Dokka Fasteners USA

Dokka Fasteners
Quality fasteners for Quality
products
Dokka Fasteners AS - Dokka
Site: Dokka, Norway, Danmark
Employees: 135
Production: 10000 tons of steel per year
Annual Sales: 60M€ (2012)
Production facilities: 13500m2.
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2
Historic view
•
1875:
Kampen Skrue- og mutterfabrikk established
•
1886:
Den Norske Naglefabrikk
•
1905:
Christiania Spikerverk starts production of screws and nails
•
1928:
The three merged into Fonas fabrikker A/S, Nydalen, Oslo
•
1970:
Production relocated to Dokka
•
1972:
Fonas becomes part of Elkem
•
1982:
Bulten Fonas established as part of Bulten Kanthal
•
1987:
Dokka Industrier (DF) becomes an independent company
•
1995:
100 % ownership by Arvid Nilsson A/S
•
2008:
Arvid Nilsson A/S and Dokka acquired by Würth Industries GmbH
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3
1945 - 2012
4
416 COMPANIES IN 84 COUNTRIES
OF THE WORLD
as of December 2011
DE
Würth-Line
Int.
Total
3
123
126
ACs
76
214
290
Total
79
337
416
5
CURRENT SITUATION
WÜRTH GROUP
YTD DECEMBER
Sales
in mio. EUR
Employees
12.3%
5.9%
9,695
8,633
2010
2011 *
+ 1,062 mio. EUR
62,433
2010
66,113
2011 *
+3,680 MA
6
Dokka Fasteners AS
The Würth Hot Forming Manufacturing Companies:
Dokka Norway:
Rosteinwegen 7, Vinjarmoen,
2870 Dokka, Norway
Dokka Auburn Hills:
2800 Superior Ct., Auburn Hills, Michigan,
48326
Cardinal Fasteners:
5185 Richmond Rd Cleveland,
Ohio, 44146
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Dokka marketplace
development
•
•
1875 – 1965: National marketplace
•
Wholesalers
•
Norwegian customers
1966 – 2004: Scandinavian to European marketplace
•
•
2005 –
•
Off shore
•
Wind
: Market starts to get more Global
•
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European customers
Our customers go Global
8
Customers and segments
Since 1975 we have delivered bolts to:
• The Energy market
•
Wind turbine manufacturers
• Industry market
•
Offshore equipment
•
Steel constructions
•
Other Industry
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Wind Turbine Bolts
manufactured by Dokka Fasteners
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Off shore equipment
• Hex bolts:
– DIN 931/933
– ISO 4014/4017
• Inner hex bolt
• Special bolts
• Stud bolts
References:
Kroll Cranes
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Steel constructions
• Construction bolts (6914)
• SB bolts (Sweden)
• Hex bolts
•
References:
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DF 2008.10.28
12
Dokka Fasteners
Vision and Strategy
• In 2006 we started a turnaround process in Dokka and a discussion
about the future.
• We had talks with our customers about their expectations from Dokka as
a supplier for their future demands within the wind turbine industry.
• This information told us that that our machines and processes not any
longer could secure our customers demands for quantity, product quality
and security.
• Customer feedback:
• Competitive prices
• Product quality and reliability
• Global presence
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Turnaround process 2006-2007
1. stage.
• All employees gets involved in the necessary changes to become more
competitive
• Information to all employees about what to do.
• Introduction to Lean/continuous improvements and how to achieve
improvements by working smarter.
• More involvement and responsibility
• Started 5S events (Skrubbe, sortere systematisere, standardisere, sikre)
• Paint wall white to show the difference – YES!
• Development of our maintenance system (ONIX)
• Improved material flow
• Pull planning
• Small investment in robot automation
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Dokka Fasteners – 5S
2009
1990
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Dokka Fasteners – 5S
2009
1990
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New Plant design 2007
2. stage.
Design start 2007:
• High grade of automation by use of robot handling and control
• Reliable and repeatable process
• Contact with Taiwanese machine builders
• Started to design a new production set up – machine – process
• Involvement of key employees with interest
Problem:
• Arvid Nilsson had no money to invest
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Investment program
European to a Global player
• 1st investment in new forging cell approved by Würth 2008
–25 MNOK
• 2nd investment plan approved July 2010
–140 MNOK in Dokka
–170 MNOK in new US plant
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Dokka Fasteners – Manufacturing
1960 - 2000
1960
1960
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2000
19
Dokka Fasteners – Manufacturing 2012
2009
1990
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Increased output
2009
1990
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New Plant
2009
We were aware of the need for new competence
and
involvement of all employees
1990
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Greatest challenge
How to change our behaviour and skills to operate a highly
automated new plant and computerized machinery?
Our knowledge in general:
• Manually operated presses and equipment
• Skills (Practical experience)
• Basic knowledge
Needed experience and skills:
• More skilled employees with machine background
• School
• Courses
• Engineers
• Automation
• Started internal (Fag B) schooling
• Employment of skilled management / specialists
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How far are we ?
• Maintenance system in place – daily follow up
• 5S in place – regular audits of the teams
• HMS awareness
• Quality production
• Increased employee involvement
• Continue internal schooling
• Training of more operators in more processes
• High operator involvement show better performance
• Targets set for OEE, SMED
We are at the beginning of our journey
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Dokka Fasteners
Thank you for the attention!