MAG Solar Abuja 2011

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The Nigeria Alternative Energy Expo 2012 is Nigeria’s leading alternative energy Expo. NAEE 2012 takes place at the Yaradua Convention Centre, Abuja Nigeria from September 17-19 2012. The event will feature an impressive line-up of local and international speakers, delegates and exhibitors, who will gather to debate a new energy future for Africa's most populous nation

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MAG Solar Abuja 2011

  1. 1. Opportunities andchallenges for investing insolar modulemanufacturing plantsMAG Switzerland AG
  2. 2. Milestones and Growth Strategies of MAG04/2005 09/2009Acquisition MAG Brasil / Sao PauloCincinnati/Lamb New sales & service location10/2005 12/2009Acquisition Organic Growth into HoningThyssenKrupp MetalCutting Technology - Cross Hüller 07/2010 - Fadal03/2006 Formation of MAG IAS GmbH - Giddings & LewisAcquisition Ex-Cell-O 09/2010 - Hessapp MAG China / Changchun - Hüller Hille01/2007 New manufacturing facilityOrganic Growth of - Witzig & FrankMAG India 10/2010 Acquisition Samputensili Chemnitz01/2007 formation of MAG Modul, center forAcquisition MAG‘s gear technologyBoehringer 11/2010 08/2007 Acquisition Pol IT, Munich and Organic Growth of merger with MAG‘s e-tekx team to MAG Russia form Delta412/2007 05/2011Acquisition Kecskemét Acquisition Forest-Liné, Machine Tools, FranceMAG Your Global Solutions Provider 28/09/2011 2
  3. 3. MAG – a Global Partner for Local Solutions With our 3400 global employees we deliver tailored solutions to leading manufacturers worldwide MAG Your Global Solutions Provider 28/09/2011 3
  4. 4. Markets, Products, Applications Industrial Equipment Automotive Aerospace Renewable Energy Rail, Construction, Power OEMs, Truck, Commercial, Military, Space, Wind, Solar Generation, Oil & Gas, Major Automotive Tier Helicopter Agriculture, GeneralMarkets Suppliers Machining, MarineMachines and equipmentApplications Cylinder Heads & Blocks, Aluminum Structures, Large Frames, Bearings, Hubs, Solar Panels, Thin Film and Cams, Cranks, Composite Structures, Planetary Carriers, Cases, Lift c-Si Solutions, Wind Blades Transmission, Chassis, Titanium Components, Arms, Wheel-Sets, Brake and Root End Milling Wheels, Shafts, Engines, Landing Gear Disks, Drive & Chassis Machines Composite Panels Components, Engines, Shafts, Pumps, Valves, Compressors MAG Your Global Solutions Provider 28/09/2011 4
  5. 5. MAG Global Services Your Single Source for Maintenance SolutionsMAG is your single source for maintenance solutions designed to optimize plant operations. Withour comprehensive product and service programs offering complete life-cycle support, manufacturersachieve maximum efficiency and reduce their cost per piece. Maintenance & Support 24 / 7 Service > Repair service > Most reliable day and night support > Tele service > Central warehouse with 24/7 spare part service > Service contracts > Service hotline > Field Service > Training > Trouble shooting Original Spare Parts Used & Retrofit Machines > Safety-related components > Modernization of all manufacturing systems > Spare part packages with manufacturer’s warranty > Spindle exchange service > Rebuild, repair and exchange services > Online parts store > Sales of used machines > Relocation of machines and complete systems Preventive Maintenance > Programs for preventive maintenance > Fingerprint > Machine certification and inspection MAG Your Global Solutions Provider 28/09/2011 5
  6. 6. MAG Renewable Energy Products Solar Laser based Handling Processes Turn-key solutions Solutions System Integration Laser Scribing Automated Sorting Interconnection Low Volume/ (P1, P2, P3) and Packaging Soldering High VolumeLaser Edge Deletion Manual Sorting Stringing Semi automated/ and Packaging Fully automated Thin-film Thin-film + c-Si c-Si c-Si MAG Your Global Solutions Provider 28/09/2011 6
  7. 7. PhotovoltaicAchievable and Sustainable Job creation Fits into Renewable Energy Agenda Low Carbon EconomyMAG Your Global Solutions Provider 28/09/2011 7
  8. 8. Solar Irradiance mapMAG Your Global Solutions Provider 28/09/2011 8
  9. 9. Many applications for PV www.energysavers.gov/ Solar Development groupMAG Your Global Solutions Provider 28/09/2011 9
  10. 10. Import of solar panels …?MAG Your Global Solutions Provider 28/09/2011 10
  11. 11. … or local production? • Local production for the local market (and neighbour countries) • Production of customized products • Support of local labor • Technology transfer to NigeriaMAG Your Global Solutions Provider 28/09/2011 11
  12. 12. PhotovoltaicProcess Chain (c-Si) 1. Silicon & Ingot Raw Pro- Silicon Cessing Brick Ingots pro- solar sawing cessing silicon 2. Cells Cleaning Remove Drying Wafer & surface Edge AR Backside Frontside n-doping phosphor & sawing smoothen- delete coating contact contact glass sintering ing 3. Modules Glass Bar Glass loading coding washing Lay EVA Place Inter- Place Testing/ Edge J-Box foil strings connect backside Laminator Framing Sun Packaging trimming assembly on glass on foil strings foils simulation Testing and Stringer sorting of cellsMAG Your Global Solutions Provider 28/09/2011 12
  13. 13. Turn-Key c-Si Module Line 30 MW capacity• MAG delivers design and turnkey system integration service• MAG has global service network Cell Glass Bar Foil Test Foil Sealing Flashing/ Sorting/ Wash Stringer Tabber Busing Laminate Trimming J-Box Loader Code lay-up & Sort lay-up Framing Test Packaging MAG Your Global Solutions Provider 28/09/2011 13
  14. 14. C-Si turnkey production lines – Standard designs byMAG 12,5 MW 25 MW 50 MW 100 MWMAG Your Global Solutions Provider 28/09/2011 14
  15. 15. MAG Certification Service = Competitive Time to Market for Our Customers1 Conventional Certification Process issued Testing Fab only 3 months Delivery time at in- after installation production line spect TÜV lab of production line 3 months 1 week 6 months2 Master Fast Track Process Fab Delivery time in- Production turn-key line spect issued 1 week 3 months directly after installation transfer of production line certificate MAG Your Global Solutions Provider 28/09/2011 15 15
  16. 16. Improving Cell Connections Manual and automatic stringing Source: Xinology Source: TeamtechnikManual stringing process Auto stringing process- quality fluctuations - high investment- unskilled operators can - professional operator required produce scrap- tabbing and stringing separate + stable and reliable process + highest soldering quality+ very low investment CellGlass Bar Foil Test Foil Sealing Flashing/ Sorting/ Wash Stringer Tabber Busing Laminate Trimming J-BoxLoader Code lay-up & Sort lay-up Framing Test Packaging MAG Your Global Solutions Provider 28/09/2011 16
  17. 17. Improving Cell Connections Semi-automatic stringing Semi-auto stringing process + Low investment Source: Xinology + stable and reliable process Source: TeamtechnikFully manual + highest soldering quality Fully automatic + medium throughput CellGlass Bar Foil Test Foil Sealing Flashing/ Sorting/ Wash Stringer Tabber Busing Laminate Trimming J-BoxLoader Code lay-up & Sort lay-up Framing Test Packaging MAG Your Global Solutions Provider 28/09/2011 17
  18. 18. Semi-automatic Stringer - Sequence Automatic infraredPreparation of strings in solderingtemplates Template Clamping of for cells bus bars Cell Glass Bar Foil Test Foil Sealing Flashing/ Sorting/ Wash Stringer Tabber Busing Laminate Trimming J-Box Loader Code lay-up & Sort lay-up Framing Test Packaging MAG Your Global Solutions Provider 28/09/2011 18
  19. 19. Comparison of investment costs for 25 MW stringing process CapEX for 25 MW stringing process800.000700.000600.000500.000400.000300.000200.000100.000 0 Equipment 1 Equipment 2 Equipment 3 Automatic stringer + layup Semi-auto stringer + layup Manual stringing + layupMAG Your Global Solutions Provider 28/09/2011 19
  20. 20. Manufacturing costs for 25 MW stringing process Total annual cost400.000350.000 Buidling cost per year300.000 Repair and Maintenance cost Spare & Wear Parts cost250.000 Total annual labor cost Labor Total annual utility cost200.000 Depreciation150.000 Utilities100.000 50.000 Depreciation 0 Equipment 1 Equipment 2 Equipment 3 Automatic stringer + layup Semi-auto stringer + layup Manual stringing + layup Operator cost 12000 Engineer cost 35000 Depreciation 5 years Number of shifts 3 Production capacity 25 MW Auto semi-auto manual Number of Operators (per shift) 0,5 5 7 Number of Engineers (per shift) 0,5 0,2 0,1 MAG Your Global Solutions Provider 28/09/2011 20
  21. 21. Annual cost vs. Operator cost 600.000 500.000 Annual cost of equipment 400.000 Equipment 1 (auto) 300.000 Equipment 2 (semi-auto) Equipment 3 (manual) 200.000 100.000 0 00 00 00 00 00 00 00 00 0 0 0 00 00 00 .0 .0 .0 .0 .0 .0 .0 .0 4. 6. 8. 10 12 14 16 18 20 22 24 Operator cost [€/y] Semi-automatic equipment is ideal in countries of low labor ratesMAG Your Global Solutions Provider 28/09/2011 21
  22. 22. Improving Interconnection Manual and automatic interconnection soldering Source: ABB Manual interconnection Auto interconnection - high investment- quality fluctuations - professional operator required- unskilled operators can - detection of soldering points produce scrap can cause problems + stable and reliable process+ very low investment + highest soldering quality CellGlass Bar Foil Test Foil Sealing Flashing/ Sorting/ Wash Stringer Tabber Busing Laminate Trimming J-BoxLoader Code lay-up & Sort lay-up Framing Test Packaging MAG Your Global Solutions Provider 28/09/2011 22
  23. 23. Improving Interconnection Semi-automatic soldering Semi-auto process + Low investment + stable and reliable process + highest soldering quality Source: ABBFully manual + medium throughput Fully automatic CellGlass Bar Foil Test Foil Sealing Flashing/ Sorting/ Wash Stringer Tabber Busing Laminate Trimming J-BoxLoader Code lay-up & Sort lay-up Framing Test Packaging MAG Your Global Solutions Provider 28/09/2011 23
  24. 24. Cross contact soldering  Function – Cross contact soldering  Highlights - One operator - Easy to operate - Line integration - All bus bars soldered in one step - Transport rate max. 0.3 m/min CellGlass Bar Foil Test Foil Sealing Flashing/ Sorting/ Wash Stringer Tabber Busing Laminate Trimming J-BoxLoader Code lay-up & Sort lay-up Framing Test Packaging MAG Your Global Solutions Provider 28/09/2011 24
  25. 25. Cross contact soldering  Function – Cross contact soldering High quality, non-contact soldering CellGlass Bar Foil Test Foil Sealing Flashing/ Sorting/ Wash Stringer Tabber Busing Laminate Trimming J-BoxLoader Code lay-up & Sort lay-up Framing Test Packaging MAG Your Global Solutions Provider 28/09/2011 25
  26. 26. Summary Opportunities of local manufacturing: – Produce customized products – Short distances for distribution – Support of the local labor – Lower labor costs Challenges: – Choose the appropriate degree of automation (optimization of CoO) – Ensure constant high quality output – Know-how transfer MAG Your Global Solutions Provider 28/09/2011 26
  27. 27. Technology, Speed, Flexibility & Service! Thank you for your attention. How can we help you? MAG Switzerland AG Amsler-Laffon-Str.1 CH-8201 SchaffhausenMAG Your Global Solutions Provider 28/09/2011 27

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