EXPERTISE TO DELIVER ADDED VALUE TO OUR CUSTOMERS
Customer provided the what – API delivers the How:
The primary task of API’s engineering department is to develop the best turnkey solutions for components and assemblies of complete engineered plastic facilities.These solutions ideally combine innovative with long-standing approaches. The main focus of these efforts is to ensure safety and worthiness. The DFMA (design for manufacture and assembly) and DTC (design to cost) methods constitute essential development parameters and guarantee the technologically and economically viable implementation of API’s creative engineering solutions.
Starting Point: The customers product requirement
Based on them, API’s engineering team, in close cooperation with the customer, develops product ideas, design drafts and compatible manufacturing concepts that excel in terms their function, structural weight, and also costing and scheduling. After all, in the plastic industry, “time to market” and ease of testing and maintenance are crucial factors. And this is exactly what API’s engineering solutions deliver.
Comprehensive range of services – from concepts to certifications:
API elaborates and provides all activities along the engineering chain, from component conception to their detailed development, the design and the production of tools and fixtures, the latest manufacturing technologies and quality engineering tests, and to comprehensive certification tests. Additionally API, together with selected supply chain partners, also offers extended upstream activities to its OEM customers. For example, API handles certification procedures with certifying authorities and also delivers product support work pages.
Design & analysis:
Based on the mentioned product requirements, API engineers, in cooperation with their customers, elaborate the technical specifications. Together with the customers and at their sites, API specialists prepare technical concepts in the so-called joint definition phases. In several design quality gates, the design is specified down to the smallest detail. Based on comprehensive strength analyses, API’s stress engineers assure the static strength and fatigue requirements of the relevant components. The Design Office translates these development activities into engineering documents (drawing and parts lists) for their use in production.
Material & process engineering:
Material and process engineers optimize materials and processes with a view to achieving the highest process reliability and quality. They are involved in development projects and provide support for the ongoing series production. In addition, these experts provide advice to other API departments in matters of process engineering. They also deliver support for internal and external process audits.
Manufacturing engineering:
During the manufacturing stage, the Manufacturing Engineering unit is in charge of the practical implementation of the product concept and the design documentation derived from it. In the case of new developments, the experts help turn the drafts into commercially manufacturable products. The Manufacturing Engineering unit, a team of specialists for the technical implementation of a product group, is available to all internal and external customers during the product manufacturing process: as a contact-partner, a problem-solver and as a communicator.
Tool design:
The Tool Design unit develops special-purpose fixtures, production tools and machining programs required for the manufacturing process. The result is CAD drawings and CAM programs used to numerically control the manufacturing machinery.
Each main manufacturing step is carried out by a specific tool or fixture adapted to the component, The three main production steps for plastic and composite components covered in tool design are:
- lay up and curing of the component
- milling and drilling of component
- positioning several tool parts to each other and fastening them in order o assemble a complete tool
Forming a link between product development and manufacturing, the Tool Design units is to significant extent responsible for the cost-efficient production of tools in line with the relevant requirements.
Q-Engineering:
This subunit of the Quality Management function monitors entirely new and previously launched products from a quality perspective. At the beginning of a project, interfaces, communication workflows and formalities are defined together with the customer. As the project progresses, the Quality Engineering units defines and monitors the conformity of the developed products with their design documentation and conducts first article inspection. In addition the team in close cooperation with the in-house departments and the final customer, coordinates and is in charge of any process improvements and corrective actions.
Testing:
Structural tests are indispensable for the development and certification of components. They verify the stress and impact engineering methods used for the overall analysis in order to ensure the efficient and safe use in operations.
The test engineers analyze and test complete plastic and fiber composite structures, subsystems and individual components for fatigue and static strength. In this connection, impacts, temperature and humidity are taken in consideration as are manufacturing defects. Based on the test concepts suitable test equipment and systems are developed.
The preparation of the measuring equipment for the test station and the final analysis of the measuring results complete the core expertise “Component and certification tests” and included support documentation. These documents are provided to the customer and the certification authorities.
Integrated logistic support:
The ILS unit is in charge of integrating and assuring the logistics activities throughout the life cycle of an equipment and tool such that the logistical products (technical publications, maintenance task analyses) are provided effectively and efficiently.
The ILS and the logistics support analyses (LSA/RAMS) in particular decisively influence the availability and life cycle costs of an machine and its components. Therefore the ILS contributes significantly to a product’s success in the market. API integrated logistic support begins with the concept phase and ends only with the decommissioning of the machine and or its components.
Engineering services:
Within API the Engineering Services unit is in charge of the large number of software tools used and the computer-assisted processes in the engineering environment. In addition services such as data transfer, document storage, document distribution, material master creation and the creation of standard components (3D models) are provided. The support for software tools covers all steps from procurement, installation, training and updating to individual user support. The engineering processes are defined in cooperation with the engineering unit, mapped in SAP PL, trained and supported.