FoU-forum. Møte 23. mars FoU finansiering vha SkatteFUNN Erfaring fra et aluminiumstøperi på Lista ved Jan Ove Løland

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1 FoU-forum Møte 23. mars 2010 FoU finansiering vha SkatteFUNN Erfaring fra et aluminiumstøperi på Lista ved Jan Ove Løland

2 FoU-forum Møte 23. mars 2010 Farsund sett fra Skjoldnesveden

3 FoU-forum Møte 23. mars 2010 Loshavn/Korshavn/Lindesnes(?) sett fra Skjoldnesveden

4 Farsund Aluminium Casting AS 2-delt foredrag: 1. Presentasjon av FAC (engelsk tekst) 2. SkatteFUNN - prosjekt finansiering Aluminum VRC/PRC Casting (LPDC) Facts: 190 Full time Employees Floor space m ISO14001 & TS16949 re-certified 2010 Alloys Cast: A356, F356 Safety Critical Products: Knuckles, Control Arms, Subframes, Nodes, Brackets, Housings, Wheel Hubs 4

5 Our Customer line up BMW Mini BMW 1 Series BMW 3 Series BMW 5 Series BMW 7 Series Porsche Panamera Ferrari California Ferrari F149 Ferrari F152 Rolls Royce Bentley Continental GT Peugeot 608 Saab 95 5

6 FAC is a full service design partner Experience in Past Programs Dimensional Management and Assembly Expertise Material Knowledge CAD/CAE Expertise Casting Simulation Process Knowledge FEA & Testing FAC is able to take a design from target requirements through all stages of development and into high volume production

7 FAC - Plant layout 3 Core Machines 11 GEN III Casters 6 GEN II Casters Core Knock Out Robotic Finishing Cell NDT (X-Ray) Heat treatment facilities Crack detection (FPI) CMM Metal Lab

8 FAC Production Flow Path 2 Metal delivery Sand core Casting Automated casting cell Core Knock Out Finishing X-ray ADR (100%) Heat treatment (Solution + Age) Crack Inspection (100%) Packaging / Shipping Machining Washing & Assembly Dimensional Control Shipping to Customer 8 8

9 The VRC/PRC casting process Developed by Alcoa Casting/ Forging Research Lab VRC in 1950 s Vacuum fills mold VRC PRC added in 1985 Pressure assists fill PRC Together, and simultaneous, the process is VRC/PRC 9

10 Metal treatment; Degassing and filtration Casting Cell Metal pump, Degasser & Filter Degasser & Filter Metal Pump 2 t 12 t 1 t Transport furnace Receive furnace Launder system 5 50m Holding furnace Casting crucible 10

11 Concurrent Engineering Product Process Tooling CAD/FEA (Re) Design Casting and Die Predict Filling, Solidification, Casting and Die Stresses SUTCAST Identify Potential Defect Regions Make High Performance Castings The First Time 11

12 Phase 1: Quotation Development Primary Responsibility: Sales Secondary Responsibility: Application Engineer Support Functions: MFA team Business Analysis Product D&E Quality Planning Major Content: Develop concept design that meets customer needs. Estimate and quote Prototype and or Production Development Budget Quote prototype tooling, piece price & timing Quote production tooling, piece price & timing Obtain customer PO for Product Development, Prototype Parts and / or Production Parts GATE 1 Sales Customer Prototype Kickoff When Req d FAC Product Development & Launch System Phases Overview Phase 2: Product Development Primary Responsibility: Application Engineer Secondary Responsibility: Sales Support Functions: PPTM Engineering Program Management Business Analysis Plant Quality Major Content: Develop prototype product as production intent design. Obtain customer design release of prototype design. Design/build prototype tooling & produce castings. Test prototype castings (DV test). Gain customer approval of prototypes. Obtain customer PO for production design & tooling. GATE 2 AE Customer Production Tooling Design Kickoff Phase 3: Production Development Primary Responsibility: Program Management Support Functions: PPTM Engineering Sales Application Engineer Plant Quality Major Content: Develop production product design. Obtain customer design release of production design. Develop detailed process & facility design for production. Design required tooling, gages and equipment. Obtain approval for capital spending (AR) if required. GATE 3 PrM Production Tooling Build Kickoff Phase 4: Launch Preparation Primary Responsibility Program Management Support Functions: PPTM Engineering Sales Application Engineer Plant Quality Major Content: Implement process & facility design for production. Plan, purchase & install all tooling, gages & equipment. Prepare the production environment for series production. Transfer program knowledge & ownership to Manufacturing. Product Validation GATE 4 PrM Customer PPAP / R@R Approval Phase 5: Production & Kaizen Primary Responsibility: Manufacturing Support Functions: PPTM Engineering Sales Program Management Plant Quality Major Content: Meet (or beat) planned quality, volume, performance, cost and delivery performance. Continues Improvement Implement customer service support plan. Implement Kaizen plan resulting from issues & opportunities. 12

13 SkatteFUNN prosjekt ved FAC 1. Aktuell finansiering av FoU ved FAC 2. Hva med SkatteFUNN? 3. Eksempel på SkatteFUNN prosjekt ved FAC 4. Hvordan komme i gang registrering av søknad 5. Oppsummering

14 Typiske FoU aktiviteter & støtteordninger FoU aktiviteter: 1. Kontinuerlige forbedringer i alle ledd av produksjonen 2. Potensielt større forbedringer av produkt/prosess/produksjonsmåte 3. Ny teknologi / nye (IT-)tjenester / nytt produkt Eksterne støtteordninger benyttet av FAC: 1. SkatteFUNN 2. Norges Forskningsråd (BIA & KMB) 3. Sørlandets Kompetansefond 4. Kunder & Leverandører av varer, utstyr & tjenester 5. Universitet og FoU Institutt

15 SkatteFUNN: 1. En rettighetsbasert ordning for virksomheter som vil skape verdier av nye ideer. Formålet er å fremskaffe ny kunnskap, informasjon eller erfaring som igjen kan føre til nye eller bedre produkter, prosesser, tjenester eller produksjonsmåter. 2. Ordningen er hjemlet i skatteloven, og administreres av Forskningsrådet og Innovasjon Norge i felleskap. 3. Søknader behandles fortløpende. Gjennom godkjenning av et prosjekt i SkatteFUNN har bedriften krav på 20 % fradrag i skatt for kostnader knyttet til FoU-aktiviteter i prosjektet. 4. Viktige kriterier: 1. Intern timesats = 0,16% x årslønn (maks 500 kr/time) og maks 1850 timer per person 2. 20% (18%) av maks 5,5 mill NOK/år kostnader pr bedrift dekkes av skattemyndighetene 3. 20% av totalt maks 11 mill NOK/år om 5,5 mill NOK kjøpes av godkjent institutt 4. Søknad før 1. september vil bli ferdigbehandlet og gjeldende for hele inneværende år. 5. Rapportering; a) årsrapport innen 1. mars og b) sluttrapport innen 1. februar

16 FoU prosjekt ved FAC (tidligere AAC & CTF) Prosjektnavn / Finansiering 1. AAC-Elkem; Thin wall casting / AAC, Elkem, SkatteFUNN (SF) 2. AAC-NTNU/SINTEF; Tomra Granulator / AAC, NFR, Tomra, SF 3. AAC-NTNU; KMB - NorLight - Design & Production (NUTS) / AAC, NFR, SF 4. AAC-SINTEF; NorLight Shaped Casting of Light Metals / AAC, NFR, SF 5. AAC-SINTEF; BIP Low pressure & gravity Die Casting / AAC, NFR, SF 6. AAC-SINTEF-Prediktor; BIP - Metal quality Aluminium casting / AAC, NFR, SF 7. AAC-Prediktor; Online data collection / AAC, SF 8. CTF-NTNU; KMB Lean Product Development / CTF, NFR, SF 9. CTF-SINTEF; BIP FREMSTØT / CTF, NFR, SF 10. FAC-Prediktor-SINTEF; BIP AutoCast / CTF (FAC), NFR, SF 11. FAC-IMPETUS; Crashworthiness of cast chassis components / FAC, IMPETUS, Sørlandets Kompetansefond, SF I snitt har FAC fått ~ NOK ,- fra skattemyndighetene hvert år (-2009)

17 HVORDAN KOMME IGANG? 1. Logg inn på Forskningsrådet sin nettside for SkatteFUNN 2. Skjemaet finner du på under Logg inn > Mitt nettsted > Prosjektinfo/Rapporter. 3. Start med å registrer deg som bruker

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19 TAKK FOR OPPMERKSOMHETEN! Jan Ove Løland, Dr.ing R&D / NPI Director Farsund Aluminium Casting AS PO Box 158, Lundevaagen S, N-4552 Farsund, Norway