processES

ONE PLANT COVERS IT ALL

EBP’s production plant in Olofström is a European leader in the manufacture of niche-volume body panels. Our flexible production system can be optimised for production runs from just a few hundred units to up to 50,000 units a year, depending on productcomplexity.

The press line, inaugurated in 2005, is one of the most powerful and versatile in Europe. The assembly line uses efficient and flexible robot technology. Our surface treatment technology is state-of-the-art, as is our packaging process. We are very open to current or new customer visits where you can come and experience what our facility has to offer
yourself.

Eye on quality

At EBP, quality improvement is an ongoing process. Quality control is built into the entire process as documented in our ISO/TS 16949 and ISO 14001 certifications. In accordance with each customer’s standards, we also carry out regular sampling to check the dimensional precision, curvature, surface finish and durability of the various products.

STAMPING

A highly developed yet fully adaptable press line

EBP’s press shop is designed to meet the automotive industry’s growing need for
OEM and OES manufacture of vehicle components and assemblies in the niche/medium volume segment. EBP specialises in meeting high requirements in terms of press force, precision, quality and capacity. At the same time, each press is designed to be easily adaptable to suit different tool designs.

The press shop consists of a 6-stage fully automated press line boasting a maximum ram force of 2000 tonnes. The largest press beds (presses 1–5) measure 5 x 2.5 metres. Presses 1–5 are hydraulic, while press 6 is mechanical. All material is put through a blank washer so that A surface and aluminium quality demands are met. The press line is fully automated with 6 ABB robots which feed the blanks between the presses. The line can be operated from press 1–6 with material output after each stage, and the press line can also be run in inverse mode with input from press 6 through to press 1.

ASSEMBLY

All common assembly techniques in one shop

EBP’s assembly concept fulfils the automobile industry’s growing need for efficient production of body panels in small to medium sized volumes, while meeting the highest OEM and OES requirements for quality, strength, fit and finish of the finished product.

Utilising flexible, adaptable production technology is largely about being able to program industrial robots and adjust fixtures, jigs and equipment. EBP personnel are thoroughly acquainted with the automotive industry’s most modern assembly technologies.

In our production plant we have robots from ABB, Kuka and Hyundai, and our systems are entirely compatible with the full range of industrial robot technologies that exist in our industry.

Hemming

Currently, we utilize two different hemming techniques: table top and roller hemming. Table top hemming is often replaced by roller hemming for spare part production after EOP, allowing production of shrinking volumes while retaining good economy and unimpaired quality.

Bonding

Our system for glue and anti-flutter application can handle fixed or robot-mounted nozzles. We use most adhesive types found on the market, in both our Flexible and stand-alone assembly cells, as well as in equipment taken over from the customer.

Spot welding

For spot welding of steel, we use both manual and robot-mounted welding guns, as well as fixed welding guns, both in our flex-lines or in equipment provided by the customer. For automated formatting of the welding electrodes, an automated electrode dressing station is used to ensure the quality of the spot weld.

MIG welding

We have the equipment and expertise for MIG welding of both steel and aluminium using automated production in robot cells. Where an automated solution is not applicable, we employ manual welding carried out by qualified welders.

Riveting and clinching

For joining of aluminium, we use clinching, self-piercing riveting and conventional riveting techniques, depending on the process the customer has selected for the specific product.

Punching and cutting

Cutting of entire body sides (cut parts) in lower volume series takes place manually via nibbling according to the customer´s requirements, while larger volume series are cut automatically in our in-house-manufactured cutter jigs.

ED-COATING

A first class coating plant with bodyside capacity

EBP’s surface treatment plant is designed to deliver OEM-quality ED coating for any metalic vehicle body component – from the smallest beams to the largest bonnets – in steel or aluminium. Large body sides and truck cabs are also surface-treated here.

EBP boasts 2 available processes for ED coating. A conventional phosphate ED process and also recently added Thin Film (Oxsilan) ED process.

Both processes are computer-controlled and have the capabillity to paint a component size of 4000 x 1000 x 1700 mm max. This system has 19 dipping stations for the de-greasing, pre-treatment, phosphate (Oxsilan), cathodic electro-dipping, hardening and sealing processes.

Compared with the conveyor belt solution that is more commonly used elsewhere, the carrier system used at EBP increases flexibility, reduces set-up time and ensures coating of the highest quality by positioning the parts in a repeatable optimal orientation through the whole process.

After Sealing

Many customers have an extra requirement after painting of applying a hem sealant for increased corrosion resistance. EBP s surface treatment plant includes this option which can be applied to the customers requirements.

Closed Water Loop protects the environment

EBP’s surface treatment plant is designed to exceed both current and forthcoming environmental requirements. The process is therefore constructed as a single closed system. Waste water is purified and reused within the plant. Other substances that are filtered or discarded during the purification process are collected for disposal.

Meeting OEM Standards

EBP’s surface treatment meets the most stringent quality requirements for corrosion protection and surface finish, including the OEM standards of manufacturers such as:

  • Volvo
  • Audi
  • Porsche
  • Aston Martin
  •  

PACKAGING

Optimal packaging for each delivery

Vehicle body components are bulky and vulnerable to impact. Packaging and transport must provide good protection and at the same time aid smooth logistics, efficient transportation and good overall economy. EBP offers an optimal holistic solution for the final, but vital, stage in the value chain - delivery.

A vehicle body component that is delivered to the assembly line for use in series production requires a certain type of packaging, while the same body part that is delivered directly to the branded workshop’s spare-parts warehouse requires an entirely different type of packaging. That is why EBP’s packaging concept is based on finding the optimum solution for each customer.The objective is always to transport the part damage-free at a low overall cost to the customer. However, a good package can generate even greater added value.

The right type of packaging and identification makes it easy to identify the product, protects it from theft, makes it possible to monitor the location of the product in the delivery chain and simplifies the receipt of goods at the delivery destination. The right packaging is also re cyclable. It also takes costly shipping of empty racks "out of the flow"


LASER

5 AXIS Laser cutting

EBP have two 5 axis laser cutting machines with large tables to handle some of the markets largest Body in White parts such as Body Sides and Hoods in both aluminium and steel.

Machine 1- Prima Optimo CO2 4000W

Cabin Volume X4500*Y2500*Z1000

Machine 2- Trumpf 7040 fiber 3000W

Cabin Volume X4000*Y2000*Z750