Success story

PASS-POL


Initial situation

PASS-POL, based in Sanok, Poland, is one of the major automotive subcontractors. The company makes cooling, fuel feed and braking lines and components for some of the most famous brands in the world; Mercedes, Bentley, BMW, Aston Martin, Audi and Volkswagen: most of the tubing used on these cars was made in the Polish plant that employs some 1700 workers. Over 5000 different assembles are made from up to 100 different tube types all in one plant. Today total production amounts to over half million assemblies per week.

Effect

Responsiveness, quality and speed are essential characteristics required to be able to work with the most important automotive brands in the world. When a car manufacturer provides a new drawing, a prototype is needed within 24 hours. It is then analyzed by the customer's engineers and modified several times to obtain the best result. Twenty or so prototypes are made every day in PASS-POL: flexibility and speed are needed to make even one sample. The choice to purchase the BLM tube bending machine was driven to the need to become independent from suppliers in making test mandrels for rubber tubes.

On the other hand, there is the requirement for production over three shifts with major volumes in addition to prototyping. Some customers are not automotive but equally famous and demanding, such as Miele. For these batches, the most appreciated features of the BLM tube bending machines are inevitably reliability and durability.

The solution

Five BLM SMART tube bending machines are the center of the PASS-POL production activities, from prototyping to production itself, with relentless production rates and quantities. SMART is an all-electric (8 axis) bending system for tubes of up to 28 mm in diameter with multi radius, left hand, right hand in-process bending capabilities.

These machines are currently being used on an important Ford project for a very large number of parts bent for a new engine that is being sold worldwide. This translates to 700,000 parts per year that require bending and assembly with rubber hoses.

The benefits

Reliability, structural robustness, quality and energy saving are the reasons that made tube bending a winning move.

Technical aspects

All-electric bending guarantees maximum accuracy and quick and easy production changeover. Plus, its ideal for making quick prototypes with maximum flexibility.