Effective Serial Production to RIVAL’s Defence Customers

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RIVAL has valuable collaborations with many companies in the defence industry, who appreciate RIVAL’s competencies within production of critical and costly components as well as serial production of system supplies.

RIVAL’s production runs around the clock and our robots work closely together with the advanced multi-processing centres. RIVAL’s employees are planning the working process in details and they make sure to follow the customer’s demands on tolerances and documentation.

To-sided production strategy
The customers in the defence industry are interested in RIVAL’s to-sided production strategy. The strategy focuses on producing other components, than those typically produced, by increasing the number of employees, who work at night.

Favourable overall economy
“An effective production, which runs according to the plan is crucial to the customers. At the same time, they value our technical insight and our ability to work in many different materials as well as accommodating the customers communication-wise,” says sales director Christian Aarup. “They appreciate the fact that we offer all of the element in the RIVAL package, which is always adjusted to each customer’s requirements. This results in our customers having a very favourable overall economy and high-quality components.”

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Close dialogue behind valuable collaboration on components for Scania lorries

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Quality control is comprehensive and everything must work smoothly right from the start when Vald. Birn manufactures brake components for Scania lorries. RIVAL has been chosen as a subcontractor for the machining of components because of its high quality, reliability of delivery and excellent communication.

Vald. Birn (BIRN) manufactures over 20,000 brake components for Scania lorries with drum brakes every year. The company is fully responsible for product maturation, casting, machining and surface treatment of the components. Everything must comply with TS 16949, which is the automobile industry’s extended version of ISO certification.

The machining of the many thousands of components in the coming period will be done at RIVAL because BIRN requires extra capacity.

Trial task was crucial
The collaboration between BIRN and RIVAL started a year ago, when BIRN had some prototypes manufactured at RIVAL. “With regard to the task, it confirmed for us that RIVAL can meet our quality and reliability of delivery requirements, and that there is really good chemistry and communication between our people,” says Method Department Manager Henrik Telling from BIRN. “This has been crucial in our decision to invite RIVAL to be part of this job, which is very comprehensive and will run for the year.”

High quality requirements
Scania and BIRN’s other customers in the automobile industry have high quality requirements, which covers for example, hardness measurement, x-ray examinations and ultrasound scanning of pre-machined components. In addition, a production test sample is prepared, where among other things, statistical process control of the dimension tolerances is carried out. The test sample is sent to Scania, as documentation that the stipulated components meet the stipulated requirements.

RIVAL approved by Scania
It also means that the subcontractors that BIRN uses must meet stringent requirements. Scania has also visited RIVAL’s premises and has approved them as a subcontractor. “The optimum is of course that RIVAL also becomes TS 16949 certified. But they are well on the way because of their ISO certification and because they have shown that they can meet the more stringent requirements,” says Henrik Telling.

Quality and delivery in place
”The first 700 components are now machined at RIVAL, and we’re very satisfied with both the quality and delivery of these components. Now we will continue like this with the next many thousands of components,” says Henrik Telling.

Good communication is a prerequisite
It has been crucial for BIRN that there has been good chemistry and communication with the people at RIVAL right from the start. “We’ve built up a small matrix organisation on this project, which ensures that there is rapid clarification of questions or uncertainties, says Henrik Telling. “That we have good dialogue at all levels is a crucial parameter in our collaboration. Things must go smoothly during the daily work when we have to meet such tight deadlines. It functions really well here together with RIVAL.”

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GE Oil & Gas, Norway

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More collaboration through documentation

Vetco Gray, which is part of the giant GE Oil & Gas increasingly demand RIVAL’s skills in machining operations.

The typical urgent job involves spare parts for tug boats or supply ships servicing the oil rigs. However, RIVAL also supplies spare parts to be stored by companies like Vetco Gray, who orders bushings for oil equipment used in the North Sea.

“In this case, we are always ahead with production so they can order parts for their warehouse in Esbjerg on an ongoing basis. Vetco Gray is part of the global GE Oil & Gas.

We have supplied GE with the requested documentation relating to our quality assurance, reliability of supply, environment, internal communication, health and safety work, procedures and ethics.

As a result, we can now be more flexible, expand the collaboration on an ongoing basis and supply more demanding components. We expect to be included in the shared database for all GE Oil & Gas units,” says Mr Sorensen.

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RIVAL Collaborates with Wärtsilä all over The World

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Whether it is in Australia, northern Norway, USA, Turkey or Hirtshals, RIVAL is always ready to help, when Wärtsilä needs quick assistance with the production of a spare part.

Through the years, RIVAL has been a regular sub-supplier to Wärtsilä’s after sales, who are responsible for delivering spare parts in case of defective gearboxes, transition flanges or sleeves, which result in a docked ship.

Time costs money
“It costs a lot of money when a cruise ship, a supply ship to an oil drilling rig or a Norwegian fjord ferry is not moving,” according to sales director of RIVAL Christian Aarup. “Therefore, it is crucial to Wärtsilä that we are ready to help, when an urgent situation occurs.”

So far, RIVAL has solved jobs for Wärtsilä in USA, France, Denmark, the Netherlands, Norway, Poland, Turkey, Estonia and Australia.

Solid competencies in after sales
RIVAL has great expertise in after sales jobs and knows what it takes, when the customer is in need of critical and costly components within short notice. This kind of expertise is also essential in the remaining part of RIVAL’s business, for instance when it comes to serial production of small or large series. “Our customers appreciate our employees’ competencies and experiences. These qualities are valuable to the customer when we produce one-off components, like those to Wärtsilä, but also when we serial-produce components, which would typically demand more craftsman processing,” says Christian Aarup.

Meet high demands
There are high demands on the components, which RIVAL produces to Wärtsilä. “The components are critical and costly to the customer, for which reason everything must succeed the first time round,” continues Christian Aarup. “Therefore, it is crucial that the customer knows, we can solve the task the first time round. In order to do so, the majority of the elements in the RIVAL package come into play. These elements are quality, reliability of delivery, certificate management, welding procedures, documentation and measurement reports.”

Trust is important
“The collaboration between RIVAL and Wärtsilä is built through many years and it’s very valuable to both parties. The close collaboration causes a trust between the two companies and Wärtsilä appreciates the good chemistry and the high quality,” says Christian. “Our skilled employees know exactly which demands and expectations, Wärtsilä has, and they meet them every time. That provides the customer with a trust in the daily work no matter whereabouts in the world it takes place.”

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RIVAL wins order worth tens of millions

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Machined component developer and manufacturer RIVAL, is well placed in the defence industry, and has just won an order on a system delivery of advanced components. This means that production will be busy.

The new order must be delivered in the coming years. “Production of the test components is starting up here now, and must be completed before the year end,” says RIVAL Sales Manager Christian Aarup.
Together with RIVAL’s CEO Carsten Tønnes, he has just been to Switzerland to negotiate and finalise the last few details in connection with the order.

Critical components
During the spring, RIVAL supplied the first critical components for a type of military vehicle. The new orders are for two other unique components for other military vehicles.

Strong system deliveries
The orders confirm that RIVAL is well placed in the defence industry, and through network collaboration it has succeeded in functioning as a system supplier on the customer’s projects, which customers really value. “We’re very pleased with the strong network of subcontractors, whom we collaborate with primarily in surface treatment, certifying materials, welding, and research and development,” says Christian Aarup.

RIVAL takes full responsibility
“We know that parameters like reliability of delivery, quality, full traceability and close collaboration on the projects are crucial parameters for our customers in the defence industry. We take full responsibility for ensuring that the project meets the customer’s specifications and expectations – and also when it applies to our subcontractors,” says Christian Aarup.

Busy at RIVAL
The new orders means that RIVAL’s production is busy. “We’re of course in an ongoing dialogue with all of our good, regular customers, since it’s important that they get their orders booked in good time,” says Christian Aarup. “We value long-term customer relationships, because we know that it creates a lot of value for the customers and RIVAL. Therefore, our regular customers of course have primary access to our capacity – also even as now, when we’re extra busy.”

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Close collaboration on the optimisation of components

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In recent years, machined component developer and manufacturer RIVAL has collaborated closely with the engineering company R&D on the technical production optimisation of several new components.

For engineering company R&D, involving RIVAL as a partner on development projects has been the obvious choice on several occasions. “We have had several opportunities to use RIVAL’s competencies, and to exchange and sound out ideas with them in technical production areas during the development of design and construction of new components,” says R&D Key Account Manager, Daniel Schou Jensen. “Because RIVAL already collaborates with several of our customers, it means that from the very beginning, they very often have a really good understanding of the customer’s requirements and expectations.”

Exchanging and sounding out ideas together
Employees from RIVAL, R&D and the customers that they are collaborating with, meet up on an ongoing basis, and exchange and sound out ideas when they collaborate on projects. Afterwards, they work further on the design, construction and optimisation of the components. During the process, RIVAL will often offer R&D valuable criticism, which on an ongoing basis, helps to optimise the products that are being developed, especially in the technical production area.

RIVAL’s key competencies
Likewise, Daniel Schou Jensen sees the benefits of collaboration with RIVAL. “At R&D we have a lot of competency in design and construction, and we also have extensive insight into technical production,” says Daniel Schou Jensen. “But at RIVAL, technical production is a key competency, which means their ability to exchange and sound out ideas is very valuable to us, because we want the strongest team in relation to the customer.

“Since RIVAL at the same time, can work with the production of component’s for 0-series production and prototypes for new products, they will often acquire valuable knowledge, which both we and the end customer can beneficially utilise in the further optimisation process.”

RIVAL’s DNA
RIVAL Sales Manager Christian Aarup has closely followed the collaboration with R&D and customers for several years. He confirms that it is precisely these tasks where ideas are exchanged and sounded out, where RIVAL has great strength, primarily because of RIVAL’s competence and culture. “My colleagues can, and have the ambition and the desire to present optimisation proposals and improvements,” says Christian. “We see many benefits in both collaborating with an engineering company like R&D and the end customer, and through that, help to develop a solution for the customer, which is optimised in all areas.”

Better to be included earlier
Looking forward, Daniel Schou Jensen can see several advantages in including RIVAL earlier on in the development process. “It will give us better opportunities to take into consideration any technical production challenges that we encounter.” He continues: “I’m sure that we will also in the future utilise RIVAL as a partner and thus together, we will help customers get the best possible exchanging and sounding out of ideas, and solutions.”

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