Our Projects
Volkswagen Motor Polska – Pneumatic Transport Optimization
At the Volkswagen Motor Polska plant in Polkowice, we developed and implemented a comprehensive solution aimed at extending the lifespan of pipes, elbows, and tees used in the pneumatic transport of chips from machining processes.
By implementing innovative solutions, such as modifying the geometry of system components and applying wear-resistant coatings, we successfully extended the lifespan of these elements from 3 months to 4 years. As a result, we achieved a significant reduction in operational costs and increased process efficiency.
We carried out the modernization of the BAYER leak testing device for EVO internal combustion engine blocks at the Volkswagen Motor Polska plant. By adapting the machine to specific requirements and integrating advanced technological solutions, we aligned the equipment with modern production standards. These enhancements resulted in increased testing precision and shortened test cycle times, significantly improving quality control efficiency.
Stalprodukt S.A. – Implementation of a New Forging Technology for Base Plates
In collaboration with HSW Kuźnia Stalowa Wola, we developed an innovative forging technology for heat-resistant base plates used in bell furnaces. Our proprietary solution, designed specifically for Stalprodukt S.A., has significantly extended the durability of these plates, leading to a substantial reduction in operating costs and enhanced operational efficiency for the company.
Arcelor Mittal Refractories – Production of a Hydraulic Press Frame
For Arcelor Mittal Refractories in Kraków, we designed and manufactured a 25-ton hydraulic press frame. The process included model development, casting, and subsequent machining. Utilizing our advanced machining capabilities and extensive experience in executing such projects, we ensured the precise fabrication of the press frame, fully meeting the stringent requirements of the client.
KGHM – Production of Wear-Resistant Plates
For the KGHM Polkowice ore enrichment plants, we developed a manufacturing technology for dual-layer wear-resistant plates, composed of high-chromium white cast iron bonded to steel. These plates were implemented in first-stage chutes, significantly enhancing wear resistance, reducing operational costs, and improving the efficiency of ore transportation processes.
Energo-Puls Sp. z o.o.
At the request of our client, we carried out the following services:
- 2023 & 2024: Inspection of ignition burners for the 910 MW boiler at Nowe Jaworzno Power Plant – Tauron S.A.
- 2024: Inspection of ignition burners for the OFz450A boiler at EC Żerań.
- 2024: Installation of shut-off gates for the pyrite hopper of coal mills No. 1 at Nowe Jaworzno Power Plant – Tauron S.A.
Optimization Projects for Various Industrial Sectors
For companies such as Timken Poland, Lead Corporation Poland, Wielton, Plettac, Infofinder, Wabco, DeLaval, and many others, we have successfully executed process optimization projects aimed at improving efficiency, reducing costs, and modernizing production operations. Our scope of work included:
- Modernization of production lines to enhance efficiency and automation.
- Machine upgrades to extend service life and improve performance.
- Production restructuring to streamline workflows and reduce waste.
- Implementation of automated warehouses to optimize logistics and material flow.
- Design of production workstations in line with Industry 4.0 principles.
- Implementation of TPM (Total Productive Maintenance) standards to increase reliability and equipment uptime.
- Supervision and implementation of production for Zebra Technologies and Kleemann at subcontractor facilities.
These projects have led to significant cost reductions, increased productivity, and improved quality, aligning manufacturing processes with modern production management standards.
Projects for the Public Sector
Our company has extensive experience in delivering custom projects for the public sector, including cultural and artistic institutions:
- Museum of the Second World War in Gdańsk (Poland): We designed and manufactured rotating display cases housing the world's only preserved prisoner identification plates from German labor camps across Europe. Additionally, we developed multimedia cabinets and interactive showcases for the Nuremberg Trials exhibition room and various other multimedia displays and exhibits located throughout one of the largest museums in Poland and Europe.
- Opera in Macerata (Italy): We designed and built a dynamic stage set featuring three platforms over 7 meters high, which dramatically "collapse" on stage during the performance, creating a spectacular visual effect.
- Opera in Valencia (Spain): We executed advanced scenography projects for the prestigious opera house in Valencia, integrating cutting-edge technology with the demanding aesthetics of theatrical productions.
- For the Silesian Planetarium, didactic stations were designed and constructed for the youngest and not only. Visitors can build their own rocket and test it to their heart's content together with other participants. Whose rocket will fly the highest and whose will fly the furthest?
These projects showcase our ability to merge technical expertise with artistic vision, delivering innovative and high-quality solutions tailored to the needs of cultural institutions.
Mercedes-Benz Manufacturing Poland – Comprehensive Production Support
Since March 2020, our company has been executing complex tasks related to the launch, coordination, and optimization of production processes at the Mercedes-Benz Manufacturing Poland plant. Our scope of work covers a wide range of activities, ensuring efficiency, quality, and seamless production workflows.
1. Coordination of Mass Production Launch
- Battery Production Line: Management of production line commissioning for battery assembly, including oversight of advanced production technologies and quality control testing, ensuring a smooth transition to mass production.
- Crankshaft Production Line: Optimization of crankshaft manufacturing processes, including machine testing, quality control, and identifying areas for improvement to enhance efficiency and minimize downtime.
- Internal Combustion Engine Production Line: Supervision of new technology implementations in engine manufacturing, focusing on process optimization, assembly efficiency, and quality assurance, ensuring compliance with Mercedes-Benz's highest standards.
2. Coordination of Specialized Production Areas Startup
- Supporting the launch of new production lines and specialized manufacturing areas, including technologically advanced processes such as heat treatment and assembly automation.
3. Implementation of Safety Policies
- Battery Production Facility: Development and implementation of a new safety policy to ensure the highest protection standards for both employees and equipment. Our activities included safety audits, personnel training, and updates to safety procedures to meet Mercedes-Benz's strict requirements.
4. Machine Condition Assessment and Technical Documentation Review
- Conducted detailed technical evaluations of machinery and documentation for the crankshaft production line, identifying key areas requiring modernization and optimization.
5. Verification and Identification of Spare Parts
- We developed a verification and identification system for critical spare parts used in the crankshaft and battery production lines, enhancing production reliability and minimizing downtime risks.
6. Coordination of Production Line Dismantling
- Managed the dismantling process for the crankshaft production line, ensuring safe, timely execution and the efficient reutilization of production components in line with Mercedes-Benz's operational standards.
7. Standardization and Optimization of Technological Processes
- Optimized the heat treatment process for crankshafts, leading to extended tool lifespan and reduced unit costs.
- Standardized technical documentation, streamlining communication and information exchange between engineering and production teams to improve operational efficiency.
8. Optimization of Tools and Processes
- We implemented design modifications and tool optimizations, significantly improving production efficiency while reducing operational costs.
9. Collaboration with Other Mercedes-Benz Plants
- We regularly coordinate operations with other Mercedes-Benz manufacturing facilities, ensuring process consistency and standardization of technological solutions across the entire production network.
10. IT System Management
- We are responsible for managing key IT systems, including PRISMA and WVS, which are critical for production process management and performance reporting.
11. Coordination of Process System Dismantling
- We supervised the dismantling of process and facility installations above production lines, requiring close collaboration with multiple technical teams to ensure safe and efficient execution.