The Otto Klumpp company We take responsibility

Otto Klumpp is a family-run company which was established by master mechanic Otto Klumpp in 1961. The company’s main activities are the development, manufacture and sale of injection moulded items made from plastic and injection moulding tools.

Perfection out of passion

The unconditional desire for perfection is the most important pillar of our philosophy. We tackle the most challenging of demands, and find unique solutions for our customers. Our own claim of perfection motivates us to constantly do our utmost and be self-critical of ourselves. All of which makes us a reliable partner. We are proud of our employees, who contribute to this.

Making good things even better

Our daily endeavour is to replace a good situation with an even better one. It is both confirmation and an incentive for us when these efforts are recognised by our customers by presenting us with awards. Our guidelines allow us to offer made-to-measure solutions, and determine our everyday activities. The perspective of our business development is the same for both our employees and our customers.

People at Otto Klumpp

The expertise and motivation of our employees counts for more than just the technical quality of our products. In order to fulfil the demands of our customers, they push the limits of what is physically possible.

The outstanding motivation of all our employees is the guarantee of speed and efficiency in overcoming even the most difficult challenges. We have made a name for ourselves in the field of sophisticated injection moulding.

History

2022

Machine pool expansion and much more

Commissioning of the 11th all-electric injection moulding machine. Insulation and maintenance of various buildings and building roofs. Conversion of the vehicle fleet to hybrid vehicles. Introduction of environmental management and certification in accordance with DIN ISO 14001. Installation of a fully automatic 8-way production system for a suction strainer. Manufactured using insert moulding.

Development of the folding technique:
Fully automatic cutting of the fabric, transfer, laying and folding of the fabric geometry, and overmoulding of the folded fabric into a suction strainer. 100% evaluation, inspection and monitoring of the filter components via a camera system, part depositing and packaging of the suction strainers.

Installation of a 3-D measuring microscope

Clean room optimisation in accordance with 14644

Digitisation:
expansion of the IT network, new ERP system, new time recording system, control computer connection to the BDE system and the introduction of the Otto Klumpp process system

Orientation of the entire company to the 5S method

2021

60th company anniversary and machine park expansion

Start-up of 10th fully electric injection moulding machine, machine park now consists of approx. 25 % of fully electric injection moulding machines.

Installation of a fully automatic 4-way production system for a suction strainer.

Manufactured using insert moulding.

Fully automatic cutting of the fabric, deep drawing of the filter geometry into a hemisphere and overmoulding of the hemisphere.

100% evaluation, inspection and monitoring of the filter components using a camera system, nest-related part depositing and packaging of the suction strainers.

Installation of an ultrasonic cleaning system for injection moulding tools.

 

2020

Machine park expansion

Start-up of the 9th fully electric injection moulding machine.

Installation of a fully automatic 16-way production system for a last chance filter for a vehicle gearbox.

Annual production volume of 20 million parts. Manufactured using insert moulding. Fully automatic 16-way cutting of the trapezoidal filter, overmoulding of the trapezoidal filter in a 16-way specialist tool.

100% evaluation, inspection and monitoring of the filter components using a camera system, nest-related part depositing and packaging of the last chance filters.

2019

Installation of a fully automatic 4-way production system for a suction strainer.

Development of deep-drawing through-punching technology Gen. 2:

Manufactured using insert moulding. Fully automatic cutting of the fabric, deep drawing of the fabric geometry into a hemisphere, overmoulding of the hemisphere.

100% evaluation, inspection and monitoring of the filter components using a camera system, nest-related part depositing and packaging of the suction strainers. FDA registration

2018

Machine park expansion

Start-up of the eighth fully electric injection moulding machine.

Construction of two additional high-precision 16-way tools, each with 64 sliders for filtration technology.

Construction and start-up of an installation injection moulding system for a filter component for e-mobility. Annual production volume of 2 million parts.

2+2-way insert moulding. Fully automatic filter production, filter component is welded to a bottom part using ultrasonic welding. The finished assembly is individually deposited into a transport tray.

2017

Start-up of the 6th fully electric injection moulding machine

Development of deep-drawing through-punching technology Gen. 1:
Installation of an 8-way fully automatic production system for a hat filter using insert moulding.

Fully automatic cutting of the fabric, moulding of the fabric geometry, transfer of moulded fabric hat into the injection moulding tool. 100% evaluation, inspection and monitoring of the filter components using a camera system. Fully automatic 100% tightness measurement of the hat filter, nest-related part depositing and packaging of the hat filter.

Start of the OK4.0 process “Fit For Future” (OK = Otto Klumpp)

Start-up of the 6th fully electric injection moulding machine with locking force of 230 tonnes in the clean room.

2016

Machine park expansion

Start-up of the 5th fully electric injection moulding machine and start-up of a flat grinding machine for mould manufacturing.

Construction of two high-precision 16-way tools, each with 64 sliders for filtration technology.

Annual production volume of 20 million parts per tool.

2015

Entry into micro injection moulding, new wire eroding machine, linear cell extended with a milling machine.

Start-up of a fully electric micro-injection machine (Start-up of the 4th fully electric injection moulding machine) and construction of 2 8-way moulds for micro components.

AgieCharmilles CUT 3000 S, consistent accuracy of the machine park in the micrometer range is now guaranteed in mould manufacturing. Addition of a second milling machine to the fully automatic linear cell. The linear cell consists of an AgieCharmilles Form 3000 HP, a Mikron HSM 600 ULP and an HSM 400 LP. The three machines are linked via a 3R Workmaster, and are monitored by a Zeiss DuraMax CNC measuring centre (fully automatic individual part manufacturing for mould manufacturing).

2014

Start-up of the fifth assembly injection moulding system

Construction and start-up of the fifth assembly injection moulding system, annual production volume of 40 million parts.

Installation of a fully automatic production system for a filter cage using insert moulding.

Automatic cutting of the fabric cylinder, placement of the fabric cylinder into the injection moulding tool via a 7-axis robot, removal of the finished filter cage from the injection moulding tool by a second 7-axis robot. Camera-assisted inspection, depositing and packaging of the filter cages.

Start-up of the second and third fully electric injection moulding machines.

2013

Move into the new administration building,

completion of all construction work started in 2011. The total area of the company premises is now approx. 12,000 m².

2012

Start-up of new warehouse, certification in accordance with ISO TS 16949

Move of mould manufacturing into new fully air conditioned warehouse, addition of a fully automatic linear cell consisting of an AgieCharmilles Form 3000 HP and a Mikron HSM 600 ULP to the mould manufacturing machine park. The two machines are linked via a 3R Workmaster, and are monitored by a Zeiss DuraMax CNC measuring centre (fully automatic individual part manufacturing for mould manufacturing).

Construction and start-up of the fourth assembly injection moulding system, annual production volume of 32 million parts.

Installation of the first fully electric injection moulding machine.

2011

Company anniversary – 50 years of Otto Klumpp, factory optimisation

Otto Klumpp turns 50.

Our factory extension also started on 01.08.2011. The construction project was divided into 3 phases:

1. Construction of warehouse with open air storage area, maintenance and storage facility and employee car parks
2. Extension of fully air conditioned production building for mould manufacturing
3. Extension of administration building and outdoor installations.

The construction project was carried out on the basis of the factory structure optimisation which was carried out beforehand. We are therefore pursuing the target of being able to consistently achieve optimum production and logistics procedures.

WOCO supplier award → Is Otto Klumpp going to be voted the best supplier? “Supplier of the Year 2010”

2010

Clean room building, 6-axis production, Otto Klumpp facelift

Modernisation of the production building for encapsulated Class 8 clean room production (100,000) with additional class 7 clean room production (10,000) for manufacturing products with the highest cleanliness demands such as medical and filtration technology. Commissioning of a manufacturing cell with a 6-axis robot and a camera system. Otto Klumpp undergoes a complete facelift.

2008

Introduction of worker self-monitoring, certification in accordance with DIN ISO 13485, clean room extension, machine park modernisation, assembly injection moulding system

Introduction of worker self-monitoring in the Plastics Processing area. Certification in accordance with Quality Management System for Medical Products DIN ISO 13485:2003.

Expansion of white room production to 500 m² with Class 7 (10000) and a production capacity of 9 injection moulding machines with mould locking force of 25 t to 280 t.

Installation of a 3D multi-sensor measuring machine.

Installation of a 5-axis milling machine. Construction and start-up of the third assembly injection moulding system with a annual production volume of 24 million parts.

2007

Expansion of mould manufacturing machine park, software conversion

Installation of another wire eroding machine in the mould manufacturing area. The CAD software was also converted. All workstations in Sales, Project Planning and within the Mould Manufacturing and Plastics Processing production areas were equipped with at least a 3D viewer.

2006

Modernisation of mould manufacturing machine park

Installation of a vertical machining centre in the mould manufacturing area.

2005

Installation of another assembly injection moulding system

Construction and start-up of the second assembly injection moulding system with integrated process and specification monitoring. Annual production volume of 16 million parts.

2004

Certification in accordance with VDA 6.1, installation of CAQ software, installation of assembly injection moulding (multi-component injection moulding)

Certification in accordance with VDA 6.1 took place for DIN ISO 9001 certification. Implementation of a computer-aided quality control system -> CAQ software.

Go-live with the assembly injection moulding procedure, with integrated process and specification monitoring, annual production volume of 8 million parts.

2003

Modernisation of plant, software changeover

Installation of a central material supply system which serves the large machine area from a central location. Changeover to new ERP system which supports operations in a plastics processing company in a better way.

2001

Expansion of the company premises

Expansion of the company premises by an additional 1400 m². The total area of the company premises is now approx. 9,000 m². An injection moulding machine with mould locking force of 1600 t has also been installed for plastic technology manufacturing. Plastic parts weighing up to 9.00 kg can be produced on this machine. The possible product range now covers parts weighing from 0.004 g to 9000 g.

2000

Extension of the IT system

Installation of a production data acquisition system for the manufacturing area.

1998

Entry into medical technology

Commissioning of Class 7 (10,000) clean room production for manufacturing medical products.

1997

DIN ISO 9001 certification

Successful certification in accordance with DIN ISO 9001.

1991

Modernisation of the company premises

The entire company is equipped with a sprinkler system.

1988

Introduction of CAD/CAM technology

Installation of a CAD system. Procurement of an injection moulding machine with mould clamping force of 1050 tonnes.

1987

Expansion of the company premises

Shipping, the finished product warehouse and assembly stations were accommodated in the newly constructed building with an area of 1800 m².

1986

Administration modernisation

Existing offices modernised and extended.

1985

Expansion of the company premises

Expansion of the plastics processing shop by an additional 800 m².

1983

Expansion of the company premises

Relocation of mould manufacturing to a newly built 840 m² manufacturing building.

1972

Expansion of company premises and machine park

Procurement of an injection moulding machine with mould clamping force of 150 tonnes. This will be set up in the new manufacturing building.

1971

Machine park expansion

A painting stand with a drying belt was installed for finishing the plastic articles.

1970

Entry into plastic technology

Procurement of the first plastic injection moulding machine. Entry into plastic technology starts by sampling moulds in-house and initial steps being taken in the series production of plastic injection moulded items.

1969

Expansion of the company premises

Expansion of the company premises by 560 m².

1963

First company building, introduction to mould technology

Construction of the building at Burgstraße 18 with an area of 220 m, in which mould manufacturing and the offices were accommodated.

Tool technology
In the years that followed, more and more cutting, stamping and progressive dies were manufactured. Mould technology, which was still in its infancy at the time, also found its way into the Klumpp company. From now on, injection moulding tools could be designed and manufactured.

1961

Founding of the company by Otto Klumpp

Otto Klumpp GmbH was established to carry out mechanical work such as drilling, turning and milling. In the same year a centre lathe was procured, which laid the foundations for the current operations. From now on, precision parts could be manufactured alongside the mechanical work.

2022Machine pool expansion and much more

Commissioning of the 11th all-electric injection moulding machine. Insulation and maintenance of various buildings and building roofs. Conversion of the vehicle fleet to hybrid vehicles. Introduction of environmental management and certification in accordance with DIN ISO 14001. Installation of a fully automatic 8-way production system for a suction strainer. Manufactured using insert moulding.

Development of the folding technique:
Fully automatic cutting of the fabric, transfer, laying and folding of the fabric geometry, and overmoulding of the folded fabric into a suction strainer. 100% evaluation, inspection and monitoring of the filter components via a camera system, part depositing and packaging of the suction strainers.

Installation of a 3-D measuring microscope

Clean room optimisation in accordance with 14644

Digitisation:
expansion of the IT network, new ERP system, new time recording system, control computer connection to the BDE system and the introduction of the Otto Klumpp process system

Orientation of the entire company to the 5S method

202160th company anniversary and machine park expansion

Start-up of 10th fully electric injection moulding machine, machine park now consists of approx. 25 % of fully electric injection moulding machines.

Installation of a fully automatic 4-way production system for a suction strainer.

Manufactured using insert moulding.

Fully automatic cutting of the fabric, deep drawing of the filter geometry into a hemisphere and overmoulding of the hemisphere.

100% evaluation, inspection and monitoring of the filter components using a camera system, nest-related part depositing and packaging of the suction strainers.

Installation of an ultrasonic cleaning system for injection moulding tools.

 

2020Machine park expansion

Start-up of the 9th fully electric injection moulding machine.

Installation of a fully automatic 16-way production system for a last chance filter for a vehicle gearbox.

Annual production volume of 20 million parts. Manufactured using insert moulding. Fully automatic 16-way cutting of the trapezoidal filter, overmoulding of the trapezoidal filter in a 16-way specialist tool.

100% evaluation, inspection and monitoring of the filter components using a camera system, nest-related part depositing and packaging of the last chance filters.

2019Installation of a fully automatic 4-way production system for a suction strainer.

Development of deep-drawing through-punching technology Gen. 2:

Manufactured using insert moulding. Fully automatic cutting of the fabric, deep drawing of the fabric geometry into a hemisphere, overmoulding of the hemisphere.

100% evaluation, inspection and monitoring of the filter components using a camera system, nest-related part depositing and packaging of the suction strainers. FDA registration

2018Machine park expansion

Start-up of the eighth fully electric injection moulding machine.

Construction of two additional high-precision 16-way tools, each with 64 sliders for filtration technology.

Construction and start-up of an installation injection moulding system for a filter component for e-mobility. Annual production volume of 2 million parts.

2+2-way insert moulding. Fully automatic filter production, filter component is welded to a bottom part using ultrasonic welding. The finished assembly is individually deposited into a transport tray.

2017Start-up of the 6th fully electric injection moulding machine

Development of deep-drawing through-punching technology Gen. 1:
Installation of an 8-way fully automatic production system for a hat filter using insert moulding.

Fully automatic cutting of the fabric, moulding of the fabric geometry, transfer of moulded fabric hat into the injection moulding tool. 100% evaluation, inspection and monitoring of the filter components using a camera system. Fully automatic 100% tightness measurement of the hat filter, nest-related part depositing and packaging of the hat filter.

Start of the OK4.0 process “Fit For Future” (OK = Otto Klumpp)

Start-up of the 6th fully electric injection moulding machine with locking force of 230 tonnes in the clean room.

2016Machine park expansion

Start-up of the 5th fully electric injection moulding machine and start-up of a flat grinding machine for mould manufacturing.

Construction of two high-precision 16-way tools, each with 64 sliders for filtration technology.

Annual production volume of 20 million parts per tool.

2015Entry into micro injection moulding, new wire eroding machine, linear cell extended with a milling machine.

Start-up of a fully electric micro-injection machine (Start-up of the 4th fully electric injection moulding machine) and construction of 2 8-way moulds for micro components.

AgieCharmilles CUT 3000 S, consistent accuracy of the machine park in the micrometer range is now guaranteed in mould manufacturing. Addition of a second milling machine to the fully automatic linear cell. The linear cell consists of an AgieCharmilles Form 3000 HP, a Mikron HSM 600 ULP and an HSM 400 LP. The three machines are linked via a 3R Workmaster, and are monitored by a Zeiss DuraMax CNC measuring centre (fully automatic individual part manufacturing for mould manufacturing).

2014Start-up of the fifth assembly injection moulding system

Construction and start-up of the fifth assembly injection moulding system, annual production volume of 40 million parts.

Installation of a fully automatic production system for a filter cage using insert moulding.

Automatic cutting of the fabric cylinder, placement of the fabric cylinder into the injection moulding tool via a 7-axis robot, removal of the finished filter cage from the injection moulding tool by a second 7-axis robot. Camera-assisted inspection, depositing and packaging of the filter cages.

Start-up of the second and third fully electric injection moulding machines.

2013Move into the new administration building,

completion of all construction work started in 2011. The total area of the company premises is now approx. 12,000 m².

2012Start-up of new warehouse, certification in accordance with ISO TS 16949

Move of mould manufacturing into new fully air conditioned warehouse, addition of a fully automatic linear cell consisting of an AgieCharmilles Form 3000 HP and a Mikron HSM 600 ULP to the mould manufacturing machine park. The two machines are linked via a 3R Workmaster, and are monitored by a Zeiss DuraMax CNC measuring centre (fully automatic individual part manufacturing for mould manufacturing).

Construction and start-up of the fourth assembly injection moulding system, annual production volume of 32 million parts.

Installation of the first fully electric injection moulding machine.

2011Company anniversary – 50 years of Otto Klumpp, factory optimisation

Otto Klumpp turns 50.

Our factory extension also started on 01.08.2011. The construction project was divided into 3 phases:

1. Construction of warehouse with open air storage area, maintenance and storage facility and employee car parks
2. Extension of fully air conditioned production building for mould manufacturing
3. Extension of administration building and outdoor installations.

The construction project was carried out on the basis of the factory structure optimisation which was carried out beforehand. We are therefore pursuing the target of being able to consistently achieve optimum production and logistics procedures.

WOCO supplier award → Is Otto Klumpp going to be voted the best supplier? “Supplier of the Year 2010”

2010Clean room building, 6-axis production, Otto Klumpp facelift

Modernisation of the production building for encapsulated Class 8 clean room production (100,000) with additional class 7 clean room production (10,000) for manufacturing products with the highest cleanliness demands such as medical and filtration technology. Commissioning of a manufacturing cell with a 6-axis robot and a camera system. Otto Klumpp undergoes a complete facelift.

2008Introduction of worker self-monitoring, certification in accordance with DIN ISO 13485, clean room extension, machine park modernisation, assembly injection moulding system

Introduction of worker self-monitoring in the Plastics Processing area. Certification in accordance with Quality Management System for Medical Products DIN ISO 13485:2003.

Expansion of white room production to 500 m² with Class 7 (10000) and a production capacity of 9 injection moulding machines with mould locking force of 25 t to 280 t.

Installation of a 3D multi-sensor measuring machine.

Installation of a 5-axis milling machine. Construction and start-up of the third assembly injection moulding system with a annual production volume of 24 million parts.

2007Expansion of mould manufacturing machine park, software conversion

Installation of another wire eroding machine in the mould manufacturing area. The CAD software was also converted. All workstations in Sales, Project Planning and within the Mould Manufacturing and Plastics Processing production areas were equipped with at least a 3D viewer.

2006Modernisation of mould manufacturing machine park

Installation of a vertical machining centre in the mould manufacturing area.

2005Installation of another assembly injection moulding system

Construction and start-up of the second assembly injection moulding system with integrated process and specification monitoring. Annual production volume of 16 million parts.

2004Certification in accordance with VDA 6.1, installation of CAQ software, installation of assembly injection moulding (multi-component injection moulding)

Certification in accordance with VDA 6.1 took place for DIN ISO 9001 certification. Implementation of a computer-aided quality control system -> CAQ software.

Go-live with the assembly injection moulding procedure, with integrated process and specification monitoring, annual production volume of 8 million parts.

2003Modernisation of plant, software changeover

Installation of a central material supply system which serves the large machine area from a central location. Changeover to new ERP system which supports operations in a plastics processing company in a better way.

2001Expansion of the company premises

Expansion of the company premises by an additional 1400 m². The total area of the company premises is now approx. 9,000 m². An injection moulding machine with mould locking force of 1600 t has also been installed for plastic technology manufacturing. Plastic parts weighing up to 9.00 kg can be produced on this machine. The possible product range now covers parts weighing from 0.004 g to 9000 g.

2000Extension of the IT system

Installation of a production data acquisition system for the manufacturing area.

1998Entry into medical technology

Commissioning of Class 7 (10,000) clean room production for manufacturing medical products.

1997DIN ISO 9001 certification

Successful certification in accordance with DIN ISO 9001.

1991Modernisation of the company premises

The entire company is equipped with a sprinkler system.

1988Introduction of CAD/CAM technology

Installation of a CAD system. Procurement of an injection moulding machine with mould clamping force of 1050 tonnes.

1987Expansion of the company premises

Shipping, the finished product warehouse and assembly stations were accommodated in the newly constructed building with an area of 1800 m².

1986Administration modernisation

Existing offices modernised and extended.

1985Expansion of the company premises

Expansion of the plastics processing shop by an additional 800 m².

1983Expansion of the company premises

Relocation of mould manufacturing to a newly built 840 m² manufacturing building.

1972Expansion of company premises and machine park

Procurement of an injection moulding machine with mould clamping force of 150 tonnes. This will be set up in the new manufacturing building.

1971Machine park expansion

A painting stand with a drying belt was installed for finishing the plastic articles.

1970Entry into plastic technology

Procurement of the first plastic injection moulding machine. Entry into plastic technology starts by sampling moulds in-house and initial steps being taken in the series production of plastic injection moulded items.

1969Expansion of the company premises

Expansion of the company premises by 560 m².

1963First company building, introduction to mould technology

Construction of the building at Burgstraße 18 with an area of 220 m, in which mould manufacturing and the offices were accommodated.

Tool technology
In the years that followed, more and more cutting, stamping and progressive dies were manufactured. Mould technology, which was still in its infancy at the time, also found its way into the Klumpp company. From now on, injection moulding tools could be designed and manufactured.

1961Founding of the company by Otto Klumpp

Otto Klumpp GmbH was established to carry out mechanical work such as drilling, turning and milling. In the same year a centre lathe was procured, which laid the foundations for the current operations. From now on, precision parts could be manufactured alongside the mechanical work.

»It’s in the mix. The synergy effects between small and large moulds make our moulds more intelligent.«

MARTIN KLUMPP
Managing Director of Otto Klumpp GmbH