Quality built in

Qualitysystem LESER and LESER production system

Introduction
Introduction Objectives of this Presentation
Design principles

Qualitysystem LESER  Explaining sample elements of the LESER approach

Production
Production system
system
to quality: Design principles, Qualitysystem LESER,
LESER Production System and supplier management
Conclusion
Conclusion
 Highlighting differences of LESER integrated
qualitysystem versus conventional quality inspections

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Introduction
Introduction The three elements of the LESER quality
Quality at LESER is more than just checks and inspections
Design principles

Qualitysystem LESER

Production system Durable Design

LESER design
Conclusion principles
Tight Finish

Design process
Globally certified
processes Materials management
Qualitysystem LESER supplier program
Preventive quality
assurance measures

Large quantities - high

Order-independent automation
manufacturing
LESER Production
system Specialized machines
Assemble to order
Integrated SAP system

Integrated inspection
program

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Introduction Reliable valve function means: Durable
Designprinciples
Design principles design for longer life
Qualitysystem LESER

Production system

Conclusion

Critical components Advantage

Needle bearings Safe pressure setting

Roller-burnished spindle Less wear and tear

Nitrocarburated guides Less wear and tear

Long-life bellows material Longer life

Shielded bellows Protection of bellows

Stellited or hardened disc Less damage when opening

Stellited or hardened Less damage when opening
nozzle

Self-draining body Less corrosion

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Introduction Reliable valve function means: Outstanding
Designprinciples
Design principles tightness increases plant efficiency
Qualitysystem LESER

Production system

Conclusion Seal type Feature and benefit

Metal-to-Metal Smoothness and flatness of the sealing
sealing with LESER surfaces in the nanometer region
Nanotightness ensure a tightness level with 50% less
bubbles than API 527
O-ring disc Optional: 10 different O-ring materials
for zero bubbles in a sturdy disc design

Sealing plate For temperature- and pressure ranges

beyond possibilities of O-ring discs

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Introduction Qualitysystem LESER
ISO 9001 cluster certification
Design principles

QualitysystemLESER
Qualitysystem LESER

Production
Production system
system

Conclusion
Conclusion Quality cluster

ISO 9001 Certification

The LESER group is certified in one certification according to ISO 9001.

 One system for the whole group
 Same processes for all locations
 Same high quality standards

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Introduction The Qualitysystem LESER uses qualified,
Design principles
global and certified processes
Qualitysystem
QualitysystemLESER
LESER
Feature Benefit
Production system
Processes The processes are internally standardized and spread out over the whole
LESER world
Conclusion
Qualified  LESER has qualified its processes
 Process ability: Reliable repeatability in a small range
Global LESER‘s processes are documented in a global Quality Management
System:
 Process models
 LESER Global Standards
 LESER Local Standards
 Work Instructions

Certified LESER‘s processes are certified by many external certification societies

according to many standards with many more globally existing regulations
regarding organizational affairs (like ISO 9001) safety valve related demands
(like PED or ASME)

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Introduction More than 200 individual approvals by top
Design principles
leading EPCs and end users
Qualitysystem
QualitysystemLESER
LESER
Prequalifications

Production system Europe

Conclusion
95
Americas
Asia
20
85

Prequalified at Since Customer audits Year Frame contracts Since

Bayer 1998 Voith 2010 BASF 2004
BASF 1999 Saudi Aramco 2011 DOW Chemical 2005
Novartis Pharma 1999 Total 2012 TetraPak 2005
Toyo Engineering 2001 Cameron 2013 Bayer 2007
Petronas 2002 Petrobras 2013 Lurgi 2007
Shell Global Solutions 2002 Stamicarbon 2014 Linde 2009
Bechtel 2011 Linde 2015 GS E&C 2014
Petrobras 2011 Cryostar 2015
Exxon Mobile 2014 BASF 2015
EIL 2015  Zero deviations

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Introduction Qualitysystem LESER
Focus on preventive measures in the design process
Design principles

Qualitysystem
QualitysystemLESER
LESER
Design processes
1. Quality function deployment (QFD) 2. Finite element method (FEM)
Production system
3. Computational fluid dynamics (CFD) 4. Solidification simulation
Conclusion 5. Failure mode and effects analysis (FMEA) 6. Design review
7. Test lab 8. Supplier management process

2. Finite element method 3. Computational fluid dynamics 4. Solidification simulation

7. Test lab

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Introduction Qualitysystem LESER
Preventive measures – Example materials management
Design principles

Qualitysystem
QualitysystemLESER
LESER  LESER not only buys material but wants to develop and cultivate the
relationships to its suppliers. This ensures high quality of raw material.
Production system

 In key supply markets like India, LESER uses only 1st tier suppliers with
Conclusion
proven track record in valve industry
 Stringent supplier management process:

Supplier management
Before release for serial production After release for serial production

Audit/release
Supplier assessment Supplier evaluation Supplier development
first-sample test

Evaluate and prove supplier qualification Evaluate, ensure and optimize supplier performance

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Introduction Qualitysystem LESER
Focus on preventive measures in materials management
Design principles

Qualitysystem
QualitysystemLESER
LESER Supplier management
Production system Continuous improvement of suppliers quality level through

Conclusion
 quality performance tracking
 comparisons between suppliers
 frequent onsite visits

Performance tracking Compaison Onsite visits

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Introduction Qualitysystem LESER
Preventive measures – Example casting pattern design
Design principles

Preventive quality measurement at design features of casting patterns:

Qualitysystem
QualitysystemLESER
LESER
 Example: Locations relevant for machining (fix and bolt points) are
Production system designed in a way that generates optimal casting quality – no grinding
allowed in these points
Conclusion

 See markings:

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Introduction LESER Production System
Design principles

 Factory location
Qualitysystem LESER
Hohenwestedt/Germany
Production system
Production system  Europe‘s largest safety valve plant and
one of the largest production sites for
Conclusion
safety valves worldwide
 Modern series production with a
capacity of 130,000 valves per year
 All manufacturing technologies in-
house:
– Including heat treatment, hardening,
pickling, electro polishing, welding,
and painting
– 100% of machining in Germany

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Introduction Highly automated serial production for safety
Design principles
valves
Precise machining in IT-based commissioning SAP-controlled assembly with full
one clamping transparency
Qualitysystem LESER

Production system
Production system

Conclusion

Machining Stock Assembly

Traceability of components through Strong packaging for safe transport

coding in the machine

 Automated manufacturing of all critical components ensures high repeatability

 All manufacturing technologies in-house, including all machining, welding and heat treatment
 75% of orders can be assembled from 10 Mio. EUR raw material and component stock
 More than 5 Mio. EUR investment in new technologies and processes every year

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Introduction Assembly to order from finished parts stock
Design principles
(ATO) ensures identical high part quality
Qualitysystem LESER

Production system
Production system

Conclusion

 10 Mio EUR finished part stock ensure that most orders can be
assembled without order-specific procurement or machining
 All components in stock fulfill the same high quality standards
 Serialialization starts after finished parts stock
 Benefit: efficient manufacturing of high quantities enables high
automation

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Introduction 35 integrated quality checks for each and
Design principles
every valve
Qualitysystem LESER Supplier development – Incoming goods inspection – Dimension check during
Support on-site Dimension check production process Tightness test after assembly

Production system
Production system

Conclusion

Suppliers Incoming insp. Machining Assembly

Supplier development – Spring test Hydrostatic test of inlet body Final check
Performance optimization

 Worldwide cluster certification of each subsidiary with identical qualified and certified processes
 Comprehensive supplier development with own team
 35 inspections for every safety valve as standard
 All inspection data is entered in SAP in real time and can be retrieved and analyzed

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Introduction Order-independent manufacturing in
Design principles
high quantities enables automation
Qualitysystem LESER

Production system
Production system

Conclusion

 High quantities allow series production and thus a high level of automation.
 Higher level of automation causes high repeatability and process reliability.

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Introduction Automated inspection centers for
Design principles
efficient and precise tests
Qualitysystem LESER

Production system
Production system

Conclusion

Automated inspection centers mean

 High throughput allows efficient 100% inspections
 No manual interference
 Absolutely identical inspection conditions

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Introduction Full material and process traceability
Design principles
through seamless SAP ERP system
Qualitysystem LESER
Large quantities allow:
 Introduction of an ERP-System
Production system
Production system
 Process accompanying instruments like:
Conclusion
- material identification
- material traceability

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Introduction Independent of the customer request, tests
Design principles
and inspections in assembly take place 100%
Qualitysystem LESER
 100% assembly inspection
Production system
Production
Production system
system
 100% Set pressure test
Conclusion
Conclusion  100% Tightness disc / seat
 100% Tightness against atmosphere
 100% Visual inspection

100% Tightness test 100% Final inspection

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Introduction LESER production system
Design principles
Instead of just checking quality, inspection data are used to calibrate
and optimise the production process
Qualitysystem LESER

LESER production system

Production system
Production system
Detailed insight in  Qualified processes Results are used to
requirement for  Process control of control lapping and
Conclusion
roughness and sealing surfaces polishing process
flatness  Optical measurement
system
 Accuracy: 20 nm

In comparison: Conventional safety valve production system

Assumptions about  Inspection Results are only used
requirements Interference to reject parts.
inspection of Manual hand-lapping
surface process “trial and
 Accuracy: 100 nm error”

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Introduction
LESER Production System
As standard: 35 tests at each valve independent of the customer order
Design principles

Qualitysystem LESER

Production system
Production system

Conclusion Test Amount

Marking 6 parts

Spring rate 1 part

Surface roughness 2 parts

Material identification 4 parts

Flatness of sealing surface 2 parts

Dimension inspection 14 parts

Hydrostatic test 4 parts

Tightness 1 part

Set pressure 1 part

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Introduction Conclusion
Design principles
The LESER approach differs in key aspects from conventional safety
Qualitysystem LESER valve manufacturing which results in reliably high quality even without
time-consuming order-specific measures.
Production system

Conclusion
Conclusion
 Up-to-date product design to minimize wear of critical parts
 Global certified Qualitysystem LESER which focuses on preventive
measures, not just checks
 LESER Production System for high-quality automated component
manufacturing to stock, then quick and efficient serialized assembly
 On customer request many more tests can be ordered

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