Untitled

The EGR Group
Automotive - The Shape of the Future
T H R E E D E C A D E S O F M A NUFACTURING EXCELLENCE
F
OUR PASSION - THE BEST THERMOFORMED AC C E S S O R I E S
E
ounded in 1973, the EGR
Group of companies forms a
privately owned multinational
Corporation that today employs
more than 1,000 people worldwide.
The Corporation’s world headquarters and six manufacturing plants
are located in Brisbane, Australia;
with regional headquarters in Nth
America and the United Kingdom.
GR’s Acrylic Automotive
Products Division designs and
manufactures a diverse range of
acrylic products such as HeadLight
Protectors, Hood Shields, Window
Deflectors and Dust Deflectors.
The Group consists of four
strategic divisions – Acrylic
Automotive Products, Industrial and
Automotive Thermoformed
Products, Point of Purchase
Displays and Plastic Sheet
Extrusion.
Together with its wholly owned
subsidiaries, EGR services a portfolio of international distributors
and some 50 OEM multinationals
located in more than 40 countries
around the world.
Complementing this range, the
Corporation’s Automotive
Thermoformed Products Division
designs and manufactures a large
variety of products.
The product range includes Fender
Flares, Rear Wheel Covers, Bodykit
Packages, Tonneau Covers, Full
Bumper Replacements and Cargo
Liners.
makes and models of current
vehicles and new vehicles as they
are released around the globe.
EGR has over 10,000 active part
numbers and develops 30 new
products each month across 6 core
product categories.
These products suit virtually all
EGR - A technical leader in its field.
HeadLamp Protectors
EGR - an internationally awarded Corporation.
Body Styling - Front Spoiler
Window Deflectors
Decklid Spoiler
Hood Deflector
Side Window Deflectors
Fender Flares
Side Window Deflectors
HeadLamp Protectors
Side Skirt
Rear Corner Piece
Fender Flare
Body Cladding
Hood Deflector
OEM Quality standards are integral to
EGR’s work practices.
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Vertical Integration - EGR’s Extrusion Division supplies raw materials to EGR
Automotive.
EGR manufactures a vast range Thermoformed Automotive Accessories to suit a wide variety of vehicles.
2
High Performance Materials
E G R M A N U F A C T U R E R S I T S OWN RAW MATERIALS
T
he EGR Group has become a
world leader in thermoformed
products by adopting the very
latest technologies. This philosophy
allows the company to vertically
integrate key production processes
and develop specific materials when
required by its customers.
The pursuit of technological
advances has seen the Group
embrace new methods in the
production of rigid plastic
sheeting.
Product development is an
ongoing process at EGR. The goal of
this process is to discover optimum
solutions in new materials for varied
applications. These solutions are
aimed at meeting specific customer
requirements in a wide range of
industrial oriented products.
EGR’s advanced plastic sheet
extrusion facility was developed in
partnership with the world’s leading
extrusion equipment manufacturer.
The extrusion line can produce
a wide range of specialised and
standard plastics that include ABS,
Polycarbonate, Impact Modified and
General Purpose Acrylic Sheet.
Apart from high throughput rates,
the technology ensures sheeting
is manufactured to exacting tolerances with controlled thermal and
mechanical properties and exceptional optical clarity. This high level
of optical clarity means the line is
capable of producing mirror grade
acrylic sheet.
A driving force behind establishing
the Extrusion Division was the desire
to improve the quality, consistency
and availability of sheet. A primary
goal was the ability to provide
customers with new and high
quality materials for use in demanding automotive environments.
EGR Extrusion Division - 7 Station gravimetric loss in weight feeding system
EXTRUSION
MATERIAL CAPABILITY
> TWO WORLD CLASS EXTRUSION MACHINES
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> MATERIALS UP TO 2530MM WIDE & 12MM THICK
> ACRYLIC, POLYCARBONATE, ABS, CAPPED ABS, PC/
ABS & POLYPROPYLENE
> CO-EXTRUSION CAPABILITY
> 2000 KG/HR CAPABILITY
> EXCEPTIONAL SURFACE FINISH AND REVERSION CONTROL
> ON-LINE VERIFICATION OF CRITICAL SHEET PROPERTIES
> 300 TONNES OF RESIN STOCK
High quality rigid plastic sheeting.
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Extruded EGR plastic materials exhibits excellent optical clarity.
> 70,000 SHEETS IN STOCK
ABS - PC/ABS
POLYCARBONATE
PETG
ACRYLIC
PMMA
POLYETHYLENE
POLYPROPYLENE
HYBRID MATERIAL ALLOYS
CARPETED PRODUCTS
THICKNESS FROM .75 MM - 10 MM TYPICAL
HIGH GLOSS, TEXTURED OR IN - MOLDED GRAIN
OPAQUE, TRANSLUCENT OR TRANSPARENT SHEET
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Integrated CAD and CNC Tooling
DIGITAL DATA FLOWS FROM DESIGN THROUGH T O P R O D U C T I O N
E
GR has always understood
the value of new technology. This has resulted in the
company integrating state of the art
IT systems into the Computer Aided
Design function of product
development.
Each Division has its own dedicated
Design, Development and technical support team. Each team is a
sophisticated user of CAD CAM
software and develops new products
in leading 3D tools such as PRO-E,
Unigraphics and ICEMSURF.
The Development Teams consist of
skilled industrial designers,
mechanical and chemical engineers,
computer programmers and
thermoforming toolmakers.
By using a fully digital workflow,
these professionals create accurate
product designs that are used to produce high precision products from
composite and aluminum tooling.
Products can be made in a wide
range of sizes and a key aim of the
design process is to ensure that raw
materials are optimized for
maximum production yields.
ICEMSURF Cad Station with CATIA
data interface.
NO DRILL ABS Fender Flares.
Above - CNC Tool making interfaces with Computer Aided Design
> DIGITAL RENDERING
> ADOBE CREATIVE SUITE
> IDEAS
> UNIGRAPHICS
> PRO ENGINEER
> AUTOCAD
> RHINO
> ALIAS WAVEFRONT
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> SURFACE CO-ORDINATE MEASURING
TESTING PROCEDURES
EGR’s CAD ENVIRONMENT
SALT SPRAY
INFRARED TEMPERATURE
EGR’s Product Development system comprises a complete digital workflow. This ranges from
digital rendering through to CAD CAM, tool making, laser and robotic trimming and full
co-ordinate measuring and surface scanning.
PAINT ADHESION
XRITE COLOUR METER
SURFACE HARDNESS
TORQUE RESISTANCE TO 20NM
Durable vac formed Cargo Liner.
ADR/ECE/DOT/TUV COMPLIANCE
CHARPY NOTCHED IMPACT
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Ve r t i c a l Integration
COM P L E T E I N - H O U S E M A N U FACTURING
ROBOTIC TRIMMING
T
• Precision Vacuum & Mechanical Assist Jigs
• Variety of Tooling & Trim Options Available
• Rapid Tool Change
• Repeatable Production Trim Tolerance +/- 0.5mm
• On-line Attribute Check Fixtures For Trim Check
• 60 Second Cycle Time Per Part
• 6 Production Lasers
• 8 CNC Routers
• In-house screenprinting
• 9 x Robotic Trim Cells - 7 Axis
• Up To 2500 x 1200 x 800mm Capacity
• Interchangeable Programs For Maximum
Scheduling Flexibility
• Dedicated Cell For Programming On Order
he cornerstone of EGR’s
manufacturing philosophy is
to vertically integrate all the
key development and production
processes into the one manufacturing
system.
The Automotive Division draws on a
large variety of production methods
that range from laser cutting, multi
axis robotic trimming, vacuum forming, compression molding, slip
forming, rotational molding, distortion printing, RIM Molding and
robotic spray painting.
Each piece of technology has been
carefully evaluated and then
optimized into EGR’s existing
production system. This approach
ensures that a high capacity manufacturing infrastructure is available to
rapidly complete customer orders.
One of the Automotive Division’s key
strengths is to thoroughly review a
customer’s brief and then propose the
most cost effective and technically
suitable production method.
This process of matching the end
requirements to technical solutions
helps deliver successful outcomes.
EGR’s Thermoforming technology environment includes:
• male molds
• female molds
• articulated undercuts and features
• mechanical and pneumatic plug assist
• slip forming
• matched molds
• pressure forming
• twin sheet forming
EGR’s thermoformed material capabilities include the
ability to manufacture high gloss, textured or in-molded
grain products in thicknesses ranging from 2 to 10 mm.
MOLDING
EGR’s R-RIM Molding Division
manufactures Full Bumper Replacements.
In-line robotic gluing station - EGR’s
Thermoforming Products Division.
2 X HIGH SPEED ROTARY MACHINES
4 X SPECIALIZED SINGLE STATION MACHINES
CONSISTENT COMPUTER CONTROLLED PROCESS
QUICK-CHANGE MOLD & SHEET CLAMPING
INTEGRATED MOLD TEMPERATURE CONTROL
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TESTING PROTOCOLS
Above : Robotic technology is used extensively at EGR.
THERMAL CYCLING
HEAT AGING
HEAT DISTORTION
DROP IMPACT
INSTRUMENTAL IMPACT
SURFACE GLOSS
STATIC LOAD TO 100KG
ULTRASONIC THICKNESS
PAINT FILM BUILD
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Manufacturing Infrastructure
WOR L D C L A S S M A N U F A C T U R I NG INFRASTRUCTURE
E
GR’s manufacturing environment can be characterized as highly flexible and able
to cope with high volume requirements.
Consistency and highly repeatable part manufacturing are major features of the system.
This is achieved by combining some of the world’s most efficient manufacturing
technology and proprietary manufacturing systems that EGR has developed over
decades of experience.
EGR’s manufacturing plants can offer the following benefits to the OEM:
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Ability to handle heavy gages of materials
Large capacity of forming cycles per shift
Wide variety of forming thickness - from 2 mm to 12 mm thickness
Wide variety of tooling and processing options available
Articulated and undercut tooling choices
Rapid tool changes for maximum process flexibility
On-site mechanical and electronics support
Wide variety of sheet materials and finishes possible
Typical forming tolerance of <1 percent
Minimum surface deviation is equivalent to an automotive “A” Class
Laser Cutting is a major production method at
EGR.
Above : Robotic Spray Painting - EGR Tonneau Covers
EGR’s MANUFACTURING INFRASTRUCTURE
EGR is a true believer in using the world’s most advanced technologies to create a high volume
manufacturing infrastructure. 10,000 components are produced daily.
CNC Robotic trimming ensures exacting trim
tolerances are met.
> ON-LINE COLOR MATCHING
> AUTOMATIC PAINT MIXING
> CONSISTENT COLOR MATCHING
> PRECISE COLOR MEASUREMENTS
> 16 COLORS AVAILABLE AT ANY ONE TIME
> X-RITE COLOR MANAGEMENT SYSTEM
1991/92
NISSAN SUPPLIER RECOGNITION
1993
FORD Q101/Q1 PROGRAM
TOYOTA “A” RATING ACHIEVED
1993
1997
ACHIEVED QS 9000
2000
ISO 9000
2000
FORD AUSTRALIA GOLD AWARD - SUPPLIER EXCELLENCE
ENVIRONMENTAL CERTIFICATION
2002
TOYOTA PRESIDENTS SUPPLY AWARD
2002
2005/06
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PREPARING TS16949
10
Manufacturing Technology
WORLD CLASS MANUFACTURING INFRASTRUCTURE
IN-HOUSE HARDWARE CAPABILITIES
CNC ROUTER
YOUR CHOICE: DRAPE AND VACUUM FORMING, BLOW, R-RIM & INJECTION MOLDING
> PATTERN AND MODEL MAKING
> ROBOTIC SPRAY PAINTING
> ON-LINE COLOR MATCHING
> X-RITE COLOR VERIFICATION SYSTEM
> DRAPE, VACUUM FORMING, BLOW MOLDING
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> REACTION INJECTION MOLDING
> INJECTION MOLDING
> OEM “A” CLASS FINISH
> 6 AND 5 AXIS CNC TRIMMING
> QS9000 SYSTEMS
OVER 10,000 COMPONENTS MADE EACH DAY
HARDWARE TOOLING DESIGN
A VARIETY OF MATERIALS & COATINGS
A WIDE RANGE OF SURFACE TREATMENTS
PRESSED METAL CLIPS
INJECTION MOLDED CLIPS
ASSEMBLY PROCESSES AT EGR
GLUING
WELDING
RIVETING
SURFACE PREPARATION
TAPING
EDGE SEALS
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Reaction Injection Molding
I
n line with Corporation’s philosophy
of using state of the art manufacturing technology, EGR has established a
world class R-RIM Molding Division.
The material used by EGR is extremely
stable and robust and offers qualities that
are equivalent to Injection Molded OEM
quality parts.
The Division focuses on designing and
manufacturing automotive parts such as
front and rear sports bumpers, side rocker
moldings, grills, spoilers and dashes for a
wide variety of vehicles.
EGR offers its customers the most cost
efficient tooling options for the R-RIM
process.
EGR’s R-RIM Molding Division manufactures in excess of 10,000 parts per month.
EGR’s pattern making and tool making
capability possesses the ability to design
and manufacture “composite resin tooling”
that is suited to low volume production
(150 to 2,500 parts per annum).
Additionally, EGR can design either steel
or aluminum tooling that is suitable for
volumes up to 10,000 parts per annum.
The size of this tooling varies from 2.8 m
x 1.5 m x 1.5 m down to multi cavity tools
at less than 0.5 m cubed. Parts can be
produced from a 1kg to 12kg shot weight.
KEY PROPERTIES OF R-RIM MOLDED PARTS
> HIGH INTEGRITY IN TERMS OF THE PART’S STRENGTH
AND ABILITY TO RETAIN SHAPE - EVEN AT LOW TEMPERATURES
> VARIETY OF PART SIZES THAT ARE LOW IN WEIGHT
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> OPTIMAL RELATIONSHIP BETWEEN PART TOUGHNESS AND RIGIDITY
> ABLE TO BE READILY PAINTED
> HIGH CHEMICAL RESISTANCE
> SUITABLE FOR IN-MOLDED INSERTS
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Product Overview
Product Overview
Slimline WindowVisors
Slimline Weathershields
Hood Deflector
Hood Deflector
Slimline WindowVisors
Chrome
Hood Deflector
Side Skirt
Side Skirt
Front Skirt
Front Skirt
HeadLight Protectors
Hood Deflector
HeadLight Protectors
HeadLight Protectors
Fender Flares
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Headlamp Protectors/Headlight Protectors
- NEW STYLING FINISH
Driving Light Protectors/Fog Light Protectors
- Clear Finish
Hood Deflector/Bonnet Protectors (Passenger)
- Dark Smoke and Clear Finish
Full Bubble Weathershields - Light Smoke Finish
Side Window Deflectors/Wind Deflectors/
StyleVisor - Dark Smoke and Clear Finish
In Channel Side Window Deflector/In Channel Side
Wind Deflectors - Dark Smoke and Light Smoke Finish
Hood Deflector/Bonnet Protectors (SUV) - Dark
Smoke and Clear Finish
Hood Deflector/Bonnet Protectors (Truck) - Dark
Smoke and Clear Finish
Hood Deflector/Bonnet Protectors - Chrome
Finish
Rear Sun Visor/Rear Sun Guard - Dark Smoke
Finish
Rear Air Deflector/Rear DustGuard - Dark
Smoke Finish
Sunroof Wind Deflector - Dark Smoke Finish
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Product Overview
Slimline
WindowVisors
Product Overview
Hood Deflector
Decklid Spoiler/Spoiler
Slimline
WindowVisors
Sports Bar
Slimline
WindowVisors
Bed Liner
Hood Deflector
Front Skid Plate
Side Skirt
Fender Flares
Full Bumper Replacement
Styling HeadLight Protectors
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Tail Light Guard - Dark Smoke Finish
Number Plate Styling - Carbon Fibre Finish
Fender Flares/Wheel Arches
Front Skid Plate
Rear Skid Plate
Decklid Spoiler/Spoiler
Fender Liners
Fender Flares with Splash Guard/Integrated
Wheel Arches with Mudflaps
Cabin Storage Unit/Internal Storage Unit/Cabin
Tidy
Roof Mount Spoiler/Spoiler
Ute Cab Roof Spoiler
Spoiler Cap
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Product Overview
Product Overview
Slimline WindowVisors
Hood Deflector
HeadLight
Protector
Side Skirts
Front Spoiler
Bootliners/Cargoliners
Ground Effects Kit/Body styling
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Side Skirt
Front Skirt
Rear Skirt
Body Side Molding/Body Side Protection
Moldings
Rear Wheel Cover
Roof Boxes
Ground Effects Kit/Body styling
Front Corner Piece/Corner Skirts/Front Quarter
Skirts
Rear Corner Piece/Corner Skirts/Rear Quarter
Skirts
Chrome Mirror
Grille/Grille Replacements/Grills & Grill Inserts
Mesh
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Product Overview
Product Overview
Slimline WindowVisors
Tonneau Cover
Body Cladding
Bumper Extender/Front Bumper Extender
Side Bars and Side Steps
Full Bumper Replacements
Sports Bar
Sail Plane
Hood Deflector
Fender Flares
Sail Plane
CONTACT EGR
EGR NORTH AMERICA
Rocker Panels
Lifestyle Tonneau with Rails
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Tailgate Latch Protector
Tonneau Cover
Bedrail and Tailgate Protectors/Bedrail and
Tailgate Caps
Bed Liners
Products offered in this Catalog and any specifications are subject to change without notice - Copyright EGR - 2005
ONTARIO - CALIFORNIA
DETROIT - MICHIGAN
email - info@egrusa.com
Tel: +1 (909) 923-7075
Fax: +1 (909) 923-0945
Toll Free +1 (800) 757-7075
4000 East Greystone Drive
Ontario, California 91761,U.S.A
email - detroitsales@egrusa.com
Tel: +1 (248) 735-4063
Fax: +1 (248) 735-4058
Toll Free +1 (800) 757-7075
EGR EUROPE
EGR AUSTRALIA
email - sales@egreurope.co.uk
Tel: + 44 (0) 1908 264 800
Fax: +44 (0) 1908 265 088
51 Burners Lane South
Kiln Farm, Milton Keynes
UNITED KINGDOM, MK11 3HA
Tel: +61 7 3337 0110
Fax: +61 7 3277 2039
50 Standish Street
Salisbury, Brisbane
Queensland, 4107,
AUSTRALIA
AUSTRALIAN REGIONAL OFFICES
BRISBANE
SYDNEY
MELBOURNE
email - sales@egr.com.au
Tel: +61 7 3277 7999
Fax: +61 7 3277 8054
84 Evans Road
Salisbury, Brisbane
Queensland, 4107, AUSTRALIA
email - sales@egr.com.au
Tel: +61 2 9439 9788
Fax: +61 2 9439 9088
Level 2, 118 Christie Street
St Leonards, Sydney
New South Wales, 2065, AUSTRALIA
email - sales@egr.com.au
Tel: +61 3 9826 1266
Fax: +61 3 9826 1233
47 Claremont Street
South Yarra, Melbourne
Victoria, 3141, AUSTRALIA
Enquiries outside the regions listed above should be directed to our World Headquarters at EGR AUSTRALIA
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