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Description
We produce composite (laminated) shields for ship superstructure components, but the production process we have used is complicated, very time- and cost-intensive, and requires the participation of a number of employees. Therefore, under the project we will introduce a new process which was devised in the ongoing development work conducted by our parent company. It is based on the idea of dividing a manufactured shield into several components of smaller dimensions, and then gluing them together with the use of new-generation adhesives. That process will entail a significant reduction in production costs (by about 25%) and, consequently, a reduction of the purchase price of the shield for the end customer. It will also reduce shield''s weight by at least 15%, and bring greater production accuracy and improved mechanical performance. As a result of the process the new product with improved properties will be introduced to the market. In addition, we expect a 30% reduction in the costs and environmental effects of waste production, as finding one defective component will not lead to disposing of the entire shield, as it is now the case. Plus, the content of recycled material in the total weight of the shield will grow to 12% (from the current 0%).
The project involves carrying out development work to optimise the material composition of the shield structure, and to validate the technological process in real conditions. A prototype product will be therefore tested, and the results of that work will be then implemented into our business activity. We will commission consulting services of the research unit, and cover the costs of labour and materials required to carry out the R&D at our site. The project costs also include the purchase of facilities, tools and equipment needed to launch the new process.
Summary of project results
The project consisted in the implementation into JFG Composites Sp.zo.o.''s own business of an innovative technological process for the manufacture of innovative composite casings for ship superstructure elements (chimneys, radars, antennas, bow and stern components, etc.). Thanks to the production of individual sub-assemblies of the product structure and their subsequent welding together (instead of laminating the product in its entirety), the Company will be able to obtain a number of competitive advantages resulting from favourable changes in the current state of technology both at the level of the process and of the finished product:
- tooling cost lower by min. 40% (models, moulds and tooling);
- shorter production cycle by min 12%;
- ability to achieve the required hole positioning accuracy;
- management of critical production problems at the sub-assembly level (rather than the entire product);
- greater flatness of the casing surface;
- at least 15% less casing weight;
- 30% higher resistance to operating loads;
- higher maximum critical surface load parameter;
- higher dimensional accuracy of the enclosure;
- at least 70% higher electrical conductivity.
The implementation of the aforementioned process into the Company''s own operations and the launch of a product with globally unique features will contribute to increasing the Company''s competitiveness on the international market and increasing revenues and profits from operations.
The project ended with the implementation of an innovative technological process for the production of innovative composite covers for ship superstructure elements.
As part of the project, development work was carried out to optimize the material composition of the structure, as well as validate the technological process in real conditions by producing a target product prototype and implementing the results of this work to JFG Composites Sp. z o.o.
In order to implement the innovative technology for the production of innovative composite covers for ship superstructure elements, the following fixed assets were purchased as part of the project: 1) CNC machine with cover (2 pcs.); 2) filtration device (2 pcs.); 3) a set of cutting tools, 4) clean room, 5) industrial refrigerator, 6) a set of tools (moulds and equipment for industrial production of covers); 7) autoclave, 8) forklift (2 pcs.); 9) work table (10 pcs.); 10) trolley for transporting semi-finished products; 11) set of shelves.
The purchase of these fixed assets was necessary as part of the implemented technological process.
As a result of the project, JFG Composites has expanded its offer with an innovative product dedicated to the maritime industry, which, in relation to the current state of technology, is characterized by:
a. lower weight
b. higher resistance to load effects
c. higher parameter of the maximum critical surface load
d. greater surface flatness
e. greater shape and dimensional accuracy
f. higher electrical conductivity.
The products that have been launched as a result of the project are aimed at manufacturers of marine vessels. Potential customers for the products include Fincantieri, Metal Shark Boats, Damen Shipyards and Dockstavarvet AB. The Company estimates the potential number of customers on the target market, i.e. the international market, at approximately 25 entities, and the potential total demand for covers at approximately 300-350 covers per year (100% foreign demand: Norway, Finland, USA, Germany, China, France, Denmark, Greece).
The implementation of the project has had a direct impact on economic growth in the region and contributed to an improvement in its economic and financial condition. The implementation of a new process involving innovative solutions, resulting in the launch of the production of innovative composite casings for ship superstructure elements, has contributed to an increase in the technological level of the region. Close cooperation between the Company and the research and development unit (Rzeszów University of Technology) established as part of the project has resulted in the exchange of statements at the interface between the worlds of science and business, contributing to the creation of a local knowledge-based economy. In addition, the Applicant''s employees participated in the research process carried out under the project, which contributed to raising the level of intellectual capital in the region. As a result of the project, 3 new jobs were created. People employed in the new positions, thanks to the in-house training programme, have been equipped with specialised knowledge, thanks to which there has been an increase in the level of intellectual capital in the region. The high qualification level of the workforce is one of the key factors in the strength of the region''s economy. Companies in the region have participated in the project''s deliveries, contributing to increased revenues and growth of their businesses.
In addition, the project generates a number of benefits for the region, which indirectly contribute to improving its economic and financial condition (in particular, drawing the attention of international business to Lublin as a region of innovative products and technologies, building a positive image in the eyes of the international community, which in a global world is an important factor in building the economic and social position of the region.