsubishi M720 Controller




Hydraulic

2400 x 1450 x 1200 200 Ton

Mechanical Mechanical

1550 x 1150 x 750

100 Ton Mechanical

Mechanical

2500 x 1450 x 950

TRIAL PRESSES 5 No’s

ERFURT 500 Ton KONZERT 400 Ton

MILAP 250 Ton




Conventional Tool room Machines

Machine Qty.

Horizontal Boring 1

Surface Grinder 5

Radial Drilling m/c. 7

Milling M/c. 5

Lathe 3

CO2 Welding 3

Knee Type Milling 2

OET Crane ( 15/5 Ton) 2

OET Crane ( 10/3 Ton) 1

OET Crane (5 Ton) 4

26 no’s




Konzert is able to manage the whole procedure from concept of the very beginning to perfect completion

of new project developments. This means higher efficiency, lower cost, shorter lead-time and much better

overall control of the operation. We will make detailed production planning and timing which are followed

up strictly by project managers who are rich experienced in mould /progressive die design, tooling

manufacture, process management. Each project is separately handled by one Project leader. We will

keep customer updated about detail information of the project by weekly report and digital picture. It is

easy for customer to monitor the project time to time. We setup an efficient team to ensure that projects

development transit smoothly from design-engineering-manufacturing to production or client.

Project Management




PROCESS ENGINEERING • Product design.

• Tooling Feasibility study

• Engineering, Process planning & Method plan

• Manufacturing process plan

• Conceptualization of jigs and fixtures

• Thorough reviews before production

• Process plan along with planning for Tools & Gauges

• Preparation of manufacturing drawings as per

Konzert Precision Engineering standards

• Our own drawings used for manufacturing to

maintain uniformity on shop floor

• In – House CAD/CAM Facilities

• 15 HI-Definition Work Station

• Work NC for CAD/CAM




100% Vacuum Heat Treatment of Die Steels.

Heat Treatment Source s:

Indo German

Bhatt Metals

Standard Elements from:

Misumi India

Punch Industries

Sankyo Oilless

Dayton

Dadco /Hyson

Tohatsu

Raw Materials Used :

K340 (HSS grade)/D2 / SKD11/Stavax From

Bohler,ASSAB,Hitachi , Tyssen, Poldi

Castings from WIL / BSL / Premier / Smart

Test Certificate verified/procured for every lot.

Supplier Partnership

Preffered Hot Runner :

Mould Master

Synventive

Yudo

Hasco

DME




Long Member Die

7 M Blank & Pierce Long Member Die (30T ) for

4 – Variant's

DAP to Proving in 93 Working Days

TOOLING PRODUCTS




EXPORT DIES FOR COMPLETE ASSEMBLY

Material SPHN400W-DS / SG41BL Sheet Thickness 3.2

MaterialSPHN400W-DS / SG41BL Sheet Thickness 2.9

Material SPHN400W-DS Sheet Thickness 2.0

Material SPHN440W-DS Sheet Thickness 2.6



Material SPHN440W-DS SF HR 290 Sheet Thk.3.2MM

Material SPHN440W-DS Sheet Thk.2MM

Material SPHN440W-DS Sheet Thk.2MM




TOOLING PROJECTS – JUST COMPLETED

Material JSH270C Sheet Thickness 2.8 mm




Material EDDIS1079 Sheet Thickness 5.50

TOOLING PROJECTS – JUST COMPLETED




Chassis Products For Commercial Vehicles Chassis Products For SUV

Automotive Tooling Products




TOOLING PARTS




Panel Checkers

CHECKING FIXTURES




Konzert Precision Tooling Division PTD delivers advanced automation, process simulation and latest technology to improve productivity and ensure first-time quality in tooling development in sectors such

as Electrical, Electronic & automotive..




Konzert PTD team combines manufacturing, technical and creative disciplines to support customers in their product development, and total solution provider for manufacturing challenges. Konzert has the unique understanding of complex plastic & sheet metal product design and the mold & progressive dies requirements suited to achieve customers' design criteria & quality requirements. Our in-house tool-room supports fast turnaround for tool modifications, iterations, and reduces overall design cycle and lead time. Whether a product is only a conceptual idea or fully developed, Konzert PTD offers a trusted, confidential partnership, even at the beginning with evaluation of product design suitability for plastic & sheet metal applications. The earlier you leverage on Konzert-PTD’s expertise, the faster you can reach your goals in today's aggressive time-to-market environment.

Cad Solutions

Siemens-Uni-graphics NX10

Siemens-Uni-graphics- Progressive die wizard

Auto form for forming simulations

Key Capabilities

Progressive Die Design & Validation

Mould Design & validation

Process Design

Design Change and Propagation Control

Documentation and Quality System

Standardized Tool /Mould design process

Detailed Mold /Progressive dies log documenting insert tolerances

Tool design to ensure maximum production efficiency and repeatability

TOOL DESIGN




Automotive Progressive Dies

World class progressive dies that meet global die standards

Automotive Progressive dies up to 4 M in length

High Precision dies for close tolerance parts

Cast or plate die construction

SPM: 80-800

Standard parts from Dayton, Misumi, Fibro,Meusburger etc.

100 % 3D design




Automotive Progressive Dies

World class progressive dies that meet global die standards




Automotive Progressive Dies-Strip Layouts

10 Stage Progressive Tool

Material :SCGA270C-45

Sheet Thickness 2mm

Pitch 67.5 mm

Strip Width:264.0mm


Material SPC440

Sheet Thickness 1.6mm

Pitch 95.0 mm

Strip Width: 138.0mm


Material SPC270C

Sheet Thickness 0.9 mm

Pitch 65 mm

Strip Width:135.0mm




Automotive Progressive Dies-Strip Layouts


Material SPH440-OD


Pitch 136 mm

Strip Width:180.0mm


Material SPH440


Pitch 57 mm

Strip Width:238.5mm


Material:WSS-M1A365-A21


Pitch 26.5 mm

Strip Width:71.0mm




AUTOMOTIVE PROGRESSIVE DIES

2 out Progressive tool with quick interchangeable inserts– End Product: Automotive Liquid-to-liquid layered-core oil coolers

Material : Aluminum 2mm thickness

Tool Size: 1350x820x520mm

SPM:100

World class Progressive Dies that meet global die standards




HIGH SPEED PROGRESSIVE DIES

High Speed Stamping Dies SPM 60 – 800

Strip Lay Out for 27 stage Progressive Die (Component Size :0.65x2.0x26.0mm) Matl: Phosphor bronze

Our tools are always maintained to very close tolerances (0.002 -0.005mm onwards) to attain the highest tool quality




High Precision Plastic Injection Molds

Customer : BEHR Mould Type: 2 Plate single cavity Component Name & Material:

Temperature Bracket-ABS

Customer : BEHR Mould Type: 3 Plate 2 cavity mould

Component Name & Material: Bracket Seal -PP

Customer : L&T Mould Type: 2 Plate 4 cavity

Component Name & Material: Card Holder-PBT-PC

Customer : L&T Mould Type: 2 Plate single cavity Component Name & Material:

Linear Front Cover-PBT-PC

Konzert’s continual investment in new manufacturing capabilities and constant drive to increase automation have resulted in improved mold quality. We offer a wide range of mold technologies and options based on your part and development needs.

Once the design team completes the appropriate development steps, our manufacturing team uses an established step-by-step process and industry-leading CNC machining technology to build in quality. This results in full interchangeability in mold components.




CNC SINK EDM Agie Charmilles Max Job 790 x 480 x 235 Travel 320 x 250 x 250 Surface Finish Ra0.3µm

CNC WIRE EDM Sodick Travel 780 x 570 x 215 mm

Taper Angle : +/-15° Max. Thickness:120mm

Precision Tool room Machines

CNC SINK EDM-FORM 20 Agie Charmilles Max Job 800 x 550 x 265 Travel 350 x 250 x 250 Surface Finish Ra0.1µm

Tight and Rigorous repeatable Machining using high speed, high precision machines from Germany, Switzerland and Japan , Reaching steel tolerances of +/-0.002, to +/- 0.005




OUR QC/QA PROCEDURES INCLUDES

Inward Inspection

Tool Steel Hardness Inspection

Tool Steel / inserts Dimension Inspection

Pattern Inspection

Casting inspection

Moulds Electrodes Inspection

Tool Pre-Assembly / Stage wise Inspection

Trial Report and Samples Inspection

Part and checking fixture CMM inspection

Tool / Parts buy off & Pre Dispatch Inspection

CERTIFICATION & QC PRO




CARL ZEISS 3D CMM 10-16-6

Measuring Range : 1000 X 1600 X 600 MM

2 micron resolution

Our molds & Dies will be fully qualified in our dedicated mold/dies testing centers, and plastic parts will be validated in our metrology laboratory. Our process and QC engineers have in depth knowledge of mold /tool validation and various industry validations protocols (PPAP) documentations.100% steel check of critical dim's and shut-off areas. Konzert has a dedicated in-house metrology laboratory. The lab's multi-shift operation supports Konzert's mold /Tool qualifications, production facility and customers' metrology inspection needs. The lab has a full suite of measurement equipment including: CMM (ZEISS), VMM,2D height gauge (Tessa)& digital calipers and gauges (Mitutoyo).

Quality Control

Rapid I CNC Vision Measuring System Measuring Range : 200 X 150 X 150 MM

2 micron resolution




BUY-OFF DOCUMENTATION We supply all the Tools and fixtures with required Buy off Documents.

Design records

Method Plan

3D Design

2D Detailing

Design sign off Documents

Test Certificates Raw Material, Heat treatment , etc. Dimensional Inspection report Part Lay out Inspection Part CMM Inspection Checking Fixture Designs Checking fixture CMM Report Part CF report Dispatch documents




Injection Moulding Machines- 80T&150T (2 - No's) Nova servo From Ferromatik Milacron with bimetallic screw barrel

Under Installation

MACHINE SPECIFICATIONS

NOVA SERVO 150 (B610) NOVA SERVO 80 B 32

FRAME

INJECTION UNIT SPECIFICATIONS UNITS

INJECTION CAPACITY MAX gms 336 125

THEORETICAL DISPLACEMENT cc 353 132

INJECTION PRESSURE MAX bar 1731 1639

INJECTION RATE(With open Nozzle) cc/sec 158 140

INJECTION SCREW STROKE mm 180 130

SCREW DIAMETER mm 50 36

SCREW L/D RATIO 20 20

SCREW SPEED rpm 222 298

SCREW TORQUE @172 bar NM 1080 671

PLASTICIZING RATE gm/sec 28 14

PLASTICIZING RATE (BARRIER) gm/sec 33.6

NO. OF THERMOCOUPLES(BRL+NZ) 3+1 3+1

TOTAL HEAT CAPACITY KW 15 7.3

HOPPER CAPACITY kg 29.5 29.5

NOZZLE ORIFICE mm Φ3.5 Φ3.5

NOZZLE RADIUS mm R15 R15

CLAMP UNIT SPECIFICATION

CLAMPING FORCE kN 1500 800

CLAMP STROKE mm 440 310

MAXIMUM DAYLIGHT mm 950 710

MINIMUM MOULD HEIGHT mm 150 150

MAXIMUM MOULD HEIGHT mm 510 400

PLATEN SIZE (H X V) mm 740 X 740 610 x 565 (H X V)

DISTANCE BETWEEN TIE ROD mm 510 X 510 405 X 360 (H X V)

TIE ROD DIAMETER mm 85 70

EJECTOR SROKE mm 130 120

EJECTOR FORCE kN 44 34

MOLD WEIGHT CAPACITY kg 1500

EJECTOR ROD THREAD M16 M16

Newly Added Molding Machine




KLT Logo India

GLOBAL DELIVERY

For global distribution Konzert has no boundaries. Products / Tools can be shipped to America, Europe or Africa, On-time, every time with the support of global carriers such as UPS, FedEx, DHL,TNT express company, and other global freight forwarders. We can assist you in determining which one will be best suited for

your cost and timeline needs




Konzert Toolings Pvt. Ltd.

Regd. Address: Plot No. EL-21/1/3, | M.I.D.C., Bhosari.,

Pune, Maharashtra, India. 411 026.

CONTACT

Mr. R. Rajiv Seshadri Head – Business Development

Phone: +91 7507 999 503, Mail to: [email protected]

make in india @ konzert_atd_ptd_04_aug_2015

Documents

trials addition

tool room tool makers

meters vmc addition

progressive die design

machining assembly design

established tool room

head cranes addition

t mechanical press