STOCKO CONTACT commences operations at a new logistics centre and state-of-the-art high bay warehouse.
Due to increasing customer demand, STOCKO CONTACT is expanding its logistics network with an area of 2,700 m² and is again investing in the Hellenthal location. This optimises the flow of goods from completion to dispatch meaning that it all takes place directly on site as a one-stop operation. In addition, a new fully automated finished goods warehouse has gone into operation.
Maximum space utilisation on a small footprint combined with speed, flexibility and energy efficiency: these are the key features of a modern compact warehouse. The new high bay warehouse covers a length of 60 metres and a height of 11 metres.
The previous capacity of the conventional finished parts warehouse will be almost doubled by the expansion.
The warehouse complex is divided functionally into the areas of high bay warehouse, outgoing and incoming goods with conveyor connection to the production and storage hall. The new high bay warehouse has 2 aisles and a capacity of 4,320 trays, which can also be loaded with 2 layers of cardboard boxes.
The new pallet rack with 617 pallet spaces accommodates the finished goods packed in bulk containers and the necessary packaging materials. EURO pallets, small pallets as well as customer-specific pallets are stored and transported. The warehouse serves as a buffer and distribution warehouse. Material movements are carried out semi-automatically via a tablet-supported information system using a new reach truck.
Modern loading ramps
The outgoing goods area has 3 loading ramps. The provision of the goods is fully automatic on a total of 3 picking workstations with drive roller technology. The outgoing goods area is connected by means of conveyor technology. Loading with filled trays and return storage of empty trays is carried out via a separate lifting station and with our own conveyor technology from and to production. Up to 100 trays per hour can be picked.
Pallet transport from production to logistics is handled by a goods lift.
Two automatic feeding stations have been installed in the assembly area, which ensure the removal of the finished goods by a 4-table unit.
High bay warehouse
New conveyor technology with up-to-date conveyor tracks
Up-to date logistics using intelligent software and storage location overview
"We are looking forward to further expanding our network with the new logistics centre in Hellenthal and thus to meeting customer needs quickly and efficiently," says Mr. Ingo Klinkhammer, Head of Materials Management at STOCKO CONTACT. "We offer a good infrastructure and thus remain enormously competitive." The new STOCKO logistics centre continues the positive, dynamic development. The extensions at the Hellenthal site thus amount to a total of 6,900 m² and are another positive sign of STOCKO's solid economic growth over the next few years.
STOCKO establishes itself in the technology location of JAPAN. The company wants to continue to take advantage of growing global opportunities.
With the establishment of STOCKO CONTACT Japan K.K. in Okayama, we have taken another important step towards expanding our market position in the automotive, heating and household appliance industries in the Japanese market.
The expansion of the site is intended to significantly improve local support from our Japanese colleagues, thus opening up new growth areas.
The objective is to introduce connector systems that are well established in Europe as well as newly developed products to the Japanese OEM's. In addition, we expect regular customer visits and intensive market observation to enable further country-specific solutions in a growing technology location.
This massively improves STOCKO's international competitiveness for its markets in the Far East.
On 17 January 2020, three more apprentices laid the foundation stone for their subsequent professional lives. During their training as tool mechanics, they have passed through many internal departments and got to know the individual activities and many employees.
In a small ceremony on 22 January 2020, the good examination results were honoured by the HR Manager, Mr Sieboldt. The completion of the training was celebrated together with the examinees, the trainers and the many training officers at a small social event with light refreshments. All the examinees were allocated to various staff teams with permanent employment contracts.
Congratulations!
Photo from left:
Thomas Frauenkron Tool mechanics
Nicolas Linden Tool mechanics
Fabienne Josephs Tool mechanics
Change of name completed:
founding of new companies STOCKO CONTACT Shanghai Co. Ltd. and STOCKO CONTACT International Trading (Shanghai) Co., Ltd.
By the change of name, the building previously shared with Wieland Electric (Shanghai) Co. Ltd. has now been made the sole headquarters of the newly established STOCKO CONTACT Co. Ltd. (SCS) in Malu/Shanghai. This gives STOCKO a very good strategic starting position for its markets in the Far East.
The SCS building complex is a two-storey complex with a total area of 5,500 m². Two production areas are located on the ground floor: the modern injection moulding production on an area of 600 m² and an assembly area of a total of 1,100 m². This in turn is divided into a fully automatic production line of 500 m² and a semi-automatic area of 600 m². There is also a storage area of 3,000 m² on the ground floor. In this way, the flow of goods from completion to dispatch is optimised and takes place directly at the Malu location from a single source. The upper floor accommodates spacious offices. They cover a total area of 800 m².
In addition, the company has decided to set up another strategic new company: STOCKO CONTACT International Trading (Shanghai) Co., Ltd. - SCT for short. It is located in the Shanghai free trade zone with local logistics and has an effective sales team. In addition to the production facility in Malu, the newly organised domestic sales in the metropolises of the local Chinese customers will further increase competitiveness.
"With these site expansions, STOCKO is positioning itself close to the beating heart of the Chinese market and setting future standards for the global orientation of the company. The production advantages in our customers' countries, coupled with Chinese development, product marketing and sales, as well as two logistics channels, will further strengthen our position with an eye to the future and form an important basis for our ambitious growth targets," says Selahattin Servi, Managing Director of STOCKO CONTACT GmbH & Co. KG.
The new 4.0 industrial halls have set standards for the future development of the company.
Following the structural expansions of recent years in Andlau, France, the investments in Hellenthal are also a clear commitment by the company to its established sites.
In a first construction phase, the assembly area has been expanded by a 1,800 m² extension (marked orange in the picture). This means that the total assembly area is currently 5,400 m² (marked blue in the picture). Machines for production have already been installed and have been in operation since summer 2019.
In a second construction phase in spring 2020, another hall will be developed directly connecting to it, which will be divided into various complexes: with an area of 2,700 m², the largest space here is assigned to the logistics area (marked green in the picture). This means that the rented external logistics hall in Schleiden, about ten kilometres away, can be dispensed with in the future. The flow of goods from completion to dispatch will be optimised in this way and take place directly at the Hellenthal site from a single source. In addition, a new fully automatic finished goods warehouse is under construction. The planned operational start is in summer 2020.
The rear building complex of this hall (marked yellow in the picture) is two-storey and covers a total of 2,000 m² largely reserved for mechanical engineering. This is occupied by office space of approx. 550 m² and a workshop of approx. 450 m² upstairs as well as a further area on the ground floor of approx. 450 m². In addition, the training workshop for the currently 35 trainees for the industrial/technical professions will move into the ground floor. This will then cover approx. 550 m². The move to the new premises is planned for spring 2020. The area of the previous training workshop in the opposite hall that will be vacated will in future be assigned to the stamping shop.
The extensions at the Hellenthal site thus amount to a total of 6,900 m² and send a further positive signal for the solid economic growth of STOCKO in the next few years.
Captions
ATotal assembly area is now 5,400 m²
BThe hall extension (B) has increased the assembly area by 1,800 m² to a total of 5,400 m² (A + B)
CLogistics covers 2,700 m²
DMechanical engineering building complex ground floor covers 450 m²
Office 550 m² and workshop 450 m² upper floor
Total area 2,000 m² including a training workshop of 550 m²
In recent years, the Andlau site has now almost doubled to a total area of approx. 50,000 m². Some 250 employees work here in production in the automotive and home appliances business segments. The growth course at our French plant will continue. After the site has recently been made fit for the future with various measures, including the purchase of additional land and hall conversions, the new central goods receiving area has now also been put into operation.
The recently completed building covers around 2,000 m². In future, all raw materials as well as operating and auxiliary media will be stored here. The central services and maintenance will also move in there and support the production departments with their activities. Fast routes, good lighting conditions and clear layout support the objective of optimising the flow of materials and the associated production processes.
The 2-shot injection moulding technology expands the range of applications of connectors and opens the way to new, innovative solutions.
STOCKO constantly strives to provide its customers with a high level of user-friendly solutions. This is why it is necessary for us to constantly adapt our connectors to the wide range of applications and requirements. We achieve this by, among other things, new product developments and ongoing improvements in manufacturing technologies.
One of the requirements that have come to the fore is that of sealed connectors. Protecting device housings from the penetration of moisture via the power supply is just as important as sealing from the insulating foam, such as in cooling units.
This offers a solution where various sealing problems are eliminated by a special connector housing made of two plastic materials. For this reason, STOCKO has included so-called 2-component injection moulding in its production programme. By combining a hard and a soft component, the electrical and mechanical requirements of a connector and the requirements for different sealing functions, such as sealing the mounting opening of a housing or sealing the wire feed-in, can be optimally met.
By using 2-shot injection moulding technology for connectors, STOCKO can offer complex components in which different functions can be integrated. In combination with the innovative and high-quality STOCKO connector technology, this opens up new possibilities for rationalization as well as new technological solutions in the connector sector.
The 2-shot injection moulding machine (Fig. 1), the 2-shot tool (Fig. 4) and a handling system (Fig. 2 and 3) form a production cell. To ensure high quality, the manufactured plug housings are removed from the tool with a removal gripper and placed on a conveyor belt.
Fig. 4a: 2-Component Injection Moulding Tool
Fig. 4b: 2-Component Injection Moulding Tool
Fig. 5: Example of the use of 2-shot injection moulding technology: connector function (white) and seal function (black) are integrated into a single housing.
STOCKO is now also showing itself to be a true global player in other respects. The company recently added its own entry to the extensive Wikipedia encyclopedia.
Anyone who is anyone – whether as a public figure or a company – tries to have their own lexicon entry on Wikipedia. It's easier said than done. Not every company is entitled to be included in the illustrious circle of those named; the exclusion criteria are very varied. The fact that STOCKO is now included once again proves the special significance of our company.
The entry can be found at: https://de.wikipedia.org/wiki/Stocko_Contact
If you think that this is a negative characteristic here, you are wrong. Take a closer look and you will see that STOCKO's zero tolerance attitude is an essential condition for precise work. In this regard, the words zero tolerance can be taken quite literally. STOCKO recently acquired a state-of-the-art scanning electron microscope.
Small components, such as plug connectors and contacts, as manufactured by STOCKO do not tolerate any fluctuations in quality. Even the most minute manufacturing tolerances can subsequently result in the failure of entire assemblies. Because the requirements imposed on quality, service life, and the precision of STOCKO products are increasing over the entire cycle, continuous adaptation of our laboratory equipment is necessary to assure our high standards.
Consequently, as another step in expanding the development of our analysis methods STOCKO has placed a ZEISS EVO MA10 scanning electron microscope (SEM) with EDX system in service.
SEMs enable microscopic examination with magnification that is approximately 100x greater than that achieved with light-optical microscopes. Now 3-dimensional presentations of the most delicate surface structures possible, and it is also possible to measure and display elements that are embedded in the surfaces.
At STOCKO the SEM is typically used for the following applications:
With the SEM, new analysis possibilities are now available to STOCKO that contribute in improving the quality of STOCKO products, starting with product development and product qualification, in production monitoring and quality control, and extending to troubleshooting.
Microscopic images show hair crystals, so-called whiskers, on a tin surface.
Resolution of the grain structure of a high-gloss tin surface.
Presentation of the element distribution in a contact surface through coloring.
Analysis of the elements in a surface according to frequency.
New tinning plant will go into operation end of 2018.
After conclusion of extensive construction measures and a structural restoration of 3,500 m² of surface area, it was possible to move our production warehouse in Andlau into a significantly larger building.
In turn, the logistics hall that will be used until then will be completely reconstructed, among other things a completely new hall floor will be installed. The hall is scheduled to be completed by the end of the year.
After a new nickel-plating plant was commissioned in 2017 in Andlau, with the new hall reconstruction now the prerequisites are in place for an additional finishing line, this time for the nickel-plating of crimp contacts in strip form. The finishing line should come on-stream in the fourth quarter 2018. With its extensive renovation work, the new plant is an investment in the mid single-digit million range. In this regard all statutory and environmental requirements had to be meticulously complied with, which is always extremely complex and work-intensive for plants of this type.
With the running nickel-plating plant and the new tin electroplating that will move into the newly converted hall, we will double our original finishing capacity. Thus we ensure that in this area STOCKO will also have a customer-oriented production with strong reserves in the future.
Elaborate preliminary work must also be done in the outside area
The extensive renovation measures also include a new hall floor
With its lead frame modules, STOCKO offers its customers customised products developed jointly with them that are optimally adapted to the respective application and the production process.
Connecting and connection technology in the automotive industry is increasingly tailored more specifically to the respective application. Both the complex installation space in the car and the application-specific loads of an electrical, mechanical or chemical nature require individual solutions. In addition, for the connection systems too, solutions are being sought that enable automated installation and integration of these components into complex assemblies.
For this reason, in cooperation with its customers, STOCKO is developing termination solutions that are directly adapted to the respective applications. In many cases, lead frames in place of wiring provide the appropriate concept, for example for terminations in AdBlue pumps, in sensor technology applications or even in lighting systems.
Lead frame modules as produced by STOCKO are complex components that go through multi-stage processes:
The multi-stage STOCKO-specific production process offers clear advantages compared with other solutions. Thus for example, they can be adapted by the 3-dimentional contour shaping of the frames particularly precisely to the respective installation position. In addition, they enable the integration of separate functional areas so multi-functional applications are also possible. From holes to the precise positioning of the frames in the application right to connection contacts for lamps etc., functions can be integrated by appropriate forming. In its lead frames, STOCKO currently offers dimensions of 120x250mm².
Furthermore STOCKO lead frame modules make contact with the circuit boards via adapted IDC direct connectors from the STOCKO programme. These connectors are plugged in directly on the edge of the circuit board, a specific mating connector is not necessary. This saves installation space and money.
Also the selection of suitable materials is significant for the adaptation of the modules to the respective application. To withstand the different thermal, mechanical and chemical loads in operation, at STOCKO metals, surface finishing and plastics are carefully selected and tested.
In conjunction with the specially adapted STOCKO IDC connector technology and the precision processing, with these lead frames, all things considered, this results in highly individual solutions that STOCKO adapts jointly with the customer exactly to the respective requirements in the automotive area.
Attached circuit board direct connector in 2.5mm pitch
Lead frame after 3D forming and fixing of the frame elements by overmoulding with plastic
Circuit board direct connector in 5mm pitch
Lead frame with 2.5mm frame connectors, attached in 5mm pitch
Use of Robotics and Manufacturing Cells at the Hellenthal Factory.
Electromechanical components are becoming increasingly more complex. The demand for a higher component quality is growing at the same time. STOCKO is meeting this challenge in its Hellenthal factory by increasing the automation of its production processes.
STOCKO is expanding its product range and using new manufacturing methods to increase its competitive edge, particularly over Asian suppliers. Production steps that were previously performed separately can now be integrated into a single manufacturing cell. Injection moulding, punching and assembly processes are integrated there to manufacture hybrid components made of plastic and metal parts using advanced robotics technology.
Example: Bulb holder for the automotive industry
These products can in many cases no longer be manufactured using conventional assembly methods. The high function integration requires the use of insert moulding technology for the complex integration of plastic and metal parts.
At STOCKO, the various processes are integrated into a single manufacturing cell: the injection moulding process for the manufacture of the housing parts, the separation of the contacts from their retainers, the assembly of the contacts and the testing processes. This allows the manufacture of a complete bulb holder in a single continuous process.
In the manufacturing cell, industrial robots perform the handling of the required parts. Functions like
are performed by multi-axis robot systems. The integrated, active systems for tolerance compensation support the robots and increase the manufacturing precision.
The use of industrial robots automates the complicated manual insertion of the contacts that is only suitable for small production volumes and the removal of the finished bulb holder from the, up to 90° C hot, injection mould.
Both the robot technology and the integration of various manufacturing processes in the manufacturing cells open up new possibilities for STOCKO. Hybrid products made of plastic and metal components – robot automation for insertion part and in reel-to-reel technology – point the way to the inclusion of more complex, higher quality and more competitive components in STOCKO’s product range.
Our factory in Andlau (France) is undergoing a continuous optimisation of its manufacturing processes through various restructuring measures.
To accommodate the further growth of our STOCKO France company, plots of land with a total area of 20,000 m² were purchased last year and a property with a floor area of about 3,500 m² situated on that land was completely renovated.
After the relocation of our finished goods warehouse into this much larger building, the previously used logistics building will be completely converted so that two further finishing lines, which will double our finishing capacity, can be put into operation in that building in 2018. This expansion gives us a substantial production quantity increase and higher flexibility in the supply of our worldwide customers with tin-plated and nickel-plated products.
The development laboratory and mechanical engineering departments relocated into the larger space in the new central logistics building immediately after its completion. We are also fulfilling the increased market requirements here by making comprehensive investments in laboratory equipment. Our certified laboratory performs development tests and production-supporting tests for our customers in the home appliances and automotive sectors.
Like our mechanical engineering department at STOCKO Germany, the mechanical engineering department at STOCKO France also develops and manufactures production plant for internal use and the finishing technology for the use of our products at our customers.
The space made available by the relocation of the aforementioned departments serves the growth of our tool-making department, which will allow us to increase our punching capacity through the use of state-of-the-art machine tools.
STOCKO will definitely continue on its expansion course in the coming years and increase the manufacturing capacities in its various factories.
With rising demands in the field of automotive technology, special ultrasonic welding technology is becoming increasingly important. A challenge which STOCKO is meeting with a high level of expertise.
Once again, the core business of the STOCKO plant in Andlau/France is proving to be a guarantor for forward-looking investments, as our expertise in the area of stamping technology is again undergoing further expansion. STOCKO is setting itself at the vanguard of a new trend with ultrasonic welding technology, as this is a technique that can be put to particularly good use in the manufacture of contact systems for the automotive sector. Aluminum wire is now increasingly frequently seen replacing the more well-established copper, for reasons of both weight and cost.
The transition of materials from copper to aluminum is a tricky issue, however, and places high demands on the contact system. A secure connection can only be guaranteed by using special geometric structures and surfaces in the connection zone of the contact and a specially designed arrangement of the sonotrodes – the tools which transmit the ultrasonic vibrations into the component being worked on – as well as welding parameters which have been carefully adjusted in accordance with the specific contact pairing.
There are also two further critical constituent elements of the new technique – firstly, the mechanical relief of the connection through an insulation crimp and, secondly, its sealing against moisture, e.g. through shrinking tubes.
Using ultrasonic welding technology as a basis, STOCKO develops specific, individual solutions, together with its customers. First of all, the customer in question communicates the particular requirements which need to be taken into account. Then, in a comprehensive test procedure, STOCKO determines the connection zones and all the processing parameters for the connection system, consisting of contact, wire and the tools for the attachment process. After approval of the connection, the manufacturing process is then carried out on the manufacturer's own premises using their own ultrasonic welding unit.
Current focus lies in the area of wires with a cross-section of 10 to 85 mm². Whilst the smaller cross-sections are used in various areas of the car, the larger ones are mainly to be found in use within the engine compartment wiring system.
STOCKO has also applied its usual high precision in small parts stamping to large stamped parts.
Besides the standard product range, e.g. connector systems and crimp contacts, customer-specific special developments are increasingly demanded by automotive industry suppliers. An example for such project business is large stamped parts for the manufacture of contacts that are mainly used for engine compartment wiring.
That is where the core competence of the STOCKO factory in Andlau comes to bear: the stamping technology.
STOCKO continuously expands its stamping technology capabilities in Andlau because customer requirements are becoming increasingly special. For example, STOCKO has invested several million euros in the recent years in the stamping technology area for large contacts. The new presses with a closing force of 80 tons to 160 tons now expand STOCKO’s range of production equipment in this area. The associated coil unwinders can be loaded with up to 4.5 tons of raw material and thus allow the necessary machine run-times for an economically efficient automated production.
This equipment now allows STOCKO to manufacture products with a strip width of 300 mm and a material thickness of 5 mm made of copper, copper alloy, aluminium and steel. The currently typical product dimensions are in the range of 120 x 250 mm. The equipment is used to produce cable lugs, e.g. for high-current areas in cars, and cable lugs with an integrated nut that is added with special tools during the stamping process.
The investment in this technology also fulfils the good forecasts that we have produced for the automotive segment during the recent years and forms the basis for future success. STOCKO thus opens up new market segments and offers its customers not only the manufacturing know-how in stamping and tool technologies for large contacts but also its product and product qualification know-how gained in its development department and laboratory – all meanwhile proven by numerous realised cable lugs projects.
