Sensei Tooling is a Turkish-Chinese joint venture company located in Gebze, Turkey that designs and produces plastic injection molds. It was established in 2014 by Ecoplas Otomotiv and Chinese company Bluestar Technology. Sensei Tooling has modern CNC and EDM machining equipment and has produced molds for automotive companies like Toyota, Renault, Fiat, and others. It also provides second stage services for molds produced by its partner Bluestar in China.

1. Sensei Tooling Page  1
Sensei Kalıp San. ve Tic. A.Ş
27.09.2018

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About Us
Sensei Tooling is J/V (70%-30%) company that was estabilished by
participation of 100% Turkish Company Ecoplas Otomotiv Sanayi ve Tic. A.Ş
(www.ecoplas.com.tr) and Chinese Company Bluestar Technology (Shenzhen)
Co.Ltd (http://www.bluestar-mould.com) to desing and produce plastic injection
moulds for companies in Turkey as well as in Europe.
Our company is located at Gebze Industrial Zone (GOSB).Sensei Tooling has
been started production activities of plastic injection moulds since September
2014 with its lastest technology machining park and talented staff.
Despite of Sensei Tooling is able to make new plastic injection
mould,modification and maintenance service in Turkey, it has also provided cost
and time advantages of mould making in China to its customers by Chinese share
holder Bluestar Technology which is 20 years experienced company at plastic
injection mould making in China.
Sensei Tooling has also provided 2nd Stage service facility to its customer
which are in Turkey or Europe for the tools made by Bluestar. 2nd Stage Service
is covered trials,maintenance and modification change after mould transfer from
China.

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SENSEİ ACİL DURUM TAHLİYE PLANI
Konvansiyonel Talaşlı İmalat Alanı
AlıştırmapresiKalıp Montaj AlanıDalma Erozyon AlanıCMM ODASI
CNCDik İşlama Alanı
GÜVENLİK
O
T
O
P
A
R
K
1
2
4
21
2
3
Ofis/Soyunma
odası/Yarı
mamul depo
1
Safety-First
Emergency Evacuation Plan

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Safety-First
0
1
2
3
4
2016 2017 2018
Work Accident
Year Work Accident Qty
2016 1
2017 3
2018 1
Safety Passageways
Safety Equipments;
1- Shoes
2-Glasses
3-Gloves
4-Working Uniform
1
2
3
4

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Sensei Company History
2014 2015 2016 2017 2018
Company
Estabilishment
Spotting Press
CMM
Laboratuary
Tool Pre-setter
Toyota
CHR
Toyota
Corolla
Toyota
Camry
Renault
Megane
Fiat
Doblo
Fiat
Egea
Renault
Clio-5

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Mission
Sensei Tooling; always bring competitive
solutions create added value for its
customer and country while produce plastic
injection moulds.
2023 Vision
Sensei Tooling; to be a world class company
in its field and serve Turkish as well as
European customers by bringing technologic
advantages while making tool desing and
manufacturing.

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Plant Location&Size
Sensei Tooling
 Factory :800m2
 Employee :22
 Certifications:ISO9001:2008
ISO14001 Planning
 40 moulds/year capacity

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Production Processes
Mould Design CNC,EDM,WEDM Mould Trial & Tunings Mould Delivery
Part design review,
Mold-Flow anlaysis
Mould Assembly
1 2 3 4 5 6
1
2
3
4
5
6

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Tool Desing and CAM Programs
- 4 users licence
- Usage for tool desing and CAM
-3 users licence
- Usage for tool desing

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Hartford HEP 2150
-Work Dimensions: 2250x1500x780mm
-Rpm: 6000 (24000 with spindle speeder)
-Loading : 6000kg
-Machining Tolerance: ±0.01
-Qty:1
Machine Park
Mori Seiki CNC MILLTAP 700
-Work Dimensions: 710 x 400mm
-Rpm: 24000
-Loading : 400kg
-Machining Tolerance: ±0.005
-Qty:1
Mori Seiki CNC NVD 5000A
-PaWork Dimensions: 1000x700x400mm
-Rpm: 20.000
-Loading: 1000kg
-Machining Tolerance: ±0.003
-Qty:1
CNC

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Agie Charmilles EDM FORM 30-3R
-Work Dimensions: 1000x700x400 mm
-Loading : 1000kg
-Qty:1
Agie Charmilles CUT 20P
-Work Dimensions: 350x250 mm
- Loading : 400kg
-Qty:1
Neaur EDM CNC - A90
-Work Dimensions: 500x400x350 mm
-Loading :1350kg
-Qty:1
EDM
WEDM

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Crane and Spotting Press
Crane
Spotting Press
-Model : Cesan SWL
-Ton: 10t/5
-Additional crane moving motor
-Qty:1
-Model : HÜRSAN
- Clamping Force : 30-150ton
- Plate dimensions: 1600x1300mm
-Max. loading weight of movable half : 7500kg
-Qty:1

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Quality and Measurements
DEA GLOBAL CMM
Model: : 09.20.08
Measurement Range : 900x2000x800mm
Loading Capacity : 1800kg
Precision : 0.001mm(1µm)

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Trial Capability
• Utilize Ecoplas plastic injection
experience and machines.
• Trial and pre-production facility in serial
production conditions with 67 injection
machines from 40t to 1300t that each
one equipped with robot arm.
• Tool launching experience with ABS, PC,
PC + ABS, POM, PMMA, PA,PPT,PE PVC
as well as other common materials and
engineering plastics.

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Project Management
Projects are managed according to ‘Project Follow Up
Process’ below by dedicated project managers.
Mould production process from desing to T1 is reported to our
customer by weekly TPR and photos.

16. Produced MouldsToyota
Air Guide Moulds x 11Hood Support
Rod Braket
560* CHR
2014
Rear Lower Trunk Garnish Side Sill FR Side Sill RR Fog Lamp Garnish
Accesories Moulds for Painted
or Chorome Coated Parts

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Produced MouldsToyota 013*-Camry Russia
2016
Seal RR Bumper
Side RH/LH
Pad FE Wheel Opening
Extension RH/LH
Bracket Bumper
Extension
Cover Sub-Assy
Insturement Panel Under
Cover Racker Panel
Moulding End FR RH/LH
Plate RR Door Scuff
Inside RH/LH
Plate RR Door Scuff
Outside LH/RH
Plate FR Door
Scuff Inside RH/LH
FR Door Scuff
Outside RH/LH

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Produced MouldsToyota Boshoku
Hinge Sub-Assy RR
Seat Back RH/LH
TBT 147* Corolla TR
2015
Panel Instrument
CSTR Finish CTR RHD/LHD
Panel Instrument
Clushter Finish RH/LH
Panel Insturement
Finish UPR
Panel Instrument

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Produced MouldsFIAT
Doblo
2017
356* Egea
2017
Battivaligia
Urea Tank Shield
Lock CoverTrunk Scuff

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Mirror Frame Mirror Bracket
Produced MouldsMagna
LFF* Megane
2015
356 HB Egea-SW
Hybrid Crash Box
Produced MouldsTKG

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595* Corolla Luggage
Lamp Lens /2015 AR949 Center High-Mount
Stop Light Lens/2015
Produced MouldsFeka (Lighting)
PSA-B9 Berlingo
LPL Outer Housing/2016
Alfa Romeo 949 Fresnel / 2015

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Personnel Informations

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Sectoral Business Distribution

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Mould Diversity

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Views of SENSEI
 Project&CAD/CAM

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 CNC Area Machine List

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 EDM Area

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 WEDM Area

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 CMM Area

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 Conventional Machining & Assembly Area

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 Assembly&Spotting Area

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• Bluestar is a shareholder of Sensei Tooling as %30
• Both company has strategic partnership for all automotive related moulds
• Strategic Territory : Turkey and all european countries
Strategic Partnership with Bluestar J/V

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Advantages for Customers
• Full service for all automotive related
moulds
• Visibility for mould progress and quality
• Competitive cost and time for mould
manufacturing by utilize China
advantages.
• 2nd Stage service for mould repair or
engineering change for the tools which
are produced in China.
Bluestar Product Portfolio - Automotive

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Suppliers

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References

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Thank you…
謝謝