Nemak: returning customers the biggest acknowledgement

AP: Győr-based Nemak is a subsidiary of the Mexican parent, but this wasn't always like this, the company's predecessor was established in 1993 by a German firm. How did the company end up in Mexico?

Zs. B.: The foundry was founded by the German VAW group twenty years ago to supply the newly built Audi plant in Győr. Constructions for the first production hall began two years later, while manufacturing was launched in 1996.

In 2002, the foundry was bought by the Norway-based Hydro group. Five years later, Nemak purchased several successful European foundries with the objective to set its foot on the continent – that is how the group's logo ended up on our facilities. Mexican-based Nemak group bought six companies in Europe. This meant that suddenly we started working with companies who had been previously our competitors.

How could you describe the collective work?

Quotation requests from our customers are sent to the headquarters in Frankfurt and then the management invites tenders from the various locations. The decisions are greatly affected by government subsidies and the proximity of the customer, but cost-effectiveness is also a primary factor.

Technical Director Zsolt Braun

Where would you rank the Győr-based foundry on the list of global subsidiaries?

Our target is to be in the top 3. I believe it is a good result that we are now considered to be in the top 5 within the group.

What is the strength of the foundry in Győr? How did you manage to obtain a position like this?

We must focus on our customers' requests. They value high quality and problem-free delivery. And should there be a problem, we have competences to react instantly. We also require this from our suppliers.

We have many returning customers – I think there is no better acknowledgement than this. It means they are satisfied, that we have done a great job.

At what capacities can you guarantee the same quality?

Last year we sold 2.4 million cylinder heads and we are also expecting similar volumes this year. Based on our projections, in the following years we could reach an annual sales volume of 2.7-2.8 million units. This means that millions of cars worldwide will be fitted with cylinder heads cast in Győr. Success also requires a good portfolio: we manufacture small displacement cylinders and cylinder heads for mass produced engines and premium engines produced in smaller volumes.

Which large manufacturers do you supply with your components cast in Győr?

We work for General Motors, which means Opel in Europe, but we also supply Renault, Audi and BMW.

Which ones are you the most proud of?

We are happy if we can keep our existing partners and gain new ones. Each customer is equally important to us, be it a manufacturer of mass-produced cars or a premium brand. However, requirements are equally high in the medium and premium segments as well. Of course, as a Győr-based company it is a huge honour that certain types produced at the nearby Audi plant are fitted with our components.

What is the challenge in metal casting?

Thanks to environmental regulations the engines are getting smaller and more complex, and we, too, must be prepared for that. This requires more accurate production, but we are trying to meet challenges by developing stable processes.

How are these obtained?

The development period is crucial for the successful production of cylinder heads, during which we have to become familiar with casting-related issues, which we have to address before mass production could begin. It is important put sufficient emphasis on the development and design processes prior to mass manufacturing. Besides it is also important to create a production line that eliminates the margin of error.

How long does it take from the arrival of an order until the start of production?

It varies, but it usually takes two years for a product to reach mass production. Although with BMW it was reduced to just one year. We received an order early in the year and mass production was launched already by the end of the same year.

Could you describe the manufacturing process at Nemak?

Casting cylinder heads is a difficult and complex procedure as we need to cast components with complex geometries in one piece in a way to include cavities in the most varied shapes and sizes. These cavities are formed using sand cores. The sand core making process is at least as complicated as casting itself. The quality of the sand, size of grains and the type of bonding agent all make a difference.

When we have the cores, we put them in a metal mould and pour hot aluminium on them at a temperature of 750 degrees Celsius.

After the cast has hardened, we remove the surplus sand and process the component according to the customer's request. Finally, each cylinder head has to go through a strict quality assessment process, providing the high quality of the product.

What challenges does the future hold for metal casting?

The future of engine production will be shaped by various environmental regulations. Engines are becoming smaller and more complex, however requirements against aluminium components will be higher, which shows primarily in mechanical qualities and durability. Besides, aluminium is gaining ground as a basic material in the automotive industry as a result of the tendency to develop more and more lightweight constructions. The group itself is also engaged in the casting of engine blocks and structural components. I don't think it's impossible that our product portfolio in Győr will be expanded one day. However, the production of engine blocks and body parts require different techniques, but of course, all of them can be learnt.

How long would it take to introduce new products to the production processes?

Should we receive and order like this, it would take about two years to launch production. It would take one year to build a new production unit, but product development would also take at least two years.