Bushing Production
Teknorot has been producing and dealing bushes to all over the World. The bushes are either packed and shipped directly to our customers or used as a component of Wishbones, Link Stabilizers, Track Control Arms and Lateral Arm.
Teknorot has been producing Engine Mounting, Transmission Mounting, Strut Mounting, Rubber Buffer for Suspension, Exhaust Mount and Antiroll Bar Bushes beside bushes.
Teknorot is the leading manufacturer which produce its bushes inhouse and has one of the biggest bushing production plant in its sector.
Bushing; smart connection between rubber and metal
Due to the their distinctive effect on driving characteristic and safety, and the increasing number of track control arms and sheet metal wishbones used in current chassis configurations, lead to the increase of the use of rubber / metal parts.
The vulcanized connection between natural rubber and metal is specially designed considering the vibrations on the vehicle and these designs make a significant contribution to driving comfort.
The bushing production department works as follows;
- The surface treatment of metal components to be used in the vulcanization process
- Vulcanization of metal components and natural rubber mixture, by using transfer and injection molding presses in which all processes are monitored and controlled by computer
Each bushing of Teknorot offers high durability and driving safety;
- Excellent compatible material properties
- Damped chassis vibrations
- Excellent assembly
Bushings are safety and comfort components, and designed uniquely to reduce vibration and noise when the vehicle is in motion. Bushings help vehicle’s suspension parts to connect to chassis. Bushing parts can be natural rubber depending on design of vehicle; however, can be produced half natural rubber half metal. In the recent years, high-enduring engineering plastics have begun to be used instead of metal.
In the bushing production, all of the raw materials imported from the outside primarily pass through a rigorous input quality control process. If metal components is used for production, the process begins with forming metal pipes by eccentric presses. Metal pipes shaped in appropriate quality conditions. Rubber is subjected to washing, sanding, degreasing and painting processes so that the metal and metal surfaces can be adhered to each other perfectly before entering the vulcanization presses. Surface-cleaned metal parts are painting at fully automatic painting line to keep the desired paint coating thickness under constant control.
After required surface operation for adhesion, metal components are processed with rubber paste, which possess cold feeder system. Then, final product can be obtained. The specifications of the rubber paste used in the vulcanization operation are exactly the same as the original part and supplied from A-class suppliers. They are kept in the cold air storage until production to protect the technical properties of the rubber paste.
The vulcanization operation and the necessary deburring process is followed by a chrome or phosphate plating that is applied on the body. This prevents products’ corrosion on different usage conditions of the vehicle. Every step of the production and quality control operations is carried out by qualified personnel. Ensuring high driving safety and continuity of strength is the common mission of the team in all bushing production operations. The bushes are either packed and shipped directly to our customers or used as a component of Wishbones, Link Stabilizers and Track Control Arms.
About Kautek
Kautek is the producer of rubber and metal products in the passenger cars and light commercial vehicles segments of the automotive sector. Kautek is one of the associations of Teknorot.
With over 30 years of experience in our sector, Kautek brand was created in 2012 to meet the requests of the valuable customers and to provide a better service in the field of rubber metal.
The vision is to follow closely the demands in the sector and to produce goods and services with highest quality that goes beyond our customers expectations; and to become a growing, strong, leading and respectable world brand.
The mission is to carry Kautek to the future by constantly increasing the quality and services of the company, which embraces the principles of persistence, honesty, innovation, determination and leadership.
Kautek’s product groups are Bushes, Engine Mount, Transmission Mounting, Strut Mounting, Rubber Buffer for Suspension, Turbo Hoses, Shaft Propeller, Exhaust mount and Antiroll Bar Bushes. Kautek is the manufacturer and distributor of these product groups.
Kautek is the one of the most leading rubber to metal parts producer and distributor in Turkey and Europe.
Please visit http://www.kautek.com.tr/ for detailed information about Kautek.
Machining
Our department is equipped with the latest and hightec CNC machines and aims to manufacture high quality products to our worldwide customers.
Teknorot has the largest machining production area for ball joint, tie rod end, inner tie rod, link stabilizer, control arm and ball pin in the steering and suspension parts sector. With largest CNC machine area in its sector, Teknorot is able to produce 110.000 pieces per day.
Our Team, which targets to become the global leader of innovation in the sector, is comprised of expert staff are continuously trained to adopt the philosophy of innovation and human respect in order to produce highest quality parts. We do this by adopting 5S, SMED and similar lean manufacturing techniques as a principle and use Kaizen, Poke-Yoke and Process-FMEA to dispatch zero-faulty products to our business partners.
Our Staff takes advantages of IFS-ERP Solutions in order to make smooth and Just-In-Time Production, while observing OEE values from screens on production lines.
Wishbone Center
Since early 2015, Teknorot has continued its sheet metal control arm production within its factory, carrying the process from raw sheet metal to the final product through modern and efficient manufacturing lines.
With its experience in the sector, culture of quality and the increasing investments made to special processes, Teknorot has the privelage to be the pioneer of wishbone production and, at the same time, a solution partner for all of its customers.
Teknorot continues to meet customer commintents of high quality and on time delivery by producing with 10 Robot welding lines and servo-controlled ball joint and bushing presses.
We are well aware that our products are safety critical items for the end users and aim to achieve always better results while improving our processes. In this context we know the importance of the welding processes in wishbone production. With the CMT Integrated Welding Robots, which started operating in 2016, Teknorot once again proved it’s difference from the sector and continue to produce in OEM quality standards.
The process standardization is secured with our Servo-controlled ball joint and bushing press parks. We are able to pack form for customers through our lean manufacturing single-band assembly-packaging lines.
Cataphoresis
Cathode Metal Coating Bath or KTL e-coating has been the essential painting process of OEM in automotive industry. Teknorot is the first aftermarket manufacturer in Turkey to apply this process in house. This experience and our chemical know-how leads to meeting and even exceeding OEM (minimum 720 hours) test results according to EN 50021 salt spray test. KTL e-coating technology provides the following benefts compared to electrostatic spray paint.
- A closed chemical process to provide enviromentally friendly solution to cating.
- Ability to paint even the most complex geomtry thanks to utilizing coating bath.
- Better surface adhision properties to have a superior cross cut and impact test result.
Our products are described as safety parts and they are located underneath the vehicles, which causes no daily visual contact with users. This matter plays a key role in Teknorot’s responsibility to their customers about the security and quality of the parts. As known, suspension parts are exposed to many different forces and adverse road conditions (road salting, rain, rock hits, traction, etc.). As a result of this, Teknorot does not only aim to produce with standardized materials and dimensions but also aim to improve the product’s life cycle and guarantee higher quality by the cataphoresis applications.
CATAPHORESIS PAINT COATING
Cataphoresis line process consist of four main phases:
- Surface cleaning phase
- Surface preparation phase
- Coating phase
- Flash-off and oven phase
Surface Cleaning Phase
In order to link the painting with iron, surface cleaning must be done in top calibre. This phase, which consists of oil-removal and rinse tanks, removes the negative structures such as oil film, welding powders, dust, etc. from the piece.
Surface Preparation Phase
This phase exists in order to lodge the ZnPO4 crystals to surface and to provide linkage between painting and iron. Activaition tanks consist of ZNPO4 tanks and DI water-swill tanks.
Coating Phase
When the necessary preparation is completed on the metal surface, the water based painting is applied. This phase consists of painting and UF tanks.
Flash-Off and Oven Phase
This is the phase where the liquid build-up in the paint is seperated from it in the form of gas and paint is solidified after after curing.
Teknorot Cataphoresis Center
Chemical steams go through the SCRUBBER application. Chemical material is captured in that steam and disposed by recycling it back to the treatment plant. The waste gas, which is cleaned in order to meet environmental standards, is released to the atmosphere. The heat recycling is performed by the oven exhaust hood. This prevents the potential negative environmental effects.Teknorot cataphoresis line is unique in the fact that it’s the only system among the others that has no paint sludge waste and has the self-cleaning feature.
Heat recycling is performed from the oven exhaust hood. By doing that, negative affect to the environmental factors is prevented in Teknorot A.Ş cataphoresis line.
Hangers used in cataphoresis line have no additional cleaning waste since they are developed in a way that the painting applied won’t stick on them. This feature makes the system different compared to the other coating systems.As all the paramterical values of the bath are recorded and tracked continuouly, Teknorot cataphoresis line has no customer claims up until today. Cross cut and impact tests are performed on the products in order to check the quality. 18µ – 20µ painting thickness values and 720-1000 hours salt test values for corrosion are provided during this application.These test results meet the OEM values with the superior qualification.
Cataphoresis is a Water-Based Paint
This is a kind of electro-chemical coating, which is applied in liquid form. This application deliveres higher performance on corrosion and impacts when compared to electro-static dust and electro-static wet paint coatings.
Cataphoresis lines consist of mostly closed circuit tanks. It’s integrated and works with auxiliary plant that can feed itself and keep chemical waste material under continuous control. That’s why chemical waste ratio is lower than any other application. The low amount of chemical waste and low operational cost of the system makes it much more convenient to work with and friendly to environment.
With this process, there won’t by any flying paint particles which would create loss of paint and inconvenience at work station.
Teknorot is always ahead…
Molding Center
Teknorot is the biggest manufacturer of Steering and Suspension parts for passenger and light commercial vehicles in Europe. In order to reach to 900 annual new items developing capacity, molding procces plays a crucial role. Teknorot has been developing and investing in its molding center. Teknorot has the biggest and most technological molding center in Automative Aftermarket Sector thanks to high tech molding CNC machines and software.
Teknorot has large product range such as ball joint, control arm, control arm with ball joint, axial joint ( inner tie rod), tie rod end, silent block, anti roll bushes, bushes, rubber to metal parts, lateral arm, lateral arm bushing, repair kit, link stabilizer, idler arm, pitman arm, center link, link stabilizer kit, wishbone, aluminum and steel control arms. Teknorot has been developing these products groups’ molds inhouse.
Techology in Molding Center
We produce all our molds by using the latest technology machinery and software. Among computer engineering software; we use several molding technologies for sheet metal and hot forging seperately . In this way, ideal mold designs are produced correctly at once.
The production, maintenance and revisions of molds for wishbone, hot forging, rubber vulcanization and cold feeder rubber injection are performed in Teknorot Molding Center by experienced and trained employees with CAD/CAM/CAE softwares.
In our molding center, we make a lot of molds with CNC processing centers;
- Hot Forging Molds and rectification
- Sheet Metal Forming Molds
- Rubber Injection Molds
Teknorot’s aim is to be always ahead for all product departments. In this regard, Teknorot has been investing a lot for molding center. Teknorot contributes a lot for Turkish economy and has been in top 500 industrial organization in Turkey since 2009.
Forging Center
Teknorot is the biggest manufacturer in the Europe which has forging facility in house. Teknorot has both aluminum and steel forging facilities with robots, heavy forging presses, PLC controlled ovens.
Teknorot Forging Center has a capacity of 15.000 tons of steel and 5.000 tons of aluminum forging per year. Steel and aluminum parts are produced based on our modern technology software and presses in 0,1 – 7 kg per piece. Our Forging Center has significant number of press machines which varies from 600 to 2500 tones in order to produce and forge steel and aluminium.
The cut pieces are heated in modern PLC controlled ovens and sent to forging presses. Operations are completed after grinding, sandblasting, ball joint hole drilling and cold calibrating stages.
Aluminum parts are subjected to heat treatment for solution and aging processes in modern PLC controlled ovens to provide the necessary mechanical properties after forging. After the heat treatment, parts are prepared for machining by sandblasting operation.
Technology in Forging
Teknorot has been using latest technology in forging plant as well as other production departments. The heated products is being tranferred from PLC controlled ovens to presses by robots.
Aluminum Forging Facility: Alteka Düzce
In order to improve forging facility, Teknorot established new extensive aluminum forging facility in 2018.
Founded in 2018 in Düzce, Alteka began producing aluminum forged parts ranging from 0.1 kg to 5 kg using advanced technology. The company has an annual average forging capacity of 3,000 tons.
Alteka is capable of forging and heat treatment of 6XXX series in automotive sector , 2XXX and 7XXX series in defense industry with high engineering and at European standards. Upon request, production can be made with customer-specific aluminum alloys. Alteka together with its advanced technology simulation programs, manufactures post-designed products at first time and accurately.
Alteka is producing aluminum forged knucle, Suspension Control Arm, control arm, ball joint, tie rod end, weapon body and bushing body. Alteka also works for the aerospace, railways, construction and energy sector.
As Alteka; thanks to the durability, lightness, economics and alongside recycling without any quality loss of aluminum forgings, we continue our efforts to leave a livable and clean world to future generations.
Aluminum Forging Production
The cut pieces are heated in PLC controlled ovens with 100% temperature control and sent to forging presses. With the drive control, press speeds can be adjusted and the ideal forging speed for aluminum is achieved.
Alteka has in the facility:
– One 2500 tons forging line
– One 1600 tons forging line
– One 1000 tons forging line
Please visit http://www.altekaforge.com/en/ for detailed information about this facility.
Caring the Environment and the Nature
Post-design simulation programs are used to produce the recently released items without any error at once, and to improve existing products. We continuously enhance projects to reduce the raw materials, energy, natural resources and waste that we use, in order to leave a livable world for future generations.
Planning and Logistics
Logistics and purchasing activities are carried out in this department in order to deliver the products requested by customers on time. In the purchasing process the most suitable components in terms of quality and cost are gained to the factory on time, all planning activates and cost improvement-comparison operations are performed by help of ERP system.
Logistic is the department manages the process that starts with entering the order received from the customer and end with shipment. In this process, supplying all raw material and semi-finished material to be used in production on time, on required quantity from relevant supplier, storing on suitable conditions and delivering to production units at the appropriate time are procured. It is also the responsibility of this department to arrange weekly and daily shipment plans, taking into accounts early and urgent shipment requests comes from our customers and direct production departments according to this plan and dispatch the goods.
Purchasing is the department that provides high quality products on time in order to be competitive in domestic and foreign markets to evaluate entire alternative global and national suppliers primarily to the suppliers near-by. This department supports the development of suppliers that considered to be business partners by giving support together with SQA team by giving importance to supplier development activities during the development phase and adding value to suppliers. In addition to these purchasing activities, one of the main responsibilities of this department is at fast developing automotive technology to provide components of new products quickly and considering the term of project to Project and R&D departments in order to introduce new products.
With its investment in a new logistics center in 2018, Teknorot aims to maximize shipment efficiency and minimize delivery times. From the moment customer orders are entered into the system until dispatch, the entire process is managed with precision to ensure Teknorot products reach their destinations on time.
By the end of 2019, in addition to the logistics center established in 2018, Teknorot expanded its operations with the acquisition of a new factory, significantly increasing its overall production capacity in Düzce.
Teknorot, is always ahead…
Assembly and Packaging
In the assembly section, by using full automatic, semi automatic and manuel assembly lines without making concessions, assembly operations are applied. In this process;
- Plastering operations are carried out with path and load control servo presses to all parts. All mounted parts are checked transiently with load-path graphic and specified torques are measured with special measuring equipments.
- On the packaging line, customers get better service with custom barcode program.With special box folding and packaging machines, our improvement works continues. Suited to lean production principles optimized material flow, by taking into consideration the labor economics designed packing tables, proofing poke-yoke and barcode systems are used.Will be able to produce for all kinds of wehicle, high technology ultrasonic melting technology is used.
