gear measuring - Metaplast Gear Technology Kkt.

METAPLAST
GEAR TECHNOLOGY KKT
Established in 1983
Innovation, not imitation !
History
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Our firm’s – METAPLAST Gear Technology Kkt. – main profile is the production of high precision gears.
The ancestor – Metaplast GMK was established in 1983 as a private family enterprise. We keep the family
oriented characteristics nowadays as well.
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In time of foundation our circle of customers were mainly the state-owned companies. These companies
collapsed and became bankrupt during the changes of political system. This downfall in economy has actuated
us to localize western export opportunities. In middle term there export partners’ orders guarranteed the
improvement of our company from all aspects.
Export to the western market required more efforts to Quality, growing up to the needs of the customers in
terms of measurement as well. We consider that quality is the most important nowadays as well.
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We have moved to a new workshop hall to the Industrial Park of Tököl middle of 2011 and working on the
widening of our capacity, as we would like to further develop the production capabilities, technologies and
widen our potentials in the field of High Quality grinded gears, to be able to meet the expectations of our
Customers.
What the Support of the European Union and
the Hungarian State have meant to our company
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First support was given by the Hungarian State in 1998, when based on the resolved request of the Customers we needed to
introduce the ISO9001 Quality Assurance System, but we did not have enough financial source on our own. This was the first time
when we received support from the Hungarian State. As a result of this help we have successfully introduced the Quality Assurance
system, and the door has opened for our company to the directon of different foreign companies (ZF Hungária Kft, BMW Traditionel,
Giddings&Lewis GmbH, Voith GmbH, Global Sourcing GmbH, Ganz Energetika Kft). Orders received from these companies and a
result of technical developments we were able to reserve funds for the base of the new workshop hall.
Economical crisis started in 2006 has touched our company very much, but in a different way then other companies operating in
Hungary. In the last few years we have managed to reserve considerable funds for the planned real estate investment. The price of the
industrial reas estates has been reduced significantly. The low price of the industrial lands and the possibility of the development fund
from the European Union (KMOP-1.5.3/C-10-2010-0047 number of project) have helped the realisation of our workshop hall
investment. As a result of the support we have moved into a workshop meeting all expectations of the XXI Century in August 2011.
This investment has increased highly our judgement towards our Curtomers, but only this investment would not be enough if we would
not have been continuing certain technical and enviromental developments. In frame of an other application KMOP-1.2.1-11/B-20120059 number of project) we have realised to build out the ISO14001 system and the puchase of a machine resulting in a technological
jump.
The EMAS system meeting all the mostly developed and strict rules was introduced based on our requirement, in own financing at the
same time as the project named above (supervised by MAG Zrt.)
We have received a great support from the EU and the Hungarian Government for further technical developments in frame of
the KMOP-1.2.1-13/B-2013-0178 Project. This project gave us a chance to further develop certain technologies and introduce new
ones into our portfolio.
Our company has celebrated the 30th birthsday in 2013. As is it clearly visible from the above facts we plan the operation of our
company for long time. This goal is supported by our investments and developments. We are the most proud of the fact that 7 people
have gone into pension from our company and we give a fix source of living for 16 families.
Technical development
of the last years
2008
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2009
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2010
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2011
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2012
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2013
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2014
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Oerlikon Maag Opal 800 – Gear Profile Grinding Machine (full hydrostatic) – this machine was sold in 2014
Schaudt CNC Cilindrical Grinding Machine
Harrison Alpha – CNC Turning Late
Frömag 425 CNC – Keyslater Machine
Whirling technology for Trapezoid worms
KAPP VAS – CNC Profile Grinding Machine (with robot)
Gratomat
DEA Mistral CMM – Measuring Machine
Höfler Promat machines – Gear Profile Grinding Machine
Samputensili – Profile Gear Grinding Machine
Höfler Helix 400 KK – Profile Gear Grinding machine (brand new) – with EU-Hungarian Government Support
Metaplast Höfler Internal Gear Grinding machine
Gleason Sigma V7 measuring machine
Kapp KX1 – gear grinding machine
With EU-Hungarian Government Support:
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OKUMA LB3000EX – CNC lathe machine
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NCT VMC – CNC vertical machine center
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CMV – shot peening machine
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Proth horizontal rotary table surfacre grinding machine
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BAOMA wire EDM machine
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Hanel Rotomat
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Digitel Hardening Tester
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Magnetic noch detecting system
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Nital eching system
Philosophy
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The main essence of our Philosophy has never changed during the long years: to Manufacture, thus Create something
that represents High Quality, to add our knowledge and experience to projects that aim to make the life of many
people easier by creating or repairing machines by using our quality products.
All our technical and personal developments aimed to support this Philosophy.
We have well qualified workers with long years of experience in the field of production of gears and geared parts. The
young colleagues (just after the Technical Secondary School of University) and continiusly developed to be able to replace
anyone in the production. We believe in the job enrichment as a form of long-term motivation.
We have a long term agreement and Co-operation with the Technical University of Budapest for further
developing the final year Engineers by giving them a real workplace to try their talent, to make them able to put the
Theory into real work.
There are always 1-2 Students from the Technical University of Budapest, who choose us to support them by giving a
Theme for their Final Project Report and knowledge to put the Theory into life.
Our company is in the circle of of the first 600 companies, which received the ISO Certification, and we are very
proud of this fact. We have the ISO9001:2000 Certificate since 2001, ISO 14001 and
EMAS since 2013.
Products & Potential sizes
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Our main profile is the Production of ground gears from DIN Q3 from the non-series
– prototype – till the mass production. Our preference is the production of small series,
including Prototypes as we are small, and like to create real value by adding high level of
technical knowledge into the manufacturing procedure.
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In the range of our products the followings take place: master gears, noise checking
gears, gearbox elements, Synchro Bodies, Shaper cutters, Internal gears, CNC cutting
rolls, milling rolls, gears (straight and skew), helical gears,, ribbed belt-pulley flywheels,
chain gears.
On top of the Manufacture of these Categories of Products we are dealing with the
Design of tools for given parts, and we Design Power Transmissions and Gearing.
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As a result of the High Quality means of Production, and the technical grounding of our
professional workers we are able to manufacture products measured by American and
British Standards. In case of special need we are ready to produce the tools for the
Production as well.
We can produce the gears from Diameter 5 till 1000 mm, between 0,5 and 14
modules; in hardened and ground form from DIN 3967 2 class. Our measuring
machines make possible the granting a quality certificate as well. In 1996 our firm has
joined to the ISO 9001 quality assurance system, this way the perfectionism of the
products is warranted.
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With Oerlikon Maag Opal 800 type of Profile Grinding machine that is able to grind in
DIN Q2 with any modifications.
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During the calculation of the production time we consider the need of the
customers, and we try to satisfy it at the possibly highest level.
List of Machines
Gear grinding machines
Other machnies
HELIX 400 KK Grinding machine
KAPP VAS CNC Grinding machine
NILES 315 CNC Grinding machine
PROMAT 200 Grinding machine
Samputensili RI 371 Grinding machine
Kapp KX-1 Grinding machine
Sharpening machine
FNGJ 20 milling machine
Measuring machines
Teeth pointing
Gleason Sigma V7 Gear measuring machine
Harrison Alpha 1400XS CNC
WENZEL WGT 350 Gear measuring center
Keysleter
DEA Mistral CMM
KAPP Spline ginding machine
ZEISS workshop microscop
Outer grinding machine
SÍP Projector
ELB face grinding
Mitutolyo surface hardness measuring
Schaudt universal CNC Cylindrical grinding machine
Digitel Hardening Tester
SPINNER VC650 CNC 4 axis CNC machining centre
Magnetic noch detecting system
Szergej face grinding
Gear cutting and hobbing machines
Nital eching system
WMW SI 40 Internal grinding machine
Gear rolling machine
Carl Zeiss 3 co-ordinates measuring machine
WMW SI 4 internal grinding
Lorenz LS150 Gear shaping machine
Höfler EMZ 500 gear measuring machine
WMW relief turning
MAAG SH 45 Gear cutting machine
OKUMA LB3000EX – CNC lathe machine
Pfauter P 160 Gear hobbing machine
NCT VMC – CNC vertical machine center
Pfauter P 403 Gear hobbing machine
CMV – shot peening machine
TOS OHA 16B Gear shaping machine
Proth horizontal rotary table surfacre grinding machine
TOS OHO-20 Gear shaping machine
BAOMA wire EDM machine
WMW Gear shaping machine
OKUMA LB3000EX II. CNC lathe machine
METAPLAST
GEAR TECHNOLOGY KKT
Picture of Products
IGM Robotsystem –
positioning gears for Robots
Budapest Public Transport Metro gearbox spare parts
BMW Tradition – gearbox
spare parts
Knorr-Bremse – break system
elements for train
Robert Bosch Group – starter,
master- and test gears
ZF Group
METAPLAST
GEAR TECHNOLOGY KKT
Established in 1983
Innovation, not imitation !
ISO Certificates
10 years of certification
in 2011 with the
Head of TÜV Bayern
Measuring Sheet - Sample
Our Customers - References
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We have become Accrediated Supplier of several Multinational Companies during the long years. We are the
(BMW AG, GE Hungary, Knorr-Bremse, Robert Bosch, VW Group, ZF Group, Scania, AVL, Igm
Robotsystems Hungary,)
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Main products are:
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Master gears, noise checking gears, etalon gears for ZF Hungary, Bosch Group, Linamar
Test centre elements (etalon shafts, hubs, gears) for Automotive Industry (Audi, AVL)
Small series for ZF and BMW Traditional Division.
Null series, prototypes for ZF Friedrichshafen, ZF Hungary, Scanica, Linamar, Knorr-Bremse
70 % of our production goes to export, main partners are from Germany and Austria. Our products are built in driving
gears, machine producing tools and gearboxes. Our tools make the production of much multinational company smooth
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We are the measurement centre of Robert Bosch Energy & Body Systems Kft and other Bosch owned factories.
(Gear Measuring Centre made by Wenzel (WGT350) support our Quality Production and give a neutral measuring report of
the required parts for our Customers.)
Detailed List of Customers on the next 3 pages.
List of References – 1.
Company Name
Location
Products, mady by our company
AVL
Graz
Test centre elements (etalon shafts, hubs, gears)
BKV
Budapest
Power transmissions and gearings for metro of Budapest, gears for the
millenium metro and for the cog-rail, grinded gears.
BMW AG
München - Germany
PTO parts for old gearboxes and gears.
Borsodi Mûhely Kft
Gyõr
GM PTO parts
Brunner Kft.
Vecsés
Gears
Doherty Hungária
Orosháza
Master gears,quality check of shaving tools
Evolvens Bt.
Siófok
Teeth grinding
Excel Európa Kft
Budapest
Gears of main driving of tool production machines
FEV Motorentechnik
GmbH
Aachen - Germany
Production of prototype gearboxes
GANZ Energetika
Kft
Budapest
Gears for the casette moving measuring device of the Nucrlear Plant
GE Hungary Rt.
Budaőrs - GE
Healthcare
Measuring of gears, gear grinding
GE Hungary Rt.
Budapest
Worm gears, racks, gears of US standards
GE Hungary Rt.
Gyõr
Gears for Lamp production machines
GE Hungary Rt.
Hajdóböszörmény
Gears for Lamp production machines
Gearspect
Prága
Planning and production of master gears
Global Sourcing
GmbH
Regensburg
Gears, driving elements
List of References – 2.
Company Name
Location
Products, mady by our company
HAFE
Budapest
Grinded gears
HM Currus
Gödöllő
Gears for winch devices of military vehicles
Hungaro Slr
Gödöllő
Planning and production of gear cutting tools
igm Robotrendszerek
Kft
Gyõr
Gears for driving parts of industrial robots, zero backlash gears, gear sections
Klingelnberg
Hungária Kft.
Győr
Production of gearings of DIN5480 standard
Knorr-Bremse
Budapest
Serie Production of gears and trapezoidal multi threading spindle for
automotive industry
KÖNIG Maschinen
Celldömölk
Driving gears for food industrial machines, chain gears, gears
LINAMAR NyRT
Orosháza
Production of prototypes, null series and pilot parts, planning and production
of Master gears, giving technological support and advice.
RLE International
Köln - Germany
Production of prototype gears for car gearboxes
MÁV Gépészet Zrt.
Budapest
Driving gears for the V43 type of locomotive
Robert Bosch GmbH
Stuttgart - Germany
Production and calibrating of master gears and testing gears
Robert Bosch Kft.
Miskolc - Power
Tools
Production and calibrating of master gears and testing gears
Robert Bosch Kft.
Miskolc - Energy &
Body Systems
Production of master gears and testing gears, production of self starting
testing gears. Calibration of geared etalons.
List of References – 3.
Company Name
Location
Products, mady by Our Company
Scania
Södertalje
Prototype gears and other parts
SZIMIKRON Kft
Kecskemét
Clutch gearing, turret head gearing
TRIGON Elektronica
Salgótarján
Plastic gears
VW Group
Volksburg Germany
Gearbox gears, synchron elements
ZF Friedrichshafen
Friedrichshafen
After market gear, shaft, synchron element production
ZF Brasil
Sorocaba - Brasil
Production of Null series
ZF Drivetech Co. Ltd.
Hangzhou China
Production of Master Gears and Noise Checking gears
Eger
Production of prototypes, null series and PTO, CNC deburring tools,
Master gears, Noise checking gears, Planning and Production of
Cutting tools
ZF Hungária
Trends in the production
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Moving into the direction of R&D - getting involved in design of complex projects
Receiving more of free hand in choosing technology and giving suggestions
Winning new Customers, new divisions of the present Clients
Finishing (mainly gear grinding) of parts prepared by Customers
Being involved more in the field of gear measuring
Involved in 3 different Technical University of Hungary – in formula 1
racecar/gokart projects (see later)
• Asked to serve as the backup produciton facility for emergency by several Clients.
• Besides automotive industry the food industry is developing continuously.
New technologies: skiving is planned to be introduced
Whom we have sponsored with our work
Technical University Of Budapest
Formula Racing Team
2015
https://www.youtube.com/watch?v=e7xBn-1MLEc
Sengine – Audi Team
Whom we have sponsored with our work
Miskolc – Technical University
„Go-Kart, Go-Bosch”
Awards in 2015:
Best Teamwork
Smartest gokart
Absolute winner
Numbers / Facts
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Year of establishment: 1983.
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ISO Certification since 2001.; ISO 14001 and EMAS since 2013.
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Manufacturing facility: 1200m2
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Number of employers: 20 people.
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Sizes of manufacture: from Diameter 5 till 1000 mm, between 1 and 14 module
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Technologies available: all for the complete production of high precision gears, (prototypes, null
series, small series and in case bigger series) List of machines a few pages before.
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Grinding: in DIN Q2 with any modifications.
Contacts
„Innovation, not imitation.”
METAPLAST
GEAR TECHNOLOGY KKT.
Hungary – 2316. Tököl, 0323/16.; Airport Ipari Park
GPS: 47.346474; 18.991225
Tel: +36-1-206-0889; Fax: +36-1-206-0888
E-mail: metaplast.gear@metaplast.hu
Technical Questions: Mr Isván Varga / Mr Norbert Varga
Any other cases: Mrs Orsolya Mallár-Varga
How to reach us
Tököl – Airport Industrial Park (In the area of the old Tököl Airport)
Hungary – 2316. Tököl, 0323/16; GPS: 47.346474; 18.991225
Directions from Wien, Austria:
• You drive to the M0 Motorway (Ring around Budapest) till the sign of "Halásztelek,
Szigetszentmiklós" (The first takeoff after the bridge over Danube coming from the M1 or
M7 Motorway)
• At the first traffic light you need to turn on the left to "Halásztelek"
• You drive through Halásztelek. After the city there will be a big curve to the left. The fence
of the old Aiport of Tököl is visible from the right side.
• You need to turn in the 3rd gate, where you see the sign of Airport Ipari Park.
• Our workshop hall is the 1st on the left hand side.
In case you need our assistance in finding us, please call on: +36-1-206-0889