PRODUCTION

AT HOME IN THE WORLD OF MOBILITY

Automobile manufacturers around the world place their trust in the excellence of our products and our reliability as a supplier. For this reason, it was always clear to us that we must maintain direct control of our production to a high degree and work with a high level of vertical integration.

We continually invest in cutting edge technology to ensure greatest possible efficiency. We focus tightly on the opportunities offered by the vertical networking strategies and horizontal integration concepts of Industry 4.0. Nevertheless, it is the perfect interaction between people, machines, and software, our engineering expertise, automation and the diligence of our employees, that combine with sophisticated quality management to ensure absolute precision in the production of our end products.

GERMANY

KIPP Gmbh & Co KG

Gottlieb-Daimler-Str. 19

72172 Sulz am Neckar

Germany

HUNGARY

KIPP Car Comfort Systems Hungary Kft.

Bányatelep 14

2084 Pilisszentiván

Hungary

MEXICO

KIPP Automotive México, S. de R.L. de C.V.

Av. Santiago Poniente No. 116

Parque Industrial Colinas

78423 San Luis Potosí

Mexico

QUALITY KNOWS NO LIMITS

The phases from start-up production to serial manufacturing maturity, including our own validation and material testing procedures, is concentrated at our headquarters in southern Germany. We have established additional capacities for product assembly at our plant in Hungary. Further production facilities have been set up in Mexico to support markets abroad with reduced logistics and overhead.

We work with identical machines and tools at all our company sites to ensure the same binding quality and sustainability standards wherever KIPP CCS products are made. This simultaneously enables us to assure the extreme flexibility and speed and the product excellence for which we are known in our markets.

STATE-OF-THE-ART MANUFACTURING

Our state-of-the-art machining capability enables a broad spectrum of manufacturing options: Toolmaking, jig and fixture construction, prototyping, milling and turning, injection molding, and assembly.

This means that we maintain direct and complete control over all essential steps of the production process. The value of this is proven not least in the product development process, as it allows us to realize and implement constructional modifications much faster.

Injection molding shop

3-shift operations on fully-automated systems built in 2013 or later.

All machines are equipped with Multilift V robotic systems and smart, flexible material feed for maximum system efficiency. Automated materials-handling technology for the production of precise quantities and sorting of finished components.

Digital connectivity between all machines via the Arburg Host Computer System (ALS), which provides current machine data with a single click.

Technical details:
  • Arburg machines with Selogica direct control for efficient processes
  • Variable clamping force range from 350 - 3200 kN
  • Flash-free overmolding of inserts
  • Thermoplastics with various fillers and additives
  • Processing temperature up to 450°C
Machining

Mainly for machining aluminum, extruded aluminum profiles and die-cast zinc blanks.

Broad spectrum, ranging from simple components to complex 5-axis machining. Backup of all necessary programming strategies for ensuring efficient process times in our CAD/CAM department, in which the 3D constructions and individual processing programs are created for each machine.

In serial production: 8 Chiron Mill 2000 High Speed and Mill 3000 High Speed series machining centers. Hydraulic clamping mechanism for secure clamping and short idle times. Spindle-integrated cutting force monitor and laser-sensor monitored tool checking for constant determination of tool wear or breakage.

In sample component, micro-batch and small-batch production: Hermle UWF 1202 H, Kunzmann WF 600 MC and CNC turning lathe. The Müga XP4-42 is provisioned by a short bar loader. Machining takes place with a main and an opposed spindle with powered tools.

Technical details:
  • Cutting of extruded aluminum profiles to length with a fully-automatic Pressta Eisele Profilma 600 R circular saw
  • Fully-automatic material feed with a loading magazine
  • Long bar magazine feeder for processing bars up to 6000 mm in length
  • Travel on X-axis up to 3000 mm, on Y-axis up to 610 mm, on Z-axis up to 630 mm
  • Automatic 24 - 40-fold tool changer
  • Infrared/wireless measuring sensor
  • Hydraulic workpiece clamping with up to 3 clamping cycles, controlled by clamping logic or the machining program
  • Siemens 840D Solution Line control
Assembly

Use of custom jig and fixture solutions constructed by in-house resources management for aggregate assembly. Realization of assembly processes for small, medium, and large scale production on automated assembly systems, depending on requirements.

Technologies such as force/stroke monitoring, electronic servo-presses, fully-automated final checking systems, continuous process function checking and documentation are integrated in all processes.

Further details:
  • Innovative mixing and application systems for bonding and sealing with 1C/2C adhesive systems
  • Semi-automated KUKA robotic system with system connection to a fully-automated carousel for space-saving storage technology
  • Final checking systems utilizing camera and sensor technology with automatic component and color identification and object inspection