Business Case - Implementation of Laser Technologies at Scania Ferruform : Welding- and cutting applications for the manufacturing of banjo parts

Scania Ferruform AB is an independent affiliate of the truck- and bus manufacturer Scania AB which produces rear axle housings among other chassis components for said vehicles. The banjo part, i.e. the base of the rear axle housings undergoes processes which have issues both in terms of exceeded technical life span and insufficient production capacity. These three processes consist of both milling and welding operations. In order to resolve these issues the discussion of future investments arise. As this is discussed, the question whether alternative technologies could be of interest, specifically the performance of welding- and cutting operations with the use of laser technologies. By reviewing state-of-the-art literature, studying the present production conditions and interviewing experts within academia as well as parties active in developing and supplying industrial laser systems it has been shown that a laser arc hybrid welding technique would be the most suitable replacement, while laser nitrogen cutting would be the most suitable cutting technique. This project presents the theoretical outcome of implementing laser arc hybrid welding as a replacement to the present and conventional gas metal arc welding, as well as the possibility of using laser nitrogen cutting as a replacement to a set of milling processes. The study has shown that by implementing these technologies in a manner which also alters the balance in performed operations achieves a cycle time below the future goal for each production section. Cycle time values, quantities and costs are expressed with an indexed value of t, n and k respectively due to confidentiality. The first investment scenario results in an annual saving of consumption costs by 4 738k SEK, with a total investment cost of 112 743k SEK and 6,9 years pay-off time. The second scenario results in an annual saving of consumption costs by 5 018k SEK, with a total investment cost of 114 843k SEK and 5,2 years pay-off time. The third scenario is similar to the second in terms of the manufacturing processes, but it is the alternative of the lowest investment cost. This scenario would result in the same sum of annual savings as the second scenario, but with an investment cost of 89 843k SEK and 0,2 years pay-off time