Production and Tooling.
OMER manufactures complete furnishing systems and railway components in aluminum alloys, steel alloys, plastic and composite materials. Specifically, the company’s infrastructure and manpower are highly specialized for the production of aluminum components.
All product transformation and processing stages are carried out with the help of the technologies and expertise owned by the company. Only particular processes and/or activities (e.g. galvanizing, forming of small plastic components) are outsourced to selected qualified suppliers, as necessary. This allows for extreme production flexibility and the maintenance of a strict control on processes and products.
Production
Production is mainly characterized by the processing of rolled aluminum and steel alloys and extruded light alloys and is developped through the following phases:
- Cut
- Plastic deformation
- Welding
- Grinding
- Bonding
- Painting
- Assembly
- Packaging
For each project, the processing phases are defined by a production roadmap established in the design phase, on the basis of a time schedule contractually agreed with the client.
ZERO WASTE
Ciascun componente viene realizzato ex novo, cioè senza utilizzo di semilavorati presenti a magazzino, in quanto ogni progetto necessita di specifici componenti, essendo caratterizzato da particolari specifiche di prodotto e vincoli di realizzazione.
In ragione di ciò, al termine della realizzazione di ogni progetto non avanzano componenti inutilizzati, se non piccola ferramenta (e.g. viteria).
Each component is made from scratch, i.e. without using semi-finished products in stock, as each project requires specific components in line with its particular product specifications and manufacturing constraints.
For this reason, on completion of each project no unused components are left over, except for small ironmongery (for instance, screws).
FOUR POINT ZERO
In the Carini industrial plant, all the machines in Plant A and Plant B are fully integrated and digitized in compliance with the Industry 4.0 rationale.
Each phase is monitored and managed through an integrated computer system that ensures a stringent control of production and an accurate traceability of materials.
The machines, which are programmed remotely by the specialist CAD-CAM office, guide the operators through the sequences to be performed.
Accurate data recording and subsequent analyses constantly maximize production efficiency.
Tooling
The ability to internally develop both design and production allows OMER to create ad hoc equipment for each process.
In particular, the company has developed a strong know-how for the production of moulds dedicated to cold & warm forming, temperature and depression tested templates for the production of composites and assembly jigs to be used in the various departments to allow an ever greater precision and optimization of machining.
Thanks to the research and development activity carried out by OMER in cooperation with Politecnico di Bari, it was possible to develop a particular proprietary forming cycle called Warm Forming, which allows OMER to create shapes with significant deformations through aluminum forming in a single phase. If this technology was not available, a variety of forming, welding and grinding operations would be required, resulting in higher costs.
In this case, OMER often resorts to the design and manufacture of high-precision templates, which are applied in every department and allow considerable time savings while guaranteeing greater precision during all of the phases, especially welding, painting, assembly and quality control.
