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Which KPI’s for more growth and more
value creation with less materials ?
Nancy, 29 June 2017
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Gränges Group
• A global leader in the market for rolled products
for aluminium heat exchangers & selected niche
applications
• Production in Sweden, China and in the US
• R&D Centre in Sweden and China
• Headquarter in Stockholm
• Gränges is represented all over the world
• ~1,500 employees
• Listed on Nasdaq Stockholm
• Production capacity of 420,000 metric tonnes
• Net sales of more than SEK 10 billion (USD
1.1 billion)We have a global market share of approximately 20% in
rolled products for brazed aluminium heat exchangers.
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Gränges focuses on two market segments in
Asia and Europe:
• Automotive heat exchanger
• Stationary heat exchangers
Gränges Group’s R&D department consists of
around 60 highly educated employees
worldwide, including metallurgists, chemists,
metallography's, physicists, mechanical
engineers and technicians.
About half of the world’s cars that are manufactured today
have heat exchangers that contain our material and expertise.
A global leader in materials for brazed aluminium heat exchangers
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A modern car can have more than
ten different heat exchangers
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~200 active alloy combinations
~3,000 active articles
Multi-layer cladding adds unique properties and enables
Gränges to offer tailored solutions
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Value chain for brazed heat exchangers
Aluminium producers Material producers Products End-markets
A global aluminium company specializing on rolled products
in the value chain for brazed heat exchangers
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Main stages in production process
• Consumes ~50% of total energy in production
• Only ~5% vs. energy consumed in production of
primary aluminium
• Initial deformation of the material
• Integrating clad with core material
• The coils are processed to meet specific
requirements for gauge, flatness and strength
characteristics
• Finished products– typically 0.05-2.0mm
thick and >10mm wide
– individually weighed,
marked and packaged
before shipping to
customers
Input materials Casting and rolling Finishing
• Share of recycled input of ~18%
• Efficient metal management enables
increased scrap recycle
rate – reduced usage of more
expensive primary
aluminium
Process scrap
(~30% of initial base)
Hot rolling / Cladding Cold rolling Slitting
Internal or external scrap
Primary aluminium
Slab Supply
Re-melting
Overview of the production process
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WMF KPI’s Gränges KPI’s (drivers for value chain KPI’s)
Use
Less
Product weight Down-gauging
Buy-to-use Yield
End-of-life recycling N/A
Use
Longer
Product lifetimeInternal corrosion
Material strength
Resale price N/A
Use
Smart
Product usage N/A
New and recycled
materials
Sales of new products
Use of external scrap
Product performance
Brazeability
External corrosion
Product conformity
Gränges KPI’s for more growth and more value creation with less materials
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• Product weight
– Down-gauging
• Improved material
properties to achieve down-
gauging
• Retained heat exchanger
performance
• Buy to use
– Yield
• KPI affected by more
advanced material
solutions
• Increase yield despite more
challenging alloys
Use Less: Gränges KPIs
0,290,287
0,2810,277
0,275
0,27 0,270,267
0,2610,258 0,259
0,24
0,25
0,26
0,27
0,28
0,29
0,3
2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017YTD
Gauge (
mm
)
Gauge development tube material
65,8
65,0
64,5
63,763,4 63,4
64,7
65,264,9
64,3
66,5
62
63
64
65
66
67
Yie
ld(%
)
Yield scalp to pack development tube material
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• Product life-time
– Internal corrosion
• Improved water side
claddings postpone
corrosion from coolant
• No global standard
– Material strength
• Improved material
strength is increasing
product life-time
• Enables down-gauging
Use Longer: Gränges KPIs
4050 55 60
70
110
145155 160
190
0
20
40
60
80
100
120
140
160
180
200
AA3003(standard)
Gen 1 HS Gen 2 HS Gen 3 HS Gen 4 HS
Post-braze tensile strength (Mpa)
Yield strength Tensile strength
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• New and recycled materials
– Sales of new alloys
• Long product development
and validation cycle
• Alloys based on recycled
material increasingly
important
– Use of external scrap
• Limited availability of usable
scrap
• End-of-life recycling
challenging for heat
exchangers
Use Smart: Gränges KPIs
11,1%11,9%
9,8%
7,8%
4,7%3,9%
8,0%
12,5%
17,1%
13,8%
12,1%
0,0%
2,0%
4,0%
6,0%
8,0%
10,0%
12,0%
14,0%
16,0%
18,0%
2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017
Share of external scrap of total raw material consumption (%)
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• Product performance
– Brazeability
• Important for design
development of heat
exchangers
• Reduces material and energy
consumption
• KPI to be developed
– External corrosion
• Improved corrosion
resistance is increasing
product life-time
• Enables down-gauging
– Product conformity
• Reduced variations improve
productivity and yield in value
chain
• Cpk used as KPI
Use Smart: Gränges KPIs
0
10
20
30
40
50
60
70
AA3003 (standard) Gen 1 LL Gen 2 LL Multi layer
Tim
eto
perf
ort
aio
n(d
ays)
Axeltitel
Time to perforation in SWAAT
Joint detail Perfect Joints
Trillium™ Clad
Flux salt residue
(non-Trillium)
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• Weight and space requirements are key drivers for the development of new materials for
automotive applications– Use of less material in Gränges part of value chain is driven by increased yield
– Use of less material in customer’s products can be supported by down-gauging
• Thinner material gauge requires better material properties to maintain or increase product
life-time– Heat exchangers fail from material strength or corrosion
– Improved life-time in terms of time in use is supported by improved material strength and internal corrosion
performance
• Smart and efficient use of the material is driven by development of new sustainable
materials with improved product performance– Successful introduction of new materials requires development of the right products with special
consideration of recycled content
– Improved product performance drives efficient use of the material when designing, producing and using the
heat exchanger
Conclusions – Gränges KPI’s for more growth and more value creation with less materials
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