The Kirchhoff Group Magazine

18th volume | Issue 41 | June 2013 18 th

volume | Issue 41 June 2013 K›MOBIL THE KIRCHHOFF GROUP MAGAZINE

We wish you a great summer season.

Customer and supplier at the same time: FAUN is the first bodybuilder for the ANTOS of Mercedes-Benz. KIRCHHOFF Automotive supplies www.kirchhoff-group.com significant frame components for this vehicle. K›MOBIL 41 // KIRCHHOFF Group KIRCHHOFF Group // 41 K›MOBIL K›MOBIL LIST OF CONTENTS

AUTOMOTIVE MOBILITY SCREWDRIVING TOOLS ECOTEC

12-57 58-63 64-71 72-103

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KIRCHHOFF Group 32 Two anniversaries—one 52 Popular employer FAUN Group 91 Well equipped success story for the Universiade 04 The key to prosperity 53 Turning an idea into reality 74 Reliably progressive Imprint 34 A project of superlatives 92 Something new K›MOBIL the KIRCHHOFF Group magazine 06 Series: From research 54 Accelerating with success 76 In tune with the times in the State of Denmark and development 37 First order from BMW Publisher: KIRCHHOFF Group, Dr.-Ing. Jochen F. Kirchhoff for Van-Rob Manchester 56 Promoting young people 78 Think BIG 93 Love Recycling Stefanstraße 2, D-58638 Iserlohn Postfach 26 26, D-58634 Iserlohn KIRCHHOFF Automotive 38 New Corvette Stingray 80 The New VARIOPRESS 94 60 counts Tel. +49 2371 820 - 261 Fax +49 2371 820 - 264 sets standards KIRCHHOFF Mobility 14 Innovation and flexibility 82 We’re revving 95 One Stop Shop Responsible for the content: Dr.-Ing. Jochen F. Kirchhoff against volatility and 40 New facilities 60 More room for more service up Germany Editorial team: Sabine Boehle, uncertainty for a new product 96 New order for HGMS Oliver Fries, Andreas Heine, 62 Better together 83 Simply enormous components Claudia Schaue 16 Ready for growth 41 Customized CNC bending Pictures: 84 Happy Birthday 97 Engaging with the US Military Adam Opel, Changan Mazda Automobile, Porsche, Volkswagen, 20 Audi is breaking new ground 42 One of the best Škoda WITTE Tools Audi, Ford, BMW, Škoda, suppliers of the world 85 Workshop 3.0 General Motors, Chevrolet, KIRCHHOFF Gruppe, Privat, 22 HYLIGHT: German Federal 66 New product for ZOELLER Group Deutsche Post, Shutterstock, Ministry funds research and 44 First hot forming line special work 86 Patent in hand FAUN, Johannes Ginsberg

development project in Hungary successfully 100 A new figure in Translation: starts series production 67 High standard—constantly 87 A new broom in the team international marketing Target Languages, Dossenheim 24 The country needs maintained thetranslationpeople, Glasgow new products 46 For the good of 88 Goodbye Germany. 101 Markets and Makers Design, Typesetting: the environment 68 Screwdriving tools—for Hello Netherlands. FETTE-BEUTE.com, Dortmund, Attendorn 26 China and Auto Shanghai professionals and discerning 102 Europe meets Africa continue to expand 48 A cut above the competition home improvers 90 Go Green Printing: becker druck, Arnsberg K›MOBIL 41 // KIRCHHOFF Group KIRCHHOFF Group // 41 K›MOBIL

The key to prosperity

Industrial value creation ensures jobs and prosperity

Dear customers and friends of our group of companies, Dear employees, 4 5

This industry term, which previously re- which started in 2008, have signifi- cation system) as a prerequisite for tion systems lead, as can be seen in economical and innovative ferred to the production of goods, has cantly reinforced the value of industry. competitive jobs. Furthermore, it is some European countries, to deindus- lightweight construction. now become considerably broader. It While Asia, in particular China, is ex- important to have a corporate culture trialisation and therefore a decline in In addition to technology describes the organisation of value periencing an unprecedented upturn that promotes the sustainable invest- jobs and prosperity. and innovation manage- chains for optimised customer/prob- with the expansion of industry and ment of profits in new machinery and ment, the range of services lem solutions and increasingly adopts infrastructure, but also countries such processes. In Germany, 95 per cent of With the initiative of EU Commission- provided will also include the process perspective. This means as Mexico, Brazil, and most recently companies are family-owned compa- er and Vice-President Antonio Tajani, qualification and knowl- the responsible use of raw materials as America, are making industry the nies that are not interested in short- an industrial revolution should make edge transfer. Our contribu- well as environmentally and resource- focus of their development, we are term success, but in long-term market industry in Europe competitive once tion to ensure the industrial friendly production technologies. experiencing a divided pattern in Eu- survival. It is therefore only possible to again. value creation of tomorrow. rope. On the one hand, Germany and innovate and use resources economi- Strong industry leads to above-aver- its central East European neighbours cally if there is a combination of well- The first few months of the year A cordial good luck! age income because industrial value have consistently supported the crea- trained people and modern machinery 2013 indicated stable development in creation generates more than twice tion of industrial jobs. On the other and workstations. Finally, policies with America and Asia and were marked Yours, as much value as other sectors. With hand, large parts of West and South framework conditions for the job mar- by weak demand in western Europe 90 per cent industry supports research Europe have not carried out important ket, the educational system, the finan- only. As well as the global economy and development and is therefore a structural reforms and have allocated cial system, the promotion of foreign grows by 3.4 per cent, the automo- key driver of innovation; industry is also more money than they earned. It is trade, and the tax system can have a tive industry will also grow to a record responsible for 90 per cent of exports. now crucial that participative, and not positive or negative effect on industri- 83 million units. To take part in this, distributive justice from policymak- al development and therefore directly we must increase the rate at which we Arndt G. Kirchhoff The two financial crises of the last dec- ers, forms the basis for the frame- on jobs and prosperity. innovate. To this end, we are opening ade, firstly the bursting of the “new work conditions in the countries. the ACS (Automotive Center Südwest- economy bubble” in 2000, and then Tax increases and other levies, unreli- falen), which is intended to become the real property, financial and, in This starts with participation in edu- able budget management, overregu- the leading development partner for some countries, sovereign debt crisis, cation (in Germany: the dual edu- lated financial, job market, and educa- K›MOBIL 41 // KIRCHHOFF Group KIRCHHOFF Group // 41 K›MOBIL

Plastic

Steel pipe

Wire frame Series: From research without plastic and development

Wires can be welded to the pipe Thread for screwing on the steering column mounting Innovations from the KIRCHHOFF group Fig. 2

provides better performance with less be joined to a steel pipe of the cross designed for urban travel. The ambi- B processing than with a straightfor- car beam to form the steering wheel tious team around Professor Achim ward steel plate solution. On the other mounting. Kampker has succeeded in attracting hand the geometry of the longitudinal the interest of the postal service for member (B) made of steel means it is The compact parts can be packed in- this concept. From July 2013 a fleet 6 better able to meet the above objec- dividually and delivered just in time to of StreetScooters will be introduced 7 tives in the face of the requirements any KIRCHHOFF Automotive site for for the delivery of letters and parcels A in this part of the component. The assembly. In a third project request, to customers in the city and the close B connection between the steel and the KIRCHHOFF Automotive is researching environs. It is still an urgent priority casting in this case is made by screw interlocking plastic and metal connec- however to hand over the further mar- fastenings. tions. See special report on page 22. keting and large series manufacture of the StreetScooters to one of our major In a second design project we are ap- Our Automotive product division is customers. plying our existing expertise in an in- also involved in the now well-advanced Fig. 1: Design of a subframe in a terdisciplinary company setting. For development of the body structure for combination of steel and ion of steel decades the WITTE tools screwdriver the all-electric StreetScooter; a vehicle and cast aluminium division has been working with us on the extrusion-coating of plastic around the wire screwdriver mandrels. Valuable expertise which has led in the Automotive product division to the first joint pre-development project based on a steel and plastic hy- Fig. 3: brid Cross Car Beam (CCB). Figure 2 StreetScooter for The current focus of F&E activi- the selection of the material and the jected to other loads exerted on the shows one such possible arrangement. the postal service ties in the KIRCHHOFF Automotive production process. Overall, the com- component. Figure 1 shows the design The aim is the integration of function product division is on hybrid de- ponent weight is kept low due to the of a subframe made of a combination in plastic components. This will reduce sign, wherein two or more dif- low stress design of the component of steel and cast aluminium. components, reduce complexity and ferent materials and manufactur- geometry to correspond to the pro- therefore transport volume and trans- ing processes, for example cast duction process and above all is cost- Cast nodes made of aluminium can port costs and guarantee higher part aluminium and sheet forming, are effective. Formed metal parts made be adapted relatively cost-effectively availability at many locations near to combined to make a component. of steel have specific characteristics for various purposes and are particu- our customers. which can only meet these objectives larly attractive commercially for small The objective of the hybrid-design with simpler component geometries. quantities. Stress peaks in the com- This hybrid concept involves extrusion- development is to absorb the differ- Cast aluminium nodes however can ponent can be eliminated by care- coating a curved steel wire (Fig. 2) to ent loads exerted on a component by meet the above objectives when sub- fully arranged ribs (see Fig.1, A). This form a connecting part which can KIRCHHOFF Group // 41 K›MOBIL

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ROTOPRESS DUALPOWER

Fig. 6: E-Rotary lifter from ZOELLER Fig. 4

Innovations for refuse collection Germany but also in Switzerland and collection vehicle naturally also re- vehicles and lifters—KIRCHHOFF in Liechtenstein. The DUALPOWER quires the electrification of the rear Ecotec drive concept has been implemented lifter to empty the collector. In this in conjunction with the ROTOPRESS area, ZÖLLER-KIPPER GmbH has made In the KIRCHHOFF Ecotec product di- superstructure (Fig. 4) and the first further advances here in the electro- vision—with the two primary brands VARIOPRESS refuse collection vehicles lifter-application. In the “Low-Level” FAUN and ZOELLER—research- and de- with packing plate compactors (Fig. 5) lifter segment for a low loading edge velopment continues to focus heavily have arrived with their customers. the Rotary-lifter which covers this use on efficient refuse collection vehicles spectrum has been electrified. (Fig. 6) and lifters. The first 20 DUALPOWER The electrification required for the re- Fig. 5: vehicles are now at work not only in covery of braking energy in a refuse VARIOPRESS DUALPOWER K›MOBIL 41 // KIRCHHOFF Group KIRCHHOFF Group // 41 K›MOBIL

Fig. 8: Fig. 9: Fig. 10: MEDIUM XLS with E-Lifter from ZOELLER ROTOPRESS with e-PTO Plastic trim panels on the ROTOPRESS DUALPOWER

Sprocket wheel 10 11

An electrically powered lifter is easier electrical operation of the compact- Also in the two other business divi- to control and has less loss, including ing machinery of the body and of the sions R&D work is being carried out in with otherwise conventionally-pow- lifter. the area of efficiency improvements, ered hydraulic bodies. It also offers material use optimisation and com- potential savings for the operation of First vehicles with MEDIUM XLS body plexity reduction to increase customer a conventional refuse collection vehi- and E-Lifter (Fig. 8) plus ROTOPRESS benefit. We will report on these in fu- cle if the lifter can be driven by and e-PTO (Fig. 9) have started work ture issues. the existing 24 volt vehicle with our customers Meldgaard in electrical system. An initial Denmark. It will soon be possible to Dr. Johannes F. Kirchhoff case study is being con- determine comparison data about ducted in the city of Dort- consumption depending on collection mund to verify the desired performance. fuel savings potential (Fig. 7 and 7a). As well as the energy-efficiency of our A further working area in the case of products, we are also researching in the refuse collection vehicles of FAUN terms of extending their service life, and ZOELLER, on the campaign for Fig. 7 and 7a: A project is currently underway minimising maintenance, manufactur- lower fuel consumption and lower E-Delta lifter from ZOELLER at FAUN on a multi-element spro- ability and the weight of components noise emissions is the plug-to-charge cket wheel made of plastic to re- from which the refuse collection vehi- battery pack for the electrical opera- duce weight and maintenance. cles and lifter are produced. Weight tion of the bodies and the lifters of re- This kind of sprocket wheel has reduction and the reduction of remain- fuse collection vehicles. This system is via the hydraulic pump attached to pack (identified by the unit behind the distinct technical benefits. A pro- ing component damage is a priority in described as an e-PTO (electric power the PTO for the compression of the driver’s cab), which is charged by night ject to analyse the wear behavi- the work to replace aluminium parts, take-off). In conventional vehicles the refuse and to lift the collector. In a at the city depot in low power-draw our and the long term durability particularly with deep-drawn plastic combustion engine supplies energy vehicle equipped with e-PTO a battery periods, delivers the energy for the is currently underway. parts in the case of trim (Fig. 10). 12 13

WE.MOVE.FUTURE. 12-57 K›MOBIL 41 // KIRCHHOFF Automotive KIRCHHOFF Automotive // 41 K›MOBIL

KIRCHHOFF Automotive develops strategies to counter challenging market developments.

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The automotive world is undergoing the Golf VI just has five years. OEMs are also affected by these influenc- be created worldwide. Furthermore, it pointer in this direction; it is opened in the Executive Board, are certain that a radical change. Markets are becom- are striking up alliances and collabo- ing factors; they are unable to shield goes without saying that the opportu- July 2013 in the immediate vicinity of our market position can survive and ing increasingly volatile, and forecasts rations and are significantly reducing themselves from these events and the nities for expanding existing or estab- the Attendorn location. grow. increasingly unreliable and vague. the number of key suppliers. Plants are circumstances prevailing in the market lishing completely new locations such Southern Europe is in crisis, as we being closed and production is being and influencing global development. as in Hungary (Esztergom) or China The new PLM system optimally sup- We are confident that KIRCHHOFF can see in Greece and Cyprus, but the transferred. New manufacturers are Conversely, this clearly means that we (Shenyang) will be reviewed and im- ports the use and exploitation of ex- Automotive as one of the large suc- economies of Spain, Italy, and Portu- entering old and new markets, thus need maximum independence from plemented. Additional expansions and isting plants, machinery, and facilities. cessful development suppliers can and gal are also stagnating or in recession, increasing competition and making it manufacturers, markets, and products new locations will also help us, in the This Product Lifecycle Management will join the automobile manufactur- which, together with the euro crisis, more difficult to survive. Well-known, to have a very high degree of flexibil- future, to upgrade and intensify our tool guarantees uniform global stand- ers on the path to a mobile future. is starting to affect more and more established companies are adjusting ity. To this end, our Company must market position and proximity to our ards and simultaneous information We will offset the volatility and un- countries in Europe. their personnel levels. continue to consistently pursue the customers in order to generate fol- and project management. certainty of the markets with innova- approach it has already taken. low-on orders and therefore capacity tions and a high degree of flexibility. Large automobile manufacturers are At first glance, this does not seem to utilisation. We are also working on the optimisa- Because: WE.MOVE.FUTURE. postponing new vehicle start-ups, be good for global automotive pro- Specifically, this means further diversi- tion of our internal structures and re- and numbers of JIT calls and orders duction. Manufacturers as well as sup- fication of our customer and product In addition, our focus and commit- sources in order to continue improving Dr. Thorsten Gaitzsch fluctuate considerably. The lifecycle pliers will be put to the test and find portfolio in order to offset the market ment must lie in the development of the cost situation and therefore our of vehicle models has halved over the themselves faced with new challenges fluctuations thanks to a broad base, new products and processes. The new competitiveness. Despite the difficult last few years in some cases: the Golf to overcome. KIRCHHOFF Automotive so that existing jobs are secured in the ACS, the Automotive Center Südwest- current situation and the adverse cir- I still had a life cycle of ten years, while and all associated Group companies long term and additional new jobs can falen, also represents a key step and cumstances and unpredictability, we, K›MOBIL 41 // KIRCHHOFF Automotive KIRCHHOFF Automotive // 41 K›MOBIL

The automotive industry in Mexico makes an annual profit of almost 30 billion USD, Mexico is among the top ten countries low levels. I would say that we will existing plants from where we already provides 500,000 jobs and makes the country the eighth biggest vehicle manufacturer of in the world producing cars, trucks, continue to see modest growth for service Volkswagen. As Audi comes to parts and components for the auto- at least the next 3 years and it will that region, we will be investing and the world. motive industry. Because of this solid, be roughly a 3 per cent increase each growing our facility in Puebla. We dynamic industry the Mexican econo- year. That will bring automobile sales have a need for additional capacity my continues to grow. into the low 16 million SAAR (Season- there and we very much look forward ally Adjusted Annual Rate) level and to working with Audi to continue to From a production perspective, the we will hold there for a few years. grow with them along with our other main reasons for the success of the customers in that region. industry are Mexico’s proximity to the A. Heine: The growth in Mexico is United States, competitive and spe- indeed stronger than in the rest of A. Heine: How important is the Mexi- cialized employees, and free trade North America. How well is Van-Rob can market for Van-Rob, for example agreements. Mexico continues to at- placed in Mexico? Can we expect new regarding a balanced customer port- tract foreign investment in this sector. investments in our Mexican plants or folio? By 2017, the capacity to produce four even the fitting of new plants to help million cars and the duplication of di- the car manufacturers manage their D. Berry: Today Mexico makes up rect and indirect jobs are expected. growth? 28 per cent of our sales and as we go forward, we see that increasing. With 16 Questions to Dennis Berry, CEO D. Berry: Certainly the new growth in that increase, we will need more ca- 17 Van-Rob: Mexico is very important to us. With pacity, like I spoke of, in the Puebla our three facilities, we are positioned area. Audi is in the process of opening A. Heine: North America is one of very well in Mexico. The most north- their new plant in the Puebla region. the biggest growing markets of the ern plant is located in Hermosillo. We This facility represents organic growth global automotive industry besides have our largest plant in Querétaro, since it is their first plant here in North China and Russia. In the first months where we started in 2000. Further- America. Furthermore, Audi’s new lo- of this year the sales of passenger more, we also have a plant in Puebla. cation in North America complies with cars and light vehicles increased by So our locations are matched very well our strategic goal to minimize risk by 8 per cent. Mr. Berry, what is your for the customers that are there today a better balanced customer portfolio. opinion? How long will we see such a and for sure for the customers that growth in North America? are coming. Honda just opened a new A. Heine: Is the Mexican business ad- plant in central Mexico and we are less ditional business or will the growth in D. Berry: We have been fortunate than an hour away. Also Audi is open- Mexico jeopardize the utilization of since the crisis of 2009. We have con- ing a plant in the region of Puebla, our plants in Canada and in the USA? tinually seen growth from those very thus again in the vicinity of one of our

DENNIS BERRY CEO Van-Rob in an interview K›MOBIL 41 // KIRCHHOFF Automotive KIRCHHOFF Automotive // 41 K›MOBIL

D. Berry: Well as far as Canada goes, ket share. So the answer to the ques- customer achieve a vehicle weight re- lighter, more accurate products for D. Berry: In the context of our strat- them achieve their objectives. We re- there is a slow reduction in the num- tions is that it will have minimal effect duction. These technologies help us our customers. Laser technology, hot egy 2020, we are insistantly working gard as our task and responsibility to ber of cars that are going to be pro- on our utilization of our facilities in the to provide solutions to our customers. forming and aluminum solutions are at expanding our core competences, support our customers at it today and duced in there. We see that over the USA and Canada because these are We have some stringent miles per gal- competitive advantages. With them, sharing that information and focusing in the future. next few years, Canada will drop from new customers for us in North Ameri- lon (MPG) requirements, 54.5 MPG by we can offer our customers solutions our specialists’ attention both in North

2.5 million cars produced to about ca. What it will do for us, is to help us 2025 and certainly in Europe the CO2 for current and future requirements America and Europe on the respec- The interview was performed by 1.8 million. Some of that loss is be- grow and diversify our customer base. reductions are significant as well. One for weight reduction in the vehicle. In tive areas. Focusing on technologies Andreas Heine, Director Communica- cause of the shift to Mexico, but also a of the ways the OEMs can achieve this 2014, 40 per cent of the products that and competences allows us to provide tion and Marketing. factor is the shift in the OEMs market A. Heine: Which technologies are very target is reduction of mass, respec- we produce here will be laser welded. lightweight solutions. Mixed materials share. With Audi coming to the North important in the future, laser welding, tively weight, thus the production of Therewith we are one of the leading and aluminum solutions, we are doing American market, it is reflective of this hot forming, the use of aluminum for lighter components. Laser technology suppliers in that technology field. all those products today here and in fact. The German OEMs are steadily instance? allows us to use thinner materials and Europe and we are focusing on these continuing to grow their market share this joining process has less distortion A. Heine: Will Van-Rob and KIRCHHOFF and other strategies as we go for- since the crisis. Honda has also added D. Berry: All of these technologies from the heat which enables us to Automotive in the future benefit even ward so that we are able to provide new capacity in central Mexico which are important today, and will be im- achieve excellent dimensional accu- more from each other than today re- solutions. That is what our customers is due to the increase in the Asian mar- portant in the future as they help the racy. Therefore we are able to provide garding their core competences? need: solutions that are going to help

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Info

The development of the automotive industry in Mexico

Eight of the ten major companies in too. In San Jose, Chiapa (by Puebla), the world for vehicle construction have Audi is constructing a new plant with assembly plants in Mexico. Over one the start of production scheduled for thousand automotive supplier compa- spring 2016. Nissan is expanding its nies are in Mexico, most of which are branch in Aguascalientes. Completion from abroad. And Mexico continues to is scheduled for the end of 2013. Fur- draw foreign investments in this sector. thermore, Mercedes-Benz and BMW The forecast for 2017 foresees four mil- are investing in additional production lion vehicles being produced and the plants in Mexico. The locations for doubling of direct and indirect jobs. these sites are not yet known.

Honda is building a new plant in Cel- Volkswagen is continuing to invest in aya, which will take up production in the its Mexican plant in Puebla, which will spring of 2014. In Salamanca, Mazda is produce the seventh generation of Golf building a new plant. Vehicles will start from 2014. Plans to construct a new to roll off the line in the spring of 2014 Volkswagen plant are also under way. K›MOBIL 41 // KIRCHHOFF Automotive KIRCHHOFF Automotive // 41 K›MOBIL

Foundation stone laid for the first Audi plant in North America

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left: at the groundbreaking ceremony: f.l.t.r.: Rupert Stadler, Chairman Audi AG, Ildefonso Guajarda Villarreal, Mexico’s Lecture by Matthias Müller, Project Manager Plant Mexico, Audi AG Minister of Economic Affairs and Rafael Moreno Valle, Governor of the Federal State of Puebla | right: Audi chief Rupert Stadler (left) hands over the keys to an Audi Q5 in a special edition for the police of the Mexican state to Rafael Moreno Valle, Governor of the Federal State of Puebla

The foundation stone for the first The event was perfectly organised and placed side by side is currently fully tract packages in the body-in-white cilitated and provided excellent sup- The supplier workshop has certainly Audi plant in the Mexican town defined by: undeveloped. and chassis product packages. These port by the Mexican and German contributed towards intensifying ex- of San José Chiapa has been laid. potential contracts would further re- authorities. Events included sessions isting contacts, creating new ties, and A new plant with press shop, car t UIFSJHIU"VEJDPOUBDUQBSUOFST Although the plant will reproduce the inforce our Mexican presence either with the President of Mexico (En- thus strengthening a more extensive body shop, paint and assembly t DPNQSFIFOTJWFJOGPSNBUJPO entire process chain from the press as an extension of existing capacities rique Peña Nieto), the Governor of the co-operation for the future. is being constructed at a cost of t BGBTDJOBUJOHQSPHSBN shop all the way to delivery to cus- at the Van-Rob KIRCHHOFF (VRK) state of Puebla (Rafael Moreno Valle), more than EUR 900 million. From t BIJHIMFWFMPGNBOBHFNFOU tomers (also known as “Zählpunkt 8” plant in Puebla or also in the form of a the Mexican Minister for Economics The fact that both Audi and other mid-2016, the successor genera- presence and [reporting point 8]), Audi is working new plant. Apart from obtaining vital (Ildefonso Guajardo Villarreal), and brands in the Volkswagen Group tion of the Q5 SUV model will roll t BEFRVBUFUJNFGPSJOUFSFTUJOH very closely with its global partners information that will help during the the German Ambassador to Mexico have placed numerous orders with off the assembly line in Mexico. bilateral conversations as well on this project. Only an estimated 30 tendering period, which has already (Edmund Duckwitz). Audi also had top- us in the past and during the current A s par t of an Audi Q5 supplier work shop parts will be produced on site for the commenced, approximately 100 invit- level representation led by Chairman business year allows us to look posi- held from 2–5 May 2013 in Mexico, the The new Audi location is being built body-in-white phase. However, these ed proprietors and managing directors of the Board of Management, Prof. tively towards the future and towards key potential suppliers were made par- in the federal state of Puebla approxi- parts are mainly outer skin parts. The from Asia, North America, and Europe Rupert Stadler, as well as Board Mem- continued growth with the entire ty to the coming challenges and pro- mately 60 km south west from the city remaining parts will be sourced from also had the pleasure of testing the bers Dr Bernd Martens (Procurement), Volkswagen family. vided with the necessary information. of the same name. In just three years’ the market. For this reason, and be- Q5 both on- and off-road. Prof. Thomas Sigi (Human Resources), As KIRCHHOFF Automotive representa- time, the first Q5 vehicle will roll off cause Audi would like to achieve a lo- and Dr Frank Dreves (Production)”, Anja Marcus tive Dr. Thorsten Gaitzsch, Chief Tech- the production line. It is hard to imag- cal content of up to 90 per cent, our “All told, the workshop was a very reports Dr Thorsten Gaitzsch. nology Officer, took part. ine as the area of 400 football pitches Company is hoping to be awarded con- interesting event, which was also fa- K›MOBIL 41 // KIRCHHOFF Automotive KIRCHHOFF Automotive // 41 K›MOBIL

!a2$ % 525/

KIRCHHOFF Automotive is working on the development of a technology for adhesive Front end carrier for the Ford Focus used as a test bonding hybrid plastic/metal composite parts in the injection moulding process. product and demonstrator within the project

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Since March 2011, the R&D team has moulding tool and injected with plas- design and construction phase. An been cut to metal blanks, KIRCHHOFF been working together with universi- tic via cut-outs and seams. This results integrated simulation is being carried Automotive employees from Iserlohn ties and industrial companies to de- in a form-fitting connection between out throughout the entire duration are responsible for forming the metal Info velop a technology for plastic/metal metal and plastic. With the new tech- of the project for this purpose. With blanks using the series-production hybrid components in the injection nology, a metal sheet is coated with the potential for deployment of such system. The manufacture of adhesive moulding process. The HYLIGHT pro- adhesive, formed and then inserted in coated metal parts in series produc- bonded metal/plastic composite parts ject is being funded by the Federal Min- an injection moulding tool. The metal tion, the Research and Development will subsequently be undertaken by istry for Education and Research. The sheet with the adhesive coating is in- department has then been assessing Montaplast using the injection mould- Adhesive bonds are all bonds where project’s remit is to create a reliable ad- jected with plastic, resulting in a ad- the forming process. ing with a plastic supplied by Lanxess. the bonding partners are held to- hesive bond between the metal which hesive bond between the plastic and The testing of the demonstrator will gether by means of atomic or molecu- is coated during the coil-coating pro- adhesive coating. The benefits of this The hood ledge test has already been be done at the automobile manufac- lar forces. Simultaneously, these are cess and the injection moulded plas- process are an improved metal/plastic carried out by Lanxess on a front end turer Ford. The project is scheduled to permanent joint connections that can tic. The front-end carrier for the Ford bond, which shows the same perfor- manufactured using the adhesive be completed in February 2014. only be separated by damaging the Focus manufactured by KIRCHHOFF mance with less material input. bond technology. This test has proved adhesive: soldering, welding, gluing, Automotive in Iserlohn/Germany is the bond strength and the associated Rolf Schwarzer, Christoph vulcanising. serving as a test product and demon- The staff in the Research and Devel- improvement in the component’s me- Wagener, Stefan Szabo strator within the project. opment department at KIRCHHOFF chanical properties. The word coil is used to denote metal Automotive have been focusing on bands or steel strip rolls. The actual production way of hybrid component production and the prop- In the further project phase, Hühoco components are, forming, cathodic erties of the adhesive coating after will examine the coating of coils us- dip-painting of metal parts. These forming. An optimal component de- ing a system based on adhesives parts are inserted into an injection sign should be created in the early from Evonik. Once the coils have K›MOBIL 41 // KIRCHHOFF Automotive KIRCHHOFF Automotive // 41 K›MOBIL

KIRCHHOFF Automotive is present with innovative, This year OEMs will bring about 32 laborations in various new projects with newly developed individual components in many models. new vehicle models onto the market. In automobile manufacturers and would this concern KIRCHHOFF Automotive is like to show you some examples. available as a competent partner of the car manufacturers with new technolo- Dr. Thomas Steinhaus gies and innovations. We are pleased to underline this again with innovative col-

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Front Bumper ©BMW AG ©BMW AG Door Locking Catch Axle Bracket

Customer / model Ford / Ford Fiesta model 2012 Customer / model Customer / model BMW / all BMW vehicles since 2011 BMW / BMW 1- and 3-series In October 2012, the Ford Fiesta with its Customer / model Illustration: BMW 640i Gran Coupé Illustration: BMW 3 Series Gran Turismo Sport Line facelift arrived on the market. The vehicle Opel / Opel Adam with its new front design offers increased safety and complies with the guidelines is- KIRCHHOFF Automotive is producing an axle The door locking catch and Isofix bracket assembly (for a safe fixation of the child seats to the rear bench seat) sued by Euro NCAP (European New Car As- bracket—a complex drawn part with a thick- are joined using laser welding, a technology offering the benefits of technical performance and precision. sessment Programme), who carries out crash ness of 3.5 mm—for the new Opel Adam. tests with new car types and subsequently There is a left and right version, the differ- For the customer BMW, KIRCHHOFF Automotive has been able to implement several products for the new assesses their safety. ence being in the drawing height. Addition- car models of the 1- and 3-series as well as for the Mini Paceman. Special emphasis was placed on the as- In this context, a new front bumper was de- ally, a bracket is welded on to both parts to pects of integration and weight reduction in the steel front end structure that we developed. In the body veloped, which was supplied by KIRCHHOFF act as a connection point for the brake line. department, we were able to integrate our expertise in the fields of “high-strength steels” and “manufactur- Automotive in collaboration with Shape. It KIRCHHOFF Automotive developed the manu- ability analysis with optimisation of deep drawn components”, e.g. for products such as side impact beams has a roll form design, which was produced facturability of the component in terms of pro- for front and rear, topshell spring supports, and console seat fixings. at the KIRCHHOFF Automotive plant in duction process in conjunction with General Iserlohn/Germany, and installed by Ford in Motors. The very narrow tolerances in the con- Cologne/Germany. nection area of the axle proved to be particularly challenging in this process. K›MOBIL 41 // KIRCHHOFF Automotive KIRCHHOFF Automotive // 41 K›MOBIL

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Present at Auto Shanghai for the third time and in China for six years, KIRCHHOFF Automotive takes advantage of the rapid development and huge potential of the Chinese automotive market.

Between 20 and 29 April, Auto Shang- cluding representatives from German ium compound with a seat shell made hai opened its doors to industry spe- and Chinese manufacturers, found from glass-fibre-reinforced plastic. cialists from around the world as well out about the latest developments as enthusiastic car fans. The trade fair in metallic structural parts and hy- The industry specialists of the future has now become the largest and most brid joints for lightweight automotive were also represented: Over 40 stu- important automotive show in Asia construction. dents from Tongji University of Shang- and therefore also one of the most hai, where KIRCHHOFF Automotive significant international trade fairs for In a separate innovation area, our sponsors the Chair for lightweight German automotive suppliers. This Company showcased selected prod- automotive construction, accepted year, KIRCHHOFF Automotive again ucts providing solutions for simplified the invitation to the trade fair and to welcomed its customers at a light, vehicle structures with constant pas- the KIRCHHOFF Automotive stand. A open-plan trade fair stand with a sur- senger safety levels. Industry specialists workshop on the topic of “innova- face area of 130 square metres over were particularly interested in a hybrid tions and the latest research in the Picture left: visit of Matthias Wissmann, President of the VDA (cen- two storeys. Numerous visitors, in- bumper made from a steel and alumin- field of lightweight construction and tre) | Picture right: Dr. Tony Chen, Vice President Supply Chain Geely K›MOBIL 41 // KIRCHHOFF Automotive KIRCHHOFF Automotive // 41 K›MOBIL

f.l.t.r.: Visit of students of the Tongji University of Shanghai | Simon Stephan (left) und Sam Li (right) are pleased about the From top left to bottom right: Our youngest car enthusiast in the electric race car | Sam Li with Prof. Wang | Booth assistance visit of Zhou Henzhong, Senior Manager Purchasing Chery Jaguar Landrover | Andreas Heine in discussion with Prof. Wang of international | Jenny Gao (centre), Global Sourcing Buyer Renault | Michael Eichert explains innovations in the field of light the Tongji University of Shanghai | Friendly reception by: Simon Stephan, Managing Director KIRCHHOFF Automotive Suzhou; weight construction | Zhou Henzhong (left), Senior Manager Purchasing Chery Jaguar Landrover | Visit of Hitoshi Tajima (2.f.r.) 28 Dr. Thorsten Gaitzsch, CTO and Andreas Heine, Director Communication and Marketing Vice President, Purchasing Mazda Motor China. KIRCHHOFF Automotive Suzhou has received its first order for a cross car beam 29 from Changan Mazda Automobile (refer also to K>MOBIL No. 40, page 35)

joining technologies” provided addi- duction in China only made up nine onstrating the high level of competi- tional incentive to study. The students per cent of all foreign production by tiveness of German OEMs and their found the highlight of the KIRCHHOFF German manufacturers. In 2012, this suppliers. This is an ideal position to Info Automotive stand particularly excit- proportion increased to 35 per cent. hold in order to continue participating ing: an electric racing car that was de- Over one in every three cars that Ger- in the forecast growth of the automo- veloped, built, and used successfully man manufacturers produce outside tive country of China—and a develop- in races by the “Speeding Scientists Germany at international locations is ment that KIRCHHOFF Automotive will Siegen” student team at the University thus manufactured in China. share with its customers. When one trade fair finishes, another one starts: the of Siegen. most important international automotive trade In recent years, the story of automo- Sabine Boehle fair, the 65th International Motor Show (IAA) In 2013, KIRCHHOFF Automotive will bile growth in China has been more Cars, takes place in Frankfurt/Main between open its third location in China at fast-paced than in any other country: 12 and 22 September 2013. Shenyang, thus addressing concerns the passenger car market in China has about increasing order volumes in the grown twenty-fold since 2000—from KIRCHHOFF Automotive will again be represented at Automotive Industry (VDA). Experience the IAA and Chinese market. A long-term com- 614,000 units in 2000 to more than the world’s largest exhibition for vehicle manufacturers find out more about the latest developments in light- parison shows how important China 13.2 million new cars in 2012. At the and their suppliers with a stand covering a surface area weight construction, materials, and joining technolo- has become as a production location same time, German manufacturers of 400 square metres. gies at our trade fair stand in hall 5.1, stand B08. for the German automotive industry: were able to increase their market “The IAA is more than just a trade fair—it is ‘the most in 2000, German passenger car pro- share to more than one fifth, dem- automobile show in the world’”, emphasises Matthias Wissmann, President of the German Association of the K›MOBIL 41 // KIRCHHOFF Automotive KIRCHHOFF Automotive // 41 K›MOBIL

Info

Facts and figures about China as a growth market (Source: VDA)

China’s automotive market is still growing Since 2008 (5.7 million passenger cars), the market volume in China has more than doubled. However, the motorisation rate in China is still comparatively low. The passenger car density is 37 units per 1,000 inhabitants. In comparison: in Germany there are 525 passenger cars per 1,000 inhabitants. In the past year, the Chinese passenger car market grew by 8.4 per cent. Overall, growth of 6 per cent is forecast for 2013, an increase of around 14 million units, thus exceeding the wes- 30 tern European passenger car market by 2.5 million vehicles. 31

German manufacturers increase their market share to more than one fifth Around 30 years ago, German manufacturers were among the first international companies to be active in China, thereby laying the foundation for today’s growth. Since 2009, German OEMs have increased their market share to 21.4 per cent and almost doubled passenger car sales in China with 2.84 million units. In the year to date, the market share has risen to 21.6 per cent in the first two months. This means that more than one in every five new cars that are sold in China today bears a German badge.

Local production is growing Since 2005, German manufacturers have increased passenger car production in China sevenfold to 2.9 million units in 2012. China considers it very important for vehicles to contain as much “local content” as possible. German manufacturers and suppliers have contributed considerably to this in recent years. Thus, certain models, which were classified as German exports one year ago, are now—due to the higher value added proportion—classified as produced in China in statistical terms. This trend is continuing in the current year. China is also becoming more important for Germany as a supplier location. Exports of parts and accessories from Germany to China amounted to an export value of EUR 7.7 billion in 2012, an increase of 30 per cent compared with the previous year’s value. K›MOBIL 41 // KIRCHHOFF Automotive KIRCHHOFF Automotive // 41 K›MOBIL

anniversaries

!; Two th 5 th 2 story One success 50 years of Gametal, 20 years of KIRCHHOFF Automotive in Portugal

50 years Gametal 20 years KIRCHHOFF Automotive in Portugal

32 In 1963, four managers founded over the company and thus started in Cucujães in 1967. From the outset, In the 1980s, the French group of Group and developed rapidly. Al- and parts from the welding stations 33 the company Gametal in Cucujães, its own global expansion. Gametal produced tools and formed companies Bertrand Faure—now Fau- though production in Cucujães had were eventually transferred to a sec- 40 km south of Porto, the industri- components specifically for the auto- recia—acquired Gametal and expand- been increased many times, the loca- ond plant in Ovar, which had also al capital of Portugal. Thirty years After its foundation, production was motive industry, which was still being ed its activities. In 1993, the compa- tion reached its capacity limit at the been extended several times already in later, KIRCHHOFF Automotive took initially carried out in a small building established in Portugal at that time. ny was then sold to the KIRCHHOFF end of the 1990s. In 1999, all presses the meantime. The number of employees grew from the initial 70 to nearly 550 and yearly sales forty-folded.

The combination of German knowhow and Portuguese adaptability are the key to this success. The focus is always on implementing the latest technologies and equipment: forming presses, robot welding, and surface treatment.

This year, after 50 years of Gametal and 20 years of KIRCHHOFF Gametal, the company is celebrating a double anniversary in two respects: two anniversaries, one success story.

Tomás Moreira

The original Cucujães plant (top left) | on the right, the three founders of Gametal, from left to right: Ruy Moreira, Eduardo Costa, José Sá | the two plants today, Cucujães (bottom left) and Ovar (right) K›MOBIL 41 // KIRCHHOFF Automotive KIRCHHOFF Automotive // 41 K›MOBIL

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In December 2010, General Motors awarded the contract for several large structural components for the K2XX platform to Van-Rob. Since that time, the entire Van-Rob family has been fully engaged in the design, development, and product realisation process. The project is the largest product launch in the history of Van-Rob and KIRCHHOFF Automotive.

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The new grille opening reinforcement (GOR) for the K2XX platform

With more than 1.2 million vehicles welds each month on 20 million stamp- complex component made from gal- worldwide, the K2XX platform is the ings and 48 million bought-in parts. vanised steel tubes and stampings, largest platform manufactured by which are laser welded together, e- General Motors in terms of volume, In order to manufacture this volume of coated (CDP), and subsequently rein- from which all pick-up trucks and orders, Van-Rob will invest over USD 34 forced with a structural plastic mould- SUVs are produced (Chevrolet pick- million in machinery and equipment. ing. A new welding process had to be up trucks, GMC pick-up trucks, and Besides many other specialised ma- specifically developed for the galva- Cadillac SUVs). K2XX is also the larg- chines, this includes twelve laser weld- nised material in the GOR laser weld- est product launch in the history of ing cells, 20 MIG welding cells, nine ing process. Nevertheless, with a great Van-Rob and KIRCHHOFF Automotive. spot welding cells, six assembly cells, deal of initiative and commitment, Four General Motors assembly plants and 61 projection weld cells, as well as Van-Rob was able to satisfy the cus- will be supplied with support from many other specialised machines. Our tomer requirements and expectations. seven Van-Rob plants in Canada, the teams are working with great com- The end of the Mazda 6 programme US, and Mexico, including a new JIT mitment towards the successful im- was a cause for concern at Van-Rob plant in Dallas, Texas. Once in full plementation of this massive project. Tecumseh. Employees were therefore production Van-Rob will produce all the more pleased to hear that Van- The new 2014 pick-up truck from General 2,780 km of laser weld, 720 km Our biggest challenge is the grille Rob had been selected as a supplier for Motors built on the K2XX platform of MIG weld, as well as 9.5 million spot opening reinforcement (GOR), a General Motors’s K2XX programme. K›MOBIL 41 // KIRCHHOFF Automotive KIRCHHOFF Automotive // 41 K›MOBIL

$2+%, -8%

In the middle of 2013, Van-Rob in Manchester, Tennessee will start producing stampings and welded assemblies for the new BMW X5 that will come out in November 2013.

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Since then, employees at Tecumseh located nearby in Arlington. However, Dallas has already started a recruit- have received training in laser safety, it will still be many months until the ment programme for graduates with quality, and weld inspection. e-coating system in the Dallas plant is the required technical degrees. fully installed and operational. At least All employees have rapidly acquired 150 jobs will be created in the Dallas- Jeff Molyneaux, Christi Williams extensive knowledge about laser weld- Fort-Worth Metroplex within the scope ing. The new Van-Rob plant in Dallas of the Van-Rob K2XX programme. will also play a part in the launch of Therefore, in partnership with local Exemplary chart of the first components that K2XX. Dallas will be producing the universities and technical schools, Van-Rob delivers for the new BMW X5, using grille opening reinforcement, radiator Van-Rob the example of the current BMW X5 support, and C-pillar parts from stampings supplied by other Van-Rob plants. These parts will be e-coated, la- The BMW X5 will be produced in the While Van-Rob in Manchester alrea- are screwed in when the vehicle is ser welded, and MIG assembly plant in Spartanburg, South dy supplies almost all US automotive assembled. welded here before Carolina, which opened in 1994 and manufacturers directly, including Ford, being delivered to the builds all of the company’s SUV models General Motors, Honda, Mazda, Nissan, The investment made in the Manches- General Motors plant for worldwide distribution. Toyota and Volkswagen, this is the first ter plant and the expansion planned for BMW order for this location. It involves 2014 offer our growing customers and Based on the close working relation- the production of stamping parts and Van-Rob the opportunity for further or- ship between BMW and KIRCHHOFF components for both body assembly ders or the intensification of the coope- Automotive in Germany, Van-Rob es- and general assembly. ration in North America. tablished partner-like connections with the Spartanburg operation. The launch In Manchester, all parts are made in Michael Kobiske, Jeff Grubisich of the new BMW X5 offers the ideal stamping presses up to 600T and sub- Eleven different samples of the opportunity to expand this new sup- sequently joined to bigger components General Motors K2XX platform ply chain and to support BMW USA as using spot or MIG welding technolo- competitive partner. gies. The parts that are then coated K›MOBIL 41 // KIRCHHOFF Automotive KIRCHHOFF Automotive // 41 K›MOBIL

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38 39 Van-Rob Manchester, Tennessee supplies 29 stampings for the all-aluminum frame of the new Corvette Stingray.

With the new Corvette Stingray the seventh generation in the 60 years of the marque’s life is newly introduced in 2014 in the car showrooms

The seventh generation Corvette will high-tech materials and features to method for Spot Welding of aluminum be an all-new model for 2014 which provide performance rivaling cars five which puts Van-Rob Manchester on went into production in June. Van- times the price. The upgrades to the the cutting edge of this technology. In Rob produces stampings and welded body, interior, power train and chas- addition to the new robotic Spot Weld assemblies for the General Motors sis/suspension are so significant that cell, Van-Rob invested in a new robotic Corvette assembly plant in Bowling General Motors has re-introduced the MIG weld cell. Green, Kentucky. Stingray name last used in 1976. Michael Kobiske Van-Rob Manchester has been a Cor- All parts for this Corvette are various vette supplier for several years and grades of high strength aluminum. is Tier 1 to nearly all US automotive The new chassis is 99 pounds (45 kg) manufacturers. The Manchester plant lighter than the previous generation’s produces metal stampings and various steel frame but 57per cent stiffer. The welded subassemblies. various aluminum pieces are welded, using Spot, MIG or Lasers plus adhe- The new C7 model is taking technol- sives to create the larger assemblies. ogy to a new level by using an all- left: Usage of the new General Motors proprietary method for Spot Welding of aluminum space frame in their base Of significance to Van-Rob, we will aluminum | right: C7 Corvette all-aluminum frame model along with numerous other use a new General Motors proprietary K›MOBIL 41 // KIRCHHOFF Automotive KIRCHHOFF Automotive // 41 K›MOBIL

Commissioning of special welding facilities for the MAN Front Underrun Protection in Iserlohn/Germany—Run @ Rate on 13–14/05/2013

Since the start of 2013, new facili- LEWA has already trained and instruct- ties were commissioned at Iserlohn: ed six system operators, two special welding facilities for the fitters and four programmers new Front Underrun Protection in preparation for the start (FUP) product for the customer of FUP series production (incl. MAN. pedestals). Now the objective is to achieve the pre-defined cycle The machine was developed and time of 4.5 minutes at a planned The CNC bending line is the largest of constructed by LEWA based in At- availability of 85 per cent. An impor- the multiple lines within Van-Rob and tendorn/Germany in conjunction with tant milestone was the visit by our is a custom, modular configuration KIRCHHOFF Automotive. Due to the customer MAN from Munich on 13 exceptional properties of the FUP, the and 14 May: the progress with the special welding facilities are larger facilities has been assessed and the than conventional welding systems. entire process chain has been au- 40 dited. No discrepancies were de- 41 The FUP is 2,324 mm in length, weighs tected and a positive summary 38.6 kg, and has a weld seam measur- was drawn. ing 9,500 mm in length. Consequent- ly, the product is unique at KIRCHHOFF Mario Kranklader Automotive in terms of dimension. For (2?(/( the coming years, it is forecast that approximately 50,000 FUPs including pedestals will be called up annually by MAN. With a turnover of an estimated EUR 7.5 million, this has considerable The bending line is the largest of the multiple lines within Van-Rob and is a custom, impact on the location’s figures. modular configuration designed for the specific customer applications.

At the end of 2012, Stefan Keller, now Head of the Iserlohn press shop, held a first KAPS workshop about welding (PPS1). After introducing the known standards TPM and 5S, the focus The front underrun protection for the MAN TGX and TGS, a product that shifted to compiling a standardised KIRCHHOFF Automotive is in charge of during all phases of the product life cycle, workflow. from design and development through prototyping to series production Approximately two years ago, Van- cific customer applications. Working gained valuable experience in CNC Rob Tecumseh installed the first CNC with the customer design teams early bending over the last 2 years and look bending line to support two major in the program, our product engineer- forward to future applications for this high volume programs for General ing group was able to incorporate the unique process. Motors and Chrysler. Van-Rob was necessary design features required for successful in winning this business be- CNC bending. John Hamel cause of the advantages of low tool cost and dimensional stability provided The line consists of 6 modules that by CNC bending. The bending line is transform the coil steel into a finished the largest of the multiple lines within product. All aspects of the line are Van-Rob and is a custom, modular monitored through an integrated con- configuration designed for the spe- trols system. The Tecumseh team has K›MOBIL 41 // KIRCHHOFF Automotive KIRCHHOFF Automotive // 41 K›MOBIL

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B pillar At the end of January, Škoda management invited its most important and best suppliers A pillar to Seville. At the World Dealer Conference (WDC) it honoured the top 5 per cent of a total of 680 suppliers for the new Škoda Octavia—and among them was KIRCHHOFF Automotive.

A and B pillars with reinforcements 42 for the latest Škoda Octavia model 43

The new Škoda Octavia

Chief Technology Officer, Dr Thorsten vices. The smooth launch of production The production of the new Octavia Gaitzsch attended the event on be- of the Octavia, the “heart of the Škoda was successfully launched. In 2018, half of KIRCHHOFF Automotive and brand”, is the basis for the continued Škoda wants to have 1.5 million new thanks all of the employees involved very positive development of the brand. vehicles registered, which represents for their exceptional commitment Karlheinz Hell and Michael Oeljeklaus, an increase of 50 per cent. A good to this project. “Our company can, Škoda executives responsible for Pro- quarter of this growth is to be achieved should, and will also profit from this curement and Production, and Dr Man- with the Octavia. Also for KIRCHHOFF growth, because Škoda emphasises fred Borth, Director of Quality Manage- Automotive as a top supplier this a long-term working relationships with ment, also praised the present suppliers bright look-out. its top suppliers.” The colleagues in in attendance for their work. Hungary manufacture A and B pil- Anja Marcus lars and reinforcements for the latest Featuring one-on-one meetings with Octavia model. Škoda executives, a short trip in the new Octavia through Andalusia, and Prof. Dr Winfried Vahland, Chairman of interesting discussions with the most the Executive Board at Škoda, thanked important German dealers, the day the suppliers for their exceptional ser- was planned and organised perfectly. K›MOBIL 41 // KIRCHHOFF Automotive

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44 45 Investment of EUR 21 million in total in the production of complex body parts

Following more than twelve The considerable rise in demand for months of project planning, series thin-walled but high-strength compo- production at the first hot forming nents moved KIRCHHOFF Automotive line in Hungary started in the mid- to invest a total of EUR 21 million dle of January. in the production of these complex On the facilities measuring 65 metres body parts at this location over a pe- in length, in future A and B pillars for riod of three years. Already in sum- Škoda, Daimler and BMW, floor assem- mer a second hot forming line will bly parts for Audi as well as bulkheads be commissioned and by the end for Volkswagen will be produced. of 2014, a total of eight state-of- the-art 3-D laser cutting machines Last year, over the course of several will be added. months, employees from Hungary were trained in Iserlohn/Germany From 2015, approximately 600 em- where this technology has been in op- ployees will be working at Esztergom/ eration already since 2009. Fitters, tool Hungary. The headcount at the plant makers as wells as quality assurance will thus have increased by almost and maintenance experts are now able 200 per cent within two years. An enor- to deploy their knowledge on site. mous effort, which is systematically Experts from Iserlohn and Attendorn/ supported from the locations in Poland Germany continue to provide assis- and Germany. tance to the Hungarian colleagues. top picture: a look into the hall with the two new hot forming lines | centre- Stefan Leitzgen right picture: continuous roller hearth furnace of the first hot forming line | center and bottom pictures: employees from the hot forming department KIRCHHOFF Automotive // 41 K›MOBIL

Establishment of an energy management system in accordance with DIN EN ISO 50001 at KIRCHHOFF Automotive Deutschland

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The energy transition in Germany towards which they should orientate at the Attendorn site in Germany is and associated price increases for themselves. These specify how much Markus Hundt, who documents all the generated energy put a strain on energy should be saved. current energy projects at the location both consumers and the economy and monitors their implementation. alike. At the heart of the specification for en- Energy teams were formed at the indi- You do not have to be a prophet to ergy management DIN EN ISO 50001 vidual locations as part of the energy predict that the re-orientation in terms is the continuous improvement in en- management campaign. Their remit is of energy generation will only succeed ergy savings. Companies should be in to identify, analyse, and where pos- if society starts to use energy more the position to increase their energy sible, exploit potential savings within considerately at the same time. And efficiency and optimise energy usage. processes. industry can make a key contribution KIRCHHOFF Automotive Deutschland towards this change. There are often GmbH therefore decided to obtain If we are successful in integrating all major potential energy savings to be certification in accordance with DIN these energy-saving efforts into our made within companies. The Ger- EN ISO 50001 for all locations in May daily work routine, then we will have man Federal Government estimates 2013. created the basis for increased efficien- EUR 10 billion/year. cy and a more sparing use of energy. To this end, an energy management In order to encourage companies to system based on a manual, work in- This would thus lead to the in-house save energy or be more efficient in structions, and an Energy Control Sys- energy revolution at KIRCHHOFF its usage, the legislator is offering tem (ECS) was introduced, with the Automotive Deutschland. tax relief. However, certain criteria help of which energy consumption must be met. As a result, the tax cap throughout the Company is docu- Uwe Suchland in line with the electricity and energy mented every 15 minutes. tax legislation has been linked to the introduction of an energy manage- Uwe Suchland was named Energy ment system in accordance with DIN Management Officer for KIRCHHOFF EN ISO 50001 as of 2013. Additionally, Automotive Deutschland GmbH by companies are set efficiency targets, the Executive Board. Energy officer K›MOBIL 41 // KIRCHHOFF Automotive KIRCHHOFF Automotive // 41 K›MOBIL

Knowledge as a competitive factor: committed, satisfied, and qualified employees contribute to the Company’s success and have a positive effect on competitiveness.

Training on the job: employees from the Logistics department are trained in the Employee training and development is our Company uses local, requirement- the largest foreign location, KIRCHHOFF various tasks at individual workstations increasingly becoming a competitive oriented employee qualification and Automotive Polska, and the most re- factor and is also taking on more im- training. We would like to illustrate the cent location, KIRCHHOFF Automotive 48 portance at KIRCHHOFF Automotive. different methods that are used by focus- România. 49 ing on two KIRCHHOFF Automotive On the one hand, central programmes locations: Our most recent plant in Craiova, process orientation and continuous opinion of our employees matters to for the promotion of particularly Romania, which was opened in improvement. To improve teamwork us”, stresses Carmen Iacob, Manag- talented employees are being April last year, is already using and awareness of sustainable actions, ing Director, KIRCHHOFF Automotive developed (see K>MOBIL win- various methods of employee train- all departments participate in spe- România. “Their feedback forms the ter edition, page 51). On the ing and on-going development. cial training programmes. The aim of basis for the creation of a pleasant other hand, A knowledge transfer programme was these programmes is to motivate em- working environment and corporate therefore developed to outline the ployees to behave proactively towards culture. A company’s most valuable processes and tasks of different work- the environment and to conserve re- asset is its qualified and committed stations. This enables employees get sources—because it is the attitude employees. We can only be a reliable to grips faster with other fields of re- that makes the difference. partner and fulfil the requirements sponsibilities and respond more flexibly of our customers flexibly and in a to changing customer requirements. This programme, which has been im- motivated manner if we have a well- plemented worldwide to improve the trained workforce.” Employees in the technical depart- leadership culture in senior and middle ments receive specific training in order management, has already started in Carmen Iacob to improve their technical knowledge. its second round in Romania. “Learn From the outset, the Romanian plant to Lead” communicates and provides has followed the lean production prin- training in the KIRCHHOFF Group ciples; to this end, it defined processes leadership principles. and standards and introduced visual checks. The long-term objective is a Employee surveys are carried out at stable lean management system with regular intervals. “This is because the

Pleased with the success of the training on the operation of our PLM (Product Lifecycle Management) systems (f.l.t.r.): Iuliana Micu (Sales), Diana Gingioveanu (Quality Control), Ileana Barbu (Controling), Benjamin Müller (Project Manage- ment) und Sabin Barbu (Production Engineering) K›MOBIL 41 // KIRCHHOFF Automotive KIRCHHOFF Automotive // 41 K›MOBIL

Completing a doctorate alongside their jobs: Robert Krupa (left) and Paweł Bałon

In 1998, KIRCHHOFF Automotive universities and supports its employees cation, together with local authorities 50 founded its first Polish plant in in part-time on-going development. and UTC Sikorsky Aircraft Corp. 51 Mielec. Since then, the improve- To this end, KIRCHHOFF Automotive ment of skills and employee works closely with the University of In the academic year 2012/2013, 29 of satisfaction has been an inte- Mining and Metallurgy in Krakow. This KIRCHHOFF Automotive’s employees gral component of the corporate is one of the oldest and best-known started a part-time engineering course philosophy. technical universities in Poland and, at the technical university in Mielec. since 2009, has also operated a loca- The prerequisites for the course are a Janusz Sobo , Executive Director of KIRCHHOFF Automotive Poland (3rd from right), Thus, KIRCHHOFF Automotive in Po- tion in Mielec. KIRCHHOFF Automotive relevant apprenticeship, at least three welcomes high-ranking representatives from the Stanisław Staszic University of Min- land cultivates partnerships with local supported the construction of this lo- years of professional experience, and ing and Metallurgy in Krakow and from Polish aircraft plants, as well as the Mayor, to KIRCHHOFF Automotive in Mielec.

a good command of English. In this Paweł Bałon, a designer in the tool often work within the profession. 30 academic year, five of these students manufacturing department, is work- KIRCHHOFF Automotive employees in will be awarded their engineering de- ing on his doctorate in the Faculty of Poland have already completed their gree by the Faculty of Engineering and Engineering and Robot Technology at postgraduate courses. Their perfor- The Rector of the University of Mechanics. the University of Mining and Metallur- mance deserves particular recognition Mining and Metallurgy, Prof. Ta- gy in Krakow. His dissertation subject, as it was achieved outside their regular deusz Słomka (centre of image) Two colleagues are even completing “Stamping tool planning and stamping work activities. and the Dean of the Faculty of doctorates alongside their jobs. Robert tool analysis using FEM”, leans strong- Mechanical Engineering and Ro- Krupa, an engineer in the tool manu- ly on his professional experience. This Janusz Sobo botics, Prof. Antoni Kalukiewicz facturing/CME department, is in his work focuses on the investigation of (right in image), award a service second year of studies at the technical steel springs during cold forming. medal to Janusz Sobo , Execu- university in Freiberg. In his disserta- tive Director of KIRCHHOFF tion, he is investigating the stamping Employees can continue their educa- Automotive Poland behaviour of high-strength steel at tion on postgraduate courses in the high temperatures. He is able to ap- areas of management, lean manufac- ply his experience in his professional turing, project management, welding area of work, the processing of high- technology, CAD systems, etc. Lectures strength steels, to this topic. take place at weekends and lecturers KIRCHHOFF Automotive // 41 K›MOBIL

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36 months of KAPS—towards a leaner Company

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The KIRCHHOFF Automotive stand at the second “Forum for Technology and Science” in Rzeszów, f.l.t.r.: Michał Kulpa (Process Engineer), Lidia Stachura (Sales Representative), Bartosz Jałocha (Personnel Officer), Bogusław Wytoszy ski (Assistant to the Executive Board) June 2010 was the starting point for ing and workshop documentation had Seven basic principles should thereby perhaps the largest internal project been developed in seven languages communicate correct leadership be- at KIRCHHOFF Automotive. With and over 3,500 employees had been haviour. Role plays created by the the support of Porsche Consulting, successfully trained. With 5S, SMED, KAPS experts themselves support the the plan was to implement a stand- and TPM workshops, considerable in- training of all managers. ardised production system in order creases in productivity were achieved These three KAPS modules have led to achieve a sustainable increase in in all plants and attention was given to the successful and sustainable im- efficiency. on avoiding waste. plementation of the new production What has been achieved in the past systems in all plants. One-piece flow three years? How far has KIRCHHOFF The permanent implementation start- projects, the conversion from forklift 6525 Automotive now come in the process ed in September 2011 with the intro- to milk run supply in production, and of transforming into a lean company? duction of a standardised shop floor changes to the layout have significant- management system. Regular team, ly altered the appearance of almost all Everything started with the definition department, and plant meetings with plants. 52 of the 7 KAPS principles, which form fixed agendas and at set times ensure 53 KIRCHHOFF Automotive in Poland is committed to technical training in the region. the basis of the change process, and that the focus is on the standard pro- After 36 months, an idea has turned A new “Regional Transfer Centre for New Technologies” develops junior talent. the preparation of a self-sustaining duction process and daily deviations into reality. KAPS organisation. Experts in all plants from this process. as well as central consultants are still at Since the beginning of the year, the Stefan Leitzgen the control centre today and are per- KAPS leadership behaviour has sup- manently driving forward continuous plemented the KAPS toolbox and the changes. Within twelve months, train- KAPS shop floor management system.

In Poland KIRCHHOFF Automotive has brought their application documents potential KIRCHHOFF Automotive em- long stood for a solid business partner and held intensive discussions with ployees in Poland. Trainees can famil- and supplier, but also for a trustwor- Polish HR representatives. High-rank- iarise themselves with technologies KAPS thy partner in the field of science and ing political representatives also vis- and processes in the Company during Leadership Behaviour education. ited the KIRCHHOFF Automotive stand their training and put their knowledge in Rzeszów, among them Stanisław in practice while they are there. The latest management methods, lo- Sie ko, the town’s Deputy Mayor, gistics processes, and production pro- Teresa Kubas-Hul, President of the Re- KIRCHHOFF Automotive has estab- cesses, as well as its core Research gional Assembly, and Mirosław Karapy- lished itself as an employer brand in 1. I respect standards and Development department make ta, President of Podkarpacie Province. Poland and has therefore created a 2. I act with respect and fairness the Company a particularly attractive sound base from which it can continue 3. I communicate clearly employer. This is demonstrated by its In December 2012 the “Regional Trans- finding and retaining qualified skilled 4. I empower and develop my team successful exhibitions at various HR fer Centre for New Technologies” was personnel in the future. 5. I share my knowledge and technical trade fairs in Poland: opened in Mielec, whose planning and 6. I promote continuous improvement numerous interested parties at the realisation KIRCHHOFF Automotive Janusz Sobo 7. I am a good example engineering trade fair in Krakow and has supported from the beginning on. The optimisation of corporate processes is one of the targets of KAPS, the the “Forum for Science and Technol- This is not only a training centre, but KIRCHHOFF AUTOMOTIVE PRODUCTION SYSTEM. This is on what the teams ogy” in Rzeszów in the past year also provides qualifications to selected are working intensively. K›MOBIL 41 // KIRCHHOFF Automotive

KIRCHHOFF Automotive receives the “Excellent Training Company” award, which intends to provide young people with information regarding the quality of training companies in our region.

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We value the opinion of our appren- and regularly adapt the content of respect. This superb achievement tices. We can only improve apprentice- our training to meet new require- is due to our trainers and specialist ships at KIRCHHOFF Automotive with ments. The assessment of our ap- training coordinators, who look af- their feedback. prentices, who graded us an excel- ter our new young talent every day. lent training company, shows that The management consultancy “Er- we have the correct approach in this Lisa Kitterer tragswirtschaft” created the training company certification in order to give young people information about the quality of training companies in our region. Apprentice Video Project Our apprentices were asked questions on subjects such as “how happy are you with your training company?” and “what other opportunities does your The Apprentice Video Project entered a new round exactly one year company provide?”, as well as “what ago. Two groups of apprentices had the task of presenting the topics could be improved?”. “general apprenticeship at KIRCHHOFF Automotive” and “industrial mechanics at KIRCHHOFF Automotive” in a video. However, before The survey showed that the opportu- the actual filming could start, the apprentices learnt how to use the nity of independent study and the fact cameras correctly in various workshops. that apprentices are highly regarded within the Company were two par- When they actually started filming, they improved their project man- ticularly positive aspects. It was also agement skills. This phase of the project was a real challenge and evident that our apprentices identified they really had to push themselves to their limits at times. And that strongly with the Company. was precisely the objective—to learn not to give up when things become difficult. The final versions of both videos have been produced We are constantly learning more and are available on our website. about the training of young people K›MOBIL 41 // KIRCHHOFF Automotive KIRCHHOFF Automotive // 41 K›MOBIL

6255

The HR marketing team is making a huge effort to find qualified young talent

For pupils, students, or experienced This is why we were represented once out about jobs and career opportuni- professionals, image has a massive again in April this year on a stand at ties at KIRCHHOFF Automotive. With influence when choosing a compa- the Soest Career Day and enjoyed the support of our trainers, they were 56 ny as an employer. Our HR market- many interesting discussions. Some even able to produce their own long- ing team has invested a great deal of those who were interested came case clocks. of energy in a variety of measures directly with specific job applications, to position KIRCHHOFF Automotive others found out general information Our participation at the VIA joint stand as an attractive employer in the job about career paths and our Company. at the Olpe job fair in May has already market and attract qualified young This year’s “Girls Day” in April was become a tradition. This is where talent. again an overall success. 26 girls found pupils and parents also have the op-

portunity to discover more about ap- reer coordinators in the Atterndorn the exciting path to finding the right prenticeship and career opportunities and Iserlohn area, we have discussed job”, stresses Lisa Kitterer, Team Man- at KIRCHHOFF Automotive. “Overall, the challenges that the current and fu- ager HR Development/HR Marketing/ we conducted more than 160 con- ture shortage of skilled workers poses Apprenticeship. sultations this year. This job fair dem- to all stakeholders. onstrates time and time again that Lisa Kitterer, Tatjana Schutte pupils and parents are very interested Various measures came out of these in this type of service”, summarises meetings: career orientation work- Michael Isphording, head of training at shops or communication training, par- Attendorn. ticipation at parent and information evenings, or workplace visits by pupils The shortage of skilled workers is a and teachers. “It is not only about pro- major topic at the moment. We are moting KIRCHHOFF Automotive as an therefore focussing on personal con- attractive employer. We are also inter- tact with schools, in addition to our ested in assuming our social responsi- Left: Olpe Job Fair | right: our team at the Soest Career Day, existing activities. In many individual bility and, together with parents and f.l.t.r.: Lisa Kitterer, Anna Knappstein and Tatjana Schutte meetings with head teachers and ca- schools, supporting young talent on 58 59

Custom-made cars— for handicapped people. 58-63 K›MOBIL 41 // KIRCHHOFF Mobility KIRCHHOFF Mobility // 41 K›MOBIL

f.l.t.r.: Employees from REHA Group Automotive GmbH & Co. KG with their Manag- ing Director Uwe Hausdorf (far right) | Bright exterior appearance of the new REHA branch with adjacent light-filled workshop with ample space for new challenges More room for more service

The move of the REHA Group Automotive headquarters to new business Since the end of 2012, the Hilden ties can now be easily adapted to have is always a parking space right in front premises amalgamates two production locations and optimises processes. company headquarters of the REHA high roofs without any manoeuvring. of the entrance. It is now even easier Group Automotive have been relocat- With the move, long work and trans- to get to REHA using public transport ed to their new buildings at 5 Nikolaus port routes resulting from split manu- too. It only takes a few minutes to get Otto Strasse in Hilden. Overall, 250 facturing locations have also become from the nearby, wheelchair-accessible square metres of office space on two a thing of the past. city train station (S-Bahn) to the REHA floors and over 700 square metres of Group Automotive headquarters. production space are now available. The entrance to the premises is now completely at ground level, enabling All in all, this is a clear improvement The new location therefore provides better access for customers with lim- for both employees and customers. increased space and better ways of ited mobility. This already starts with using this space. With this amalgama- the journey to REHA. Located cen- Rolf Mättig tion, twice the number of employees trally between the A3, A46, and A59 now work together on various pro- motorways, it is possible to reach the jects. In the new workshop, vehicles REHA Group Automotive directly by for transporting people with disabili- car from the motorway exit and there K›MOBIL 41 // KIRCHHOFF Mobility

REHA Group Automotive and PRUCKNER rehatechnik are joining forces for the benefit of their customers.

62 Since the start of the year, PRUCKNER K>MOBIL: What makes PRUCKNER ners provide us with the technical GM Thomas Pruckner: Now we are K>MOBIL: Mr Pruckner, many thanks 63 rehatechnik GmbH in Tresdorf/Austria rehatechnik unique? basis for tailored solutions that give able to implement plans that I had for the interview and information. has been a majority-owned mem- our customers maximum freedom to made a long time ago more quickly K>MOBIL would like to wish you a ber of the REHA Group Automotive GM Thomas Pruckner: We originate shape their lives both privately and and to a far better degree. At the good start and continued success in headquartered in Hilden/Germany. and have gained most of our experi- professionally. same time, products and solutions the REHA Group Automotive! Thus, the REHA Group Automotive ence from the active driver sector in from the KIRCHHOFF Mobility sector, has systematically expanded its sphere supplying tailored solutions. We are K>MOBIL: How are you benefit- particularly in the passive driver sector Dr. Axel Panne and range of activity. Following the used to satisfying our customers by ing from joining the REHA Group for family and trade, are now available acquisition of Jelschen Behinderten- going beyond the common-place Automotive? to us too. fahrzeuge GmbH last year, this latest solution. acquisition means that an additional Our goal is for our customer to drive company with more than 20 years of home with “his” solution. At this, experience in converting vehicles for PRUCKNER rehatechnik is one of the disabled people and the elderly is join- few full-range providers in Austria. ing the Group. Info Our excellent, tailored customer ad- K>MOBIL held its first interview with vice, the spatial possibilities within the the General Manager, Thomas Pruckner. building, and the excellent accessibil- ity thanks to our close proximity to the Contact: K>MOBIL: Why does PRUCKNER new Autobahn ring road in Vienna PRUCKNER rehatechnik GmbH rehatechnik become a new member of Thomas Pruckner provide us with a unique position. Schuster Straße 1 the REHA Group family? A-2111 Tresdorf This was taking the next systematic K>MOBIL: Which companies have T + 43-2262-721 40-0 GM Thomas Pruckner: We have in- step, which has occurred only be- you collaborated with until now? F + 43-2262-721 40-19 tended to separate the dealership and cause of the integration into the REHA [email protected] rehabilitation technology for quite Group. For me personally, this has GM Thomas Pruckner: We have been Facebook some time, especially as this busi- been a very positive development, as working as direct partner with many facebook.com/PrucknerRehatechnik ness has appeared as an independent I see many more expansion and de- well-known equipment suppliers such Youtube brand to the outside world for several velopment opportunities in the REHA as Veigel, Autoadapt, and Guidosim- youtube.com/user/PrucknerRehatechnik years now. sector than in pure automotive sales. plex for some time now. These part- Pruckner team from left to right: Manfred Seidl, Consulting; Thomas Pruck- www.rehatechnik.co.at ner, General Manager and Alexander Mixa, Consulting/Customer service 64 65

When function and effect are in line. 64-71 K›MOBIL 41 // WITTE Werkzeuge WITTE Werkzeuge // 41 K›MOBIL

New product High standard— for special work constantly maintained

WITTE Werkzeuge develops Impact-Bit 2VBMJUZNBOBHFNFOUTZTUFNGSPN8*55&8FSL[FVHFDFSUJGJFEJOBDDPSEBODF XJUI*40GPSZFBST

What is now regarded as a matter of ISO 9003 in 1992 and with 9001 dur- course was just a marketing instru- JOHUIFGPMMPXJOHZFBS"UUIFTUBSUPG NFOUZFBSTBHP8*55&8FSL[FVHF 2013, the “Federal Materials Testing is one of the first companies to have Office North Rhine-Westphalia” suc- JUT RVBMJUZ NBOBHFNFOU TZTUFN DFSUJ DFTTGVMMZ DPODMVEFE BO JOTQFDUJPO PG GJFE CPUIXJUIJOUIFUPPMJOEVTUSZBT UIF2.TZTUFNJOJUTUXFOUJFUIZFBS XFMMBTXJUIJOUIF,*3$))0''(SPVQ Frank Rohlfs, Oliver Fries 66 In 1992/93, the Materials Testing Of- 67 fice North Rhine-Westphalia as a re- HJPOBM BVUIPSJUZ XBT POF PG UIF GFX iOPOQSPGJU DFSUJGJDBUJPO PGGJDFTw "QBSUGSPNUIFJSFDPOPNJDOFVUSBMJUZ UIF BVUIPSJUZT FYQFSUJTF JO NBUFSJ als testing made MPA-NRW an obvi- PVT DIPJDF 5IF BVUIPSJUZ BDDSFEJUFE WITTE Werkzeuge in accordance with

Professional cordless screwdrivers t JOEJWJEVBMUPSTJPOTIBQF t UIFDPNCJOBUJPOPGBQFSGFDUMZJOUF are becoming ever more powerful t QBSUJDVMBSMZFMBTUJDNBUFSJBM grated torsion range and controlled and require special bits. We have de- t TQFDJBMUFNQFSJOH IBOEMJOHPGUIFUPPMJOQSPYJNJUZPG veloped the WITTE Impact-Bit spe- the screw cifically for work with these tools. The compact design with a length of 38 mm enables: Oliver Fries Compared with conventional bits, the t UIF EJSFDU VTF JO BO JNQBDU TDSFX Impact-Bit has an increased service life driver without the use of a bit holder thanks to: K›MOBIL 41 // WITTE Werkzeuge

Screwdriving tools—for professionals and discerning home improvers

68 69 8*55&8FSL[FVHFBMXBZTIBTUIFGJUUJOHBOETPQIJTUJDBUFETDSFXESJWJOHUPPM

Securely tightening and loosen- FOE VTFST BMJLF QBSUJDVMBSMZ TPQIJTUJ- tooling expertise, these solutions unite ing tight screw connections—these cated, superior, and effective tooling comfort with performance thanks to have been the key themes on which TPMVUJPOT UIFJS EFTJHO BOE DIPJDF PG NBUFSJBMT WITTE screwdriving tool develop- ers have been working on relent- Broad range of screwdrivers (1) Power in your hand lessly for decades. #ZNBJOUBJOJOHB WITTE has the right hand tools for All models in the PROTOP II and close contact to the market and users, wherever screws must be tightened or MAXXPRO series have the tried-and- OFXJEFBTBOEJOOPWBUJPOTBSFBMXBZT MPPTFOFE"QBSUGSPNDMBTTJDUPPMTTVDI UFTUFE USJBOHVMBS EFTJHO 5IJT BDDPN- emerging, which WITTE Werkzeuge as the traditional screwdriver with NPEBUFT UIF IBOET JEFBM BOHMF PG TZTUFNBUJDBMMZJNQSPWFTJOEFUBJM beech handle and continuous blade, a SPUBUJPO BOE FOBCMFT BO FBTZ comprehensive programme for electri- but powerful screwing action with a Focus on user benefit cal engineering and electronics (VDE), NJOJNBM BNPVOU PG DPOUBDU QSFTTVSF WITTE screwdriving tools (screwdriv- there are also precision, T-handle, and Thanks to this optimised handling, a ers, bits, and bit boxes) cater for both PGGTFUTDSFXESJWFSTBWBJMBCMF fixed link between the head of the QSJWBUFBOEQSPGFTTJPOBMVTFSTCZPGGFS- TDSFX BOE UIF CMBEF UJQ JT GPSNFE JOHBTNBOZCFOFGJUTBTQPTTJCMF"TB Innovation highlights The materials are selected such that SFTVMU UIF$PNQBOZGPDVTFTPOPWFSBMM Two highlights of the WITTE screw- screwdriver and hand form a unit DPODFQUTUIBUTJNQMJGZXPSLBOENBLF driver range are the PROTOP II and BOE BOZ TMJQQJOH JT QSFWFOUFE 5IF it more comfortable and safer to ex- MAXXPROTFSJFT#PUITFSJFTBSFUIF PROPTOP II plus and the MAXXPRO FDVUF*OTPEPJOH UIF$PNQBOZIBT product of close co-operation with plus are equipped with a special established itself as a specialist global JOEVTUSZ EFTJHOFST BOE GBDVMUJFT GPS non-slip micro-fibre coating, which QMBZFSUIBUPGGFSTUSBEF JOEVTUSZ BOE FSHPOPNJDT $PNCJOFE XJUI 8*55& FOBCMFT XPSL FWFO JO EBNQ BOE PJMZ K›MOBIL 41 // WITTE Werkzeuge WITTE Werkzeuge // 41 K›MOBIL

1 2

DPOEJUJPOT 8*55& 8FSL[FVHF JT UIF (5) Screwing at angles #09 #*54/"1 130#*5#09 5IFTFBSF POMZ QSPWJEFS PO UIF NBSLFU PGGFSJOH The WITTE offset screwdriver (hexa- FBTZUPUBLFXJUIZPVBOEPGGFSQSBDUJ- a screwdriver with cork insert in the gon, Torx, triple-square) are manufac- cal handling for removing and swap- HVJTF PG UIF ."99130 OBUVSF $PSL UVSFE GSPN B QBSUJDVMBSMZ IJHIRVBMJUZ QJOHCJUTJOBOVODPNQMJDBUFENBOOFS JT B OBUVSBMMZ SFOFXBCMF SFTPVSDF JT chrome-vanadium steel to enable pow- The COMBIT-BOXES 7 and 17 can also QBSUJDVMBSMZTMJQSFTJTUBOU BOEBCTPSCT FSGVM ZFU TBGF XPSL 1BSUJDVMBSMZ QSBDUJ- be used as a hand-held screwdriver— NPJTUVSFPQUJNBMMZ5IFIBOEMFTIBQFT DBM JT UIF TQFDJBMMZ EFWFMPQFE IPMEFS UIFNBHOFUJDIPMEFSJTTJNQMZQVTIFE GPS CPUI TFSJFT IBWF OPU TJNQMZ CFFO that keeps all offset screwdrivers in one into the box housing, which acts as a scaled in the various sizes but been DPNQBDUTFU&BTZUPPQFO UIFIPMEFS IBOEMF 3 4 TQFDJGJDBMMZDPODFJWFEBOEEFWFMPQFE enables the individual offset screwdriv- FSTUPCFUBLFOPVURVJDLMZBOEFBTJMZ (8) RATCHDRIVE and BITDRIVE (2) Quality blades and blade tips The RATCHDRIVE is an all-in-one bit 0OFPGUIFRVBMJUZBUUSJCVUFTPG8*55& (6) The complete WITTE bits range CPYBOESBUDIFU5IFNBHOFUJDIPMEFS TDSFXESJWFST BSF UIF QSFEPNJOBOUMZ 8*55& IBT UIF SJHIU CJU GPS BOZ UBTL and bits have a space-saving design matt, chrome-plated blades along BOE BMNPTU FWFSZ TDSFX ESJWF UZQF and are housed in the ratchet han- XJUIUIFCMBDLCMBEFUJQT"MMCMBEFTBSF (Phillips, Pozidriv, PH module, PZ mod- EMF FBTZ UP BDDFTT BU BOZ UJNF 5IF NBOVGBDUVSFEGSPNTQFDJBM IJHIMZUFN- ule, slot, hex socket, hex screw, Torx, BITDRIVE is a screwdriver with a bit QFSFE TUFFM NBEF JO (FSNBOZ XIJDI Torx TR, triple-square, Robertson, IPMEFS 5IF IBOEMF IPVTFT B SFUSBDU- FOTVSFTTBGFUZBOEBMPOHTFSWJDFMJGF TRI-WING, TORQ-SET, five-pointed able magazine with six professional 5IFUZQJDBMCMBDLCMBEFUJQJTQIPTQIBU- TUBS 5IFTF TQFBL GPS UIFNTFMWFT CJUT 5IF #*5%3*7& IBT B DIBOHF- FEBOEOPUDISPNFQMBUFE UIFSFCZPG- thanks to the choice steel qualities, able ratchet (clockwise, anti-clockwise 70 fering both a high degree of precision special hardening processes, and ex- SPUBUJPO FYUSFNFMZ IJHI NFDIBOJDBM 71 BOE SFTJTUBOU DPSSPTJPO QSPUFDUJPO act fittings in their fields of application strength, and saves a considerable with the optimum transfer of torque, amount of time thanks to quicker 5 6 (3) Precision work with WITTRON MPOHVTFGVMMJWFT BOEMPOHTFSWJDFMJGF TDSFXJOHPQFSBUJPOT 8*55& IBT TQFDJGJDBMMZ EFTJHOFE UIF WITTE develops and produces bits that 8*5530/TFSJFTGPSIJHIMZQSFDJTFXPSL are not included in the range upon WITTE for end users in the fine mechanical and electrical SFRVFTUBTBUBJMPSNBEFTPMVUJPO $VSSFOUMZ 8*55& JT CVJMEJOH B CSBOE GJFMET 8JUI B EFFQ GJOHFS SFDFTT TMJN new online shop, where all WITTE fast-turning section, a slide guard close Six bit series: products will be available to discerning to the blade and rotating central head, In order to have the right bit in FOEVTFSTJOGVUVSF"UQSFTFOU 8*55& all components and details are tailored B WBSJFUZ PG BQQMJDBUJPO FOWJSPO- products can be obtained across Eu- UPXBSET QSFDJTJPO XPSL 5IF QSBDUJDBM ments, WITTE offers the bit series rope from Hornbach hardware stores colour coding speeds up the process of INDUSTRIE, BITFLEX, EXTRAHART, TIN (bits in blister packaging and the DIPPTJOHUIFDPSSFDUCMBEFUJQ (Titanium nitride coating), DIAMOND COMBIT-BOX 11) and from the Swiss (tips containing diamond particles), JUMBO hardware stores (MAXXPRO (4) Smooth T-HANDLE BOE 45"*/-&44 TQFDJGJDBMMZ GPS TUBJO- Nature and VDE, PROTOP II plus, If high torques are required, then MFTT TUFFM TDSFXT 5IF */%6453*& TF- 8*5530/ BOE#*5%3*7&XJUISBUDIFU WITTE has the perfect solution with its 7 8 SJFTJOQBSUJDVMBSBMXBZTIBTUIFQFSGFDU 5)"/%-& TFSJFT 1BSUJDVMBSMZ BEWBO- solution with a wide and deep range Jens Schönlau tageous is the smooth design of the PGCJUT0OFQBSUJDVMBS8*55&JOOPWB- handle that enables the user to work UJPOJTUIF#*5'-&9TZTUFNUIBUCVGGFST QBJOGSFFEFTQJUFIJHITDSFXQSFTTVSF PWFSUPSRVF BOE BOZ USBOTJFOU UPSRVF With the shorter blade integrated in QFBLT UIVTHVBSBOUFFJOHDPOTJEFSBCMZ UIF IBOEMF UIF BMSFBEZ IJHI UPSRVF JODSFBTFETFSWJDFMJWFT USBOTNJUUFE CZ UIF 5)"/%-& DPO- DFQUJTGVSUIFSJNQSPWFECZVTJOHUIF (7) Practical bit boxes MPOHFSCMBEFBTBMFWFS5IFTFSJFTSF- *OPSEFSUPBMXBZTIBWFUIFSJHIUCJUUP ceived the “red dot award” for product hand, WITTE has a wide range of par- EFTJHO UJDVMBSMZ DPNQBDU CJU CPYFT $0.#*5 72 73

ZUVERLÄSSIG FORTSCHRITTLICH 72-97 K›MOBIL 41 // FAUN

Reliably progressive

Restructuring of the Management Board of the FAUN Group from left to right: Patrick Hermanspann, Dr. Johannes F. Kirchhoff, Tim Collet and Dr. Armin Vogel 74 75

After almost 20 years as active Man- cent years has meant more and more the Group he was very successfully whom he had already collaborated The position of Managing Director of to the management of the Swiss com- aging Director, on 1st March Dr. new tasks and responsibilities for in charge of the areas of marketing, since 1986 in the disposal industry, from FAUN Expotec GmbH and Export Sales pany J. Ochsner AG. Johannes F. Kirchhoff handed over Dr. Johannes F. Kirchhoff. So in fu- the expansion of FAUN Services GmbH MSTS to FAUN. Having started as Head Manager has now been taken by Tim the operational management of the ture Kirchhoff will concentrate even as a rental and leasing company and of Marketing, since September 1996 Collet. The Managing Director of the Everything flows and nothing abides, FAUN Group to Patrick Hermanspann. more intensively on the further de- building up the FAUN brand in China. Dr. Armin Vogel was responsible for the Swiss FAUN subsidiary J. Ochsner AG as Heraclitus said. We thank Dr. Armin velopment of the KIRCHHOFF Ecotec Together with Peter Höning (CFO) and international sales and marketing for has also been working for FAUN since Vogel and say farewell and we wish all In 1994 the Kirchhoff family of indus- area of business—with both the main the Board of Directors, Hermanspann FAUN as Managing Director of FAUN 1995. On his arrival the 47 year old four men much joy and success in their trialists from Iserlohn took over the brands of FAUN and ZOELLER—and on is now steering the fortunes of the Expotec and since 1999 also as Manag- took over the management of mar- new jobs. FAUN Group. Under the leadership of developing the Group further particu- leading Europe-wide manufacturer ing Director of the Group and as Chief keting from Dr. Armin Vogel. In the technophile Dr. Johannes F. Kirchhoff, larly at international level. of refuse collection vehicles and road Sales Officer. All through these years course of his career with the FAUN Claudia Schaue FAUN successfully developed to the sweepers. Dr. Armin Vogel has shaped the FAUN Group, Collet was responsible for ex- point of becoming the European mar- To replace him in his duties as CEO brands extraordinarily strongly and panding and integrating the Papaix ket leader in refuse collection vehicles of the FAUN Group, Kirchhoff has Passing on the baton has achieved great success in sales by SAS company in France taken over and road sweepers. found an ideal successor in Patrick Dr. Armin Vogel is another rock in building up new markets and customer by FAUN and later he became a co- Hermanspann. The 39 year old has the recent history of FAUN and waste relations. After 18 years he is now leav- director of the French FAUN SAS in The integration of the lifter and dis- been employed in the group of com- disposal technology to be leaving the ing the company at his own wish and Toulouse. He then worked intensively posal vehicle manufacturer ZOELLER panies since 1999 and, before his job group. In 1995 Dr. Johannes F. Kirchhoff has switched to a leading role in waste on building up new foreign markets, into the KIRCHHOFF Group in re- as CTO (Chief Technical Officer) for summoned his comrade-in-arms, with technology at Fritz Schäfer GmbH. before in 2012 Tim Collet stepped up K›MOBIL 41 // FAUN FAUN // 41 K›MOBIL

In tune with the times

The industry meets up for the Municipal Vehicles Experience and FAUN ideally suited as a chassis for the body- Group, got to the heart of the mat- shows the New VARIOPRESS on the Antos chassis for the first time. builder. In combination with the new ter: “Events like this are immensely im- VARIOPRESSS in the new container de- portant for the bodybuilder. We bring sign, this refuse disposal vehicle is not bodybuilders, manufacturers and us- Info only a feast for the eyes, it also stands ers together. In our discussions and out in terms of loading capacity. one-to-one dialogues we can track down the latest trends together and On 30 April 2013 the waste manage- The latest trends exhibited a VARIOPRESS 524 with a The industry event brought 140 ex- get in tune with the times. We can all You can find detailed information ment industry met up in Wörth for In addition to a prototype of the new 24 m3 container capacity, 4 m wheel- perts together from waste manage- profit from it—for the benefit of citi- on the AKT programme at: the first Municipal Vehicles Experience FAUN SIDEPRESS with ZOELLER Delta base and ZOELLER Delta lifter. More rement businesses. The Mercedes-Benz zens and our environment.” event held by AKT (the German acad- lifter for containers from 80 - 1,100 litres, fuse management vehicles of this type business information centre (BIC) pro- www.kommunalfahrzeuge.biz emy for municipal vehicle technology) the New VARIOPRESS on the Antos chas- are to follow in the future and make vided an outstanding backdrop for this Claudia Schaue under the leadership of Dr. Hans-Peter sis from Mercedes-Benz was particularly their mark on the waste management and the latest trucks were ready for Obladen. Together with ZÖLLER-KIPPER highlighted. As the leading second-stage and recycling industry. The Antos is test drives. Interesting talks and discus- GmbH, FAUN participated in the AKT manufacturer worldwide, FAUN had designed for light and heavy distribu- sions rounded off the programme. In specialist event and demonstrated the the opportunity to fit a body onto the tion transport and with its 26 tonne his welcoming speech Dr. Johannes F. latest trends in vehicle technology. new Antos with a Euro 6 engine. FAUN maximum permitted laden weight it is Kirchhoff, CEO of the KIRCHHOFF

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SIDEPRESS New VARIOPRESS on Antos K›MOBIL 41 // FAUN

Think BIG

FAUN with two road sweepers of the Streamline Generation at the most successful bauma of all time. With 530,000 visitors from 200 countries and an exhibition space of 570,000 m2, this bauma made history.

At the bauma everything is just a bit formance, the optimal aerodynamics, versatile and adjustable high-pressure bigger. This goes for the stands, the more water storage volume and the washing system with a huge water 1 23 78 exhibits and the expectations. FAUN, air circulation system give the road storage capacity of up to 3,000 l. 79 too, exhibited two large dimension sweeper structure its name: Streamline Burkard Oppmann (Sales Manager road sweepers of the Streamline Gen- Generation. This VIAJET 12 was spe- for Germany) and Tim Collet (Export eration for special applications to trade cially assembled and built for the Götz Sales Manager) were very happy with professionals in Munich. Not to be cleaning company in Haiterbach, Ger- the way the bauma exhibition went. overlooked was the VIAJET 12 R/L HS many. The second road sweeper of the Tim Collet: “In fact our expectations with sweeping units on both side of Streamline Generation which was ex- were exceeded on the Export front. the vehicle as well as suction equip- hibited in Munich was a VIAJET 7 R/L H. Expressions of interest came above all ment on the back and a high-pres- New features of the machine are the from the Asiatic and African area.” sure washing system. This new road revised blower design for a higher A successful appearance for FAUN at sweeper has been specially designed suction power and the modern suc- the bauma 2013. We are certain that 4 for use on construction sites and for tion equipment on the back. An ad- 2016 will be even bigger. tunnel cleaning. The high suction per- ditional technical characteristic is the VIAJET 12 Claudia Schaue

Benefits t 4VDUJPOSPBETXFFQFSXJUIN2 system volume t UBYMFTFSJFTUSVDLDIBTTJTXJUIBIJHIMPBEJOHDBQBDJUZ t 5IFNPTUQPXFSGVMSPBETXFFQFSGPSDPOTUSVDUJPOTJUFTBOE special applications

1. The powerful suction equipment on Characteristics the back t 7FSTBUJMFFRVJQNFOUSBOHFGPSUIFUPVHIFTUBQQMJDBUJPOT 2. Accessory equipment for cleaning t )JHIUPSRVFIZESPTUBUJDESJWFGPSBIJHIQFSGPSNBODFBU tunnels low speeds 3. Brushes on both sides t 0QUJPOBMTVDUJPOFRVJQNFOUPOUIFCBDLXJUIBOFXUZQFPG 4. VIAJET 12 road sweeper for special air conveyance for perfect surface suction applications in tunnel cleaning t 7FSTBUJMFBOEBEKVTUBCMFIJHIQSFTTVSFXBTIJOHTZTUFNXJUI sufficient water storage capacity FAUN // 41 K›MOBIL

The New VARIOPRESS

The rear-end loaders from FAUN have a new face

Presented at the IFAT in Munich last year, the new body construction for the VARIOPRESS and POWERPRESS rear-end loaders has been in series production since the end of 2012.

The structure has undergone a complete facelift and the construction of the body has been revised. The unit is available in sizes from 8 to 33 m3 81 with smooth side walls or optionally also with ribs. Claudia Schaue

What’s new:

Light t "DDFTT DPWFS XJUI HBMWBOJTFE DPOOFDUJPO t 8FJHIUSFEVDUJPOXJUITJNVMUBOFPVTWPMVNF frame to prevent corrosion optimisation t 5IF VTF PG FYUSFNFMZ IJHIQSFDJTJPO SPMM t 4NPPUITVSGBDFTJOTJEFUIFCPEZNBYJNJTFE forming profiles at the four corners of the cross-section for optimum waste compaction container and for the guide rails t 4JEFXBMMTBOEGMPPSJONN TFSJFT Durable t 6TF PG IJHIRVBMJUZ NBUFSJBMT BOE QFSGFDU Clean finishing t &BTZUPLFFQDMFBOXJUIUIFBCTFODFPGEJSU t 5ISPVHIQVU QMBUF XJUI SVCCFS TFBM PO UIF traps container walls (series) t /PSVOTPGEJSUZXBUFSEPXOUIFTJEFXBMMT t $POUSPMCVUUPOTUPPQFOBOEDMPTFUIFSFBS from the roof section integrated directly into the container without additional attachments Elegant t -PX DPSSPTJPO XJUI QSFEPNJOBOUMZ DMPTFE t $MFBS NPEFSOEFTJHO profiles t 1FSGFDUMZTVJUFEUPUBLFBEWFSUJTJOH K›MOBIL 41 // FAUN FAUN // 41 K›MOBIL

Simply enormous

As of now, the FRONTPRESS is available as a four-axle vehicle with 35 m3 and 13 tonnes loading capacity.

We all know what it’s like. If some- The FRONTPRESS can now also have nation with pocket containers of up to thing turns out particularly well and a sliding lid 7 m3 can be envisaged depending on we are very happy with it, then what the version of lid. With the pneumatic We’re revving do we want? More of it. Another highlight has been created drive for the “third flap” on the roof by FRONTPRESS constructor Frank of the body and the gas spring hinged This is the case with the popular Stephan with the sliding lid opening frame, the sliding lid opening mecha- up Germany FRONTPRESS. The version with 33 m3 mechanism for MGB bins according nism, the FRONTPRESS also stays with- on a 3-axle chassis ought to be just a to DIN EN 840-3. This means that the in the maximum permissible height of bit bigger, as the front-loader with its FRONTPRESS range is extended by four metres in accordance with road very good compacting performance an additional option and once again traffic regulations when in the drive quickly reaches the 26 tonne per- meets a customer wish to be able to position. Amazing possibilities for yet mitted laden weight. The engineers collect all MGB types under DIN EN more customer benefits. therefore took a 32 tonne chassis with 840 with the comb and trunnion lift- With the ROTOPRESS on a demonstration tour in Germany three main axles and one trailing axle ing combination. The convenient op- Claudia Schaue and adapted the FRONTPRESS struc- tional infrared remote control enables 83 ture to 35 m3. two-wheeled MGB bins with a capacity of 80 litres right through to 5000 The body was 500 mm longer, the litres to be picked up without wheelbase was 5,100 mm and the problem. Also the combi- The classics among refuse disposal loading capacity increased to more vehicles are on a promo tour of the than 13 tonnes. A terrific result Republick. ROTOPRESS which has already convinced its first customers. The operating mechanism of the rotating drum vehicle and the advantages associated with it are unique and At a glance therefore reason enough to put the In contrast to a conventional press plate vehicle, the FAUN ROTOPRESS vehicle on the wish list of clients. does not need any hydraulically driven press system in order to achieve compaction. The compaction system consists of a cylindrical drum con- Burkard Oppmann, Sales Manager for tainer with two spiral-shaped screw conveyors. The drum rotates con- Germany, also tells us why: “There is tinuously. The screw conveyor causes the waste to be conveyed forwards always much to say. But only when right from the start of loading. This means that an optimum axle load you test and drive the ROTOPRESS distribution is ensured. The waste is compacted by the stationary screw yourself can you be impressed by the press in the back part. advantages of this refuse collection With up to a tonne more load with two collection rounds a day, you vehicle.” Until the end of August, two can carry away up to ten tonnes more a week – depending on the chas- ROTOPRESS vehicles are touring sis! Thus you can save one complete round per week as compared with through the disposal areas of Germany. conventional collection vehicles. Work out what that means over a year! An unbeatable advantage for the rotating drum principle and the FAUN If you are interested, please send a ROTOPRESS. message to: [email protected] And a further cost benefit: years of experience and practical statistics confirm it: the ROTOPRESS is impressive with its considerably lower ser- Claudia Schaue vicing and maintenance costs as compared with the conventional press- plate vehicle. K›MOBIL 41 // FAUN FAUN // 41 K›MOBIL

Happy Birthday

FAUN Services GmbH celebrates ten years of existence

Three was a magic number for FAUN who has been Managing Director Services GmbH. Founded in the year of FAUN Services GmbH since 2009, 2003, at the beginning there were thanks the team for their fabulous three leased vehicles available and service and commitment through the the team consisted of three mem- years. “Without the team we would bers of staff. certainly not have reached our tenth anniversary.” Workshop 3.0 Today the company achieves a turnover of 30 million and the rental fleet For the coming years he sees the fol- numbers 110 refuse collection vehi- lowing activities as being in focus: cles—from the rear-end loader right “We are going to intensify our activi- through to the hybrid vehicle and ties abroad and expand the rental fleet New leadership in the FAUN After Sales Service everything in between—plus 17 road by additional vehicles. I am thinking 84 sweepers. here, for example, of dustbin wash- 85 ing vehicles and skip lorries as well as There are eight employees in the crew. roll-off vehicles. In addition we will be Burkard Oppmann At the beginning of the year there marketing our services more strongly were a few changes. For example the on the Internet.” used vehicle centre moved from Augs- burg to Ebelsbach. Burkard Oppmann, Claudia Schaue The responsibility for the After progressive system for the after sales Sales area at FAUN Umwelttechnik areas. The satisfaction of our custom- GmbH & Co. KG was taken over in ers is significantly determined by our February 2013 by Christian Bremer. performance in terms of service. This is also something we require because This qualified industrial engineer has the quality of a company is reflected been working for FAUN since 2006 in continuously high-quality customer Info and has gathered a great deal of expe- care.” rience, firstly as Assistant to the Man- aging Director of FAUN Expotec GmbH FAUN already runs eight customer The range of services of and later as Section Manager for spe- centres in Germany today and, from FAUN Services GmbH cial waste containers and also in the the Osterholz-Scharmbeck location, it international sale of FAUN products. looks after the service partners estab- Vehicle hire: Bremer will contribute his knowhow lished worldwide as well as the inter- waste disposal vehicles available prompt- in the after sales and customer service national spare parts business. ly no matter when and no matter where area and, together with the team, will continue develop this very important “We are already very well set up in Vehicle financing: area for FAUN. He will be reporting to Germany” continues Bremer “but we of the FAUN training programme for decent conditions for decent vehicles Burkard Oppmann, Managing Director are constantly working on intensify- customers and partners.” of FAUN Services GmbH and Head of ing and optimising our customer care. Used vehicles: Sales for Germany. Another major subject which we are Claudia Schaue even after years of hard service, still going to be tackling in the near future, maintained in good order Bremer outlines the following key ar- taking account of the high export ratio eas for his future work: “We also want at FAUN, is availability in international to set up an even more reliable and service support and the expansion K›MOBIL 41 // FAUN FAUN // 41 K›MOBIL

Patent in hand A new broom in the team

Ann-Kristin Dalheimer takes over the Sales Management Reinhard Röder is the new salesman for road sweepers of the Ochsner Bucket in Germany

J. Ochsner AG is aiming at extend- Ochsner Bucket patent In May Reinhard Röder took over We warmly welcome Reinhard Röder! ing the sales channels for the pat- Brushed chrome steel, clear minimalis- from Volker Hengstenberg, who ented Ochsner design bucket in tic lines and a distinctive design mark has moved to ZÖLLER-KIPPER GmbH We wish Volker Hengstenberg great Germany. We have managed to get out the patent Ochsner bucket as as Head of the Customer Centre in success in his new job and thank him Ann-Kristin Dalheimer to look after being truly Swiss. As a practical con- Herne. for his commitment during his eleven this area. tainer for utensils in daily use or wood years in the FAUN Group. for the fireplace, as a seat with storage Reinhard Röder studied business man- The 32 year old has been head of mar- room, what was formerly an ashbin agement and can look back at many Claudia Schaue keting at FAUN since 2008 and she can can be an indispensable item for every years of professional experience in now offer her talent for sales and her household. sales. In future he will be selling road affinity for design specifically to this sweepers for FAUN in the areas of new task. Details: North Rhine-Westphalia. t 7PMVNFBWBJMBCMFJOMBOEM 86 Originating from Switzerland, this prod- t #PEZ MJEBOEGJUUJOHTJOIJHIHSBEF 87 uct is as yet unknown in this country stainless steel so Ann-Kristin Dalheimer also sees an t #FFDI XPPE IBOEMF '4$ DFSUJGJFE interest in this item for discriminating wood from ecological Swiss stock) and design-oriented households. “My t -PX PEPVS UIBOLT UP MJE TFBMJOH first tasks will be to prepare a market rubber edge protection on the bot- and competition analysis, to determine tom of the container potentials and strengths and to look for t 8FJHIULH LH suitable sales channels. The product is t %JNFOTJPOT PG TUBOEBSE CVDLFU a high quality, modernised traditional (W x H) 42 x 51 cm, 43 x 42 cm Swiss product which combines aes- t 8JUI JOUFHSBM TIPWFM BOE CSVTI thetics and usefulness. I can very always to hand well imagine that Germany is a market for the bucket”, says Claudia Schaue Dalheimer of her new job.

Info

More information at: www.patent-ochsner.com or The Ochsner Bucket www.youtube.de (keyword: Produktlinie Patent Ochsner S664) K›MOBIL 41 // FAUN FAUN // 41 K›MOBIL

Goodbye Germany. Hello Netherlands.

Working aboard—trainee Cindy Bargmann has taken advantage of this opportunity

88 89

“For once to get out of the daily rou- BAND exchange programme (bilateral of some stereotypes: “Yes, there is lots qualifications for European business tine, to get to know another culture exchange programme between the of bicycling, yes there is an unbeliev- men and women, but also to our in- and new people and to get involved Netherlands and Germany) she saw able number of type of cheese, yes the dustrial trainees as well. Cindy Barg- Info in something completely new.” With this as an opportunity to get to know Dutch are incredibly laid-back and we mann very much wanted to go to the these words Cindy Bargmann de- about other training practices. Cindy were warmly welcomed everywhere Netherlands and we were happy to scribes her motivation to take part in was selected from 60 co-trainees and and no, the Dutch do not go to coffee give her this possibility.” a three-week exchange programme in in April she travelled to Zandvoort shops every day” Cindy summarises In June 2013 two more trainees from With the German-Dutch “BAND” exchange programme, the the Netherlands. with five other young people. In the with a smile. logistics will complete a three-week Deutsche Gesellschaft für International Zusammenarbeit GmbH three week industrial placement she stay in the context of the “Leonardo (GIZ) on behalf of the Federal Ministry for Training and Research is In September 2012, Cindy Bargmann worked in a supermarket. Goods had “We wanted to give our trainees the project” in Budapest. making it possible to young people to complete their training with successfully completed her training to be sorted and priced on the shelves. opportunity to gather some experi- a few weeks in the Netherlands. With this programme, GIZ and the as a specialist in warehouse logistics On Fridays she went to college. ence in a professional, and also a cul- You can find more information about Ministry want to get trainees and their companies to participate in at FAUN Umwelttechnik. In addition tural environment beyond our country training at FAUN at: a qualification abroad at an early stage. (Source: www.giz.de) to the correct storage of goods and The trainee said about these activities: borders”, explains Marc Grube, FAUN www.facebook.com/faunkarriere products and logistical planning and “At FAUN I have more challenging Head of Personnel about the activities In addition to the BAND project, FAUN is also participating in the EU organisation processes, the 19 year tasks and my work is more varied. But abroad for young people. “However Claudia Schaue Leonardo project (www.na-bibb.de/leonardo_da_vinci.html) old also learned how conveying sys- it is good to try out other jobs once in we do not only want to offer these tems or storage and retrieval machines a while.” In addition to day-to-day op- opportunities to our business trainees, are operated. When an advert was dis- erations, the Dutch adoptee also had for whom a stay abroad is basically played in the vocational school for the the opportunity to get to the bottom included in the planning of additional K›MOBIL 41 // FAUN

Go Green

It’s small, it’s agile and it’s quiet.

POWERPRESS in all its colours

91 dioxide and noise and fuel savings. Using the Smart e-drive also continues the idea in terms of local traffic. Well equipped

Patrick Hermanspann, CEO of the FAUN Group, on this addition: “We for the Universiade have always been open to new ideas. With the Smart e-drive we are com- bining driving pleasure, coolness and environmental protection in an ideal way.” FAUN delivers 20 vehicles to Kazan

In the context of the electro-mobility business initiative (UI Elmo) in the model region of Bremen/Oldenburg, FAUN has tapped into the project, which was initiated by the Nehlsen Kazan, deep in the heart of Russia, is with suitable disposal technology and sis made their journey back in Decem- company. The aim of the initiative is to a multicultural city with a centuries- found the ideal partner in FAUN. ber 2012 and the second batch, plus a conduct a cross-company and cross- old history which goes back to the VIAJET 6 as a exchangeable model, fol- sector trial of electric mobility in op- year 1005. The city with 1.3 million in- FAUN Sales Manager Ewgenij Schön- low in early Summer 2013. In time for erational practice. So far 60 electric habitants is the capital of the Tatarstan berg: “They were looking for a reliable the Universiade, the competitions for vehicles are on the road in the Bremen Republic and also the target of numer- and progressive supplier who can also students from all over the world which Since June a Smart e-drive has been With DUALPOWER vehicles, FAUN has area in the context of this initiative. ous tourists on account of its diverse guarantee the right service.” will be held in Kazan this summer. part of the fleet at FAUN Umwelt- for years been demonstrating and sell- With Nehlsen as the central contact, buildings and historic monuments. technik in Osterholz-Scharmbeck. ing itself as one of the first businesses not only are vehicles and infrastructure The vehicles are primarily used for Claudia Schaue Employees use the electric vehicle offering holistic environmental pro- used more efficiently but information In order to offer visitors and residents household waste disposal and they for business trips in the surround- tection in waste disposal. The themes is exchanged about loading locations. a modern, aspiring metropolis, the empty 5000 1.1 m3 bins and 300 8 m3 ing area and put green thinking are lower emission pollution of the Christy Gorod waste disposal company containers. The first VARIOPRESS and onto the streets. environment through reduced carbon Claudia Schaue was looking for a supplier to provide it POWERPRESS vehicles on VOLVO chas- K›MOBIL 41 // FAUN

Something new in the State of Denmark

12 SELECTAPRESS for the Island of Zealand MICROPRESS on FUSO Canter chassis

A very good start with the success of back section, its own throughput plate The batteries in the e-PTO are charged the new FAUN dealer in Denmark Ove and its own lifter. The further develop- by Reno-Norden A/S overnight with Kock from Ove Kock A/S from Esbjerg. ment of the SELECTAPRESS has made the advantage of power produced At the end of 2012 he received an or- it even lighter and the rear section has from wind energy. der for twelve SELECTAPRESS DUO for been able to be shortened. Nine vehi- the Reno-Norden A/S waste manage- cles are equipped with a FAUN UNILIFT Good feedback ment company. and three vehicles with ZOELLER Delta Feedback from the media in Denmark to 2301/2342 lifters. the modern, environment-friendly ve- SELECTAPRESS DUO hicles has been enormous. RenoNorder The project is a joint effort within Less emissions with e-PTO has been using the SELECTAPRESS the FAUN Group. Looked after by Ex- Eleven of the SELECTAPRESS vehicles since May 2013 in Slagelse on the port Manager Thomas Hoffmann, the are equipped with the e-PTO (electric main Danish Island of Zealand for the SELECTRAPRESS was produced in the power take off). Both the body and collection of refuse from 32,000 resi- Love Recycling French factory in Valence at FAUN the lifter are driven via the e-PTO. dents: household refuse in the large 92 Environnement. The French team has When the refuse bins are emptied, compartment and organic waste in 93 specialised in the production of the the chassis engine is switched off via the small one remain cleanly separat- twin-compartment SELECTAPRESS the inbuilt automatic start-stop device ed from one another. FAUN ZOELLER (UK) Ltd. will be supplying a total vehicle. Different types of refuse can and it starts automatically as soon as of 35 Refuse Collection Vehicles to Kier Group be collected in two independent com- the vehicle moves on. This means that Claudia Schaue partments end emptied separately noise and waste gas emissions are re- from each other. Each side has its own duced when the vehicle is stationary.

Kier Environmental & Street Services quality of which will often influence lifters mounted on 7.5 tonne Canter provide sustainable waste manage- the public’s perception of an organi- chassis which will allow them bet- ment and recycling services to local sation as a whole. As a result it is in ter access to restricted areas. FAUN authorities, government agencies and Kier’s best interests to acquire the very ZOELLER (UK) Ltd. and Kier are already the private sector within the UK. With best vehicles and equipment to ensure working successfully together in other high standards of service delivery at the needs of the service are met. parts of the UK, FAUN ZOELLER (UK) the forefront of their operations Kier Ltd. is proud that their partnership and FAUN ZOELLER (UK) Ltd. share With years of specialist experience with the Kier Group is flourishing and a like for like business philosophy. In Kier’s fleet management resources as a result providing innovative solu- October 2012 Four East Sussex Lo- ensures their Clients acquire the tions for all parties involved. cal Authorities jointly awarded Kier a right vehicles at the right price help- ten year-contract to deliver waste and ing them to make strategic decisions Kier said: “We have worked closely recycling collections, street cleansing and maximising return on investment. with FAUN ZOELLER throughout the and beech cleansing. The East Sussex Their recent order with FAUN ZOELLER mobilisation period to ensure that the Waste Partnership contract, which will includes 20 VARIOPRESS with 22m³ vehicles chosen were the best suited left: The Danish Transport Minister cover nearly 200,000 properties over bodies and 11 COMBIPRESS with to support the service. Recognising Henrik Dam Kristensen got his own a 550 square mile area, is expected to 22m³ bodies with recycling pods that the importance of a seamless service impression of the SELECTAPRESS save an estimated £30m over the next will be used for glass collection, all of start and transfer FAUN ZOELLER also during the Transport Exhibition decade. FAUN ZOELLER (UK) Ltd. will which have been fitted with ZOELLER provided an onsite response team, in Herning, Denmark | above: be supplying a total of 35 Refuse Col- Rotary bin lifters and mounted on 6 x 2 throughout the initial start up week, The batteries of the e-PTO in the lection Vehicles to Kier Group. Both rear steer Mercedes-Benz Econic chas- who were onsite working closely with SELECTAPRESS are charged with Companies recognises that waste col- sis. To complement they have also the Kier team”. green power from wind energy lection is a high-profile service, the ordered 4 MICROPRESS with 202.80 Kristie Sanderson K›MOBIL 41 // FAUN

60 counts

Awarded a 10 year after sales contract across three locations Great team work: Colin O’ Donnell (left side) and Vincent Donnelly (right side) both from Kier an Ben Lord (FAUN ZOELLER (UK))

Private waste disposal and recycling specialist Biffa have recently placed One Stop Shop 94 an order with FAUN ZOELLER (UK) for 95 an impressive 60 refuse vehicles. They have also awarded us a “10 year” repair and maintenance contract. Pro- viding innovative versatile vehicles for FAUN ZOELLER (UK) Ltd. won £3.5 Million contract waste collection is how we have built our respected brand name and we know that the best products have to be accompanied with an outstanding aftersales service.

The process of winning the contract We are continually working to create ly-friendly waste collection service by Ben Lord, FAUN ZOELLER (UK) Re- XBTSJHPSPVTXFMJUFSBMMZIBEUPDPN- added benefit for Municipalities look- optimizing driving for stop/start refuse gional Account Manager said: “FAUN pete in a head to head challenge with ing to purchase a new fleet of vehicles. collection cycles. ZOELLER excels in working together our nearest rivals, enhancing our ser- FAUN ZOELLER (UK) Ltd. yet again with its customers in order to deliver vice offering to create the complete works seamlessly in offering the ulti- Vincent Donnelly, Transport Manag- and maintain top quality products and bespoke package. mate ‘one stop shop’ for customers. er said: “When it came to selecting services. Our qualified and profession- a new fleet it was apparent that we al engineers combined with excellent The mobilisation of the vehicles has UK Municipality in Sefton, Merseyside needed a high performing waste man- resources ensure that we are able to been staggered across two work- UK has renewed its fleet contract or- agement solution that was environ- deliver the best possible solutions to shops in Mid Kent, UK. These work- 5IFGJSTUSPMMPVUUPPLQMBDFUIJT+VMZ tential for development and growth, dering refuse collection vehicles and mentally friendly. Through a competi- clients.” shops will be operated, fully equipped the second will be taking place in Au- with plans to utilise the space for com- eco-drive assistants in a deal worth tive tendering process FAUN ZOELLER and staffed by our own team. Highly gust and the third in February 2014. mercial retail business. £3.5 million. The order comprises a (UK) Ltd. were eventually selected as Kristie Sanderson trained engineers and dedicated man- Each depot will be taking delivery of variety of 26-tonne and 32-tonne ca- the best option. In addition to deliver- agers will be based on site overseeing a combination of SELECTAPRESS and The whole team would like to thank pacity FAUN VARIOPRESS rear-loaders ing on price and quality, the customer all service activity from start to finish. VARIOPRESS with Rotary lifters, all Biffa for investing their trust in FAUN plus ZOELLER lifting systems. Every service on offer has been outstanding, To offer our customer an unbeatable highly popular UK products. ZOELLER. Together we can keep a vehicle is equipped with an innovative with after sales support from the ser- service we are also taking on respon- healthy fleet of refuse vehicles on the Eco Drive Assistant (EDA). Designed vice department and field service en- sibility of maintaining their existing The aftersales contract will generate road. to fit the chassis of any refuse collec- gineers proving particularly valuable in fleets whilst the new vehicles are an estimated minimum of £7million tion vehicle, the EDA helps to deliver a the past. Our overall experiences have introduced. revenue and will offer long term po- Kristie Sanderson more economical and environmental- been wholly positive”. FAUN // 41 K›MOBIL

Engaging with the US Military

Tailored solutions to ground mobility showcased to US troops

In November’s issue of Army Engi- UAV Landing Mats (UAVLM), and Ra- neer, FAUN TRACKWAY USA outli- pid Runway Repair (RRR). Then on 15 ned a deliberate engagement with - 16 May, FAUN TRACKWAY USA vi- all branches of the US military as a sited Fort Leonard Wood to conduct a way of unlocking new markets for demonstration of HGMS for the troops our suite of defence products. and requirement development team at the US Army Engineers Bridge Trai- We’re pleased to report that we’ve made ning Center. Michael Holdcraft, vice serious in-roads after holding our fourth president of business development at demonstration to US military forces to FAUN TRACKWAY USA, said: “The US show the expertise of FAUN TRACKWAY lity System (HGMS)—FAUN TRACKWAY is at the core of FAUN’s future strate- USA and the tailored solutions we have USA’s leading portable roadway solution gy, particularly where research and de- developed to meet the ground mobili- for wheeled and tracked vehicles—and velopment are involved. Collaboration ty needs of armed forces. The first two our newest product, the Adjustable and engagement with American engi- 96 demonstrations, held in 2011 for the US Ground Mobility System (AGMS), which neers will be the key to unlocking this. 97 Navy and 2012 for the US Army, were can be mounted on a broad range of New order for HGMS components complemented by two very successful medium front-end loaders and is delibe- “As an engineering business that works events earlier this year. rately flexible in its design to be deplo- with armed forces to understand the From 7 - 8 March we held our first ses- yed with both Military Load Classifica- specific challenges they face and tailor sion for the United States Marine Corps tion (MLC) 30 and 70 Trackway. solutions to their needs, hosting de- (USMC) Engineering School and Requi- The event also acted as an opportunity monstrations for key personnel and end Irish Defence forces extend Relationship rement Development centre at Camp to present sample sections of our ro- users is an important facet to our success with FAUN TRACKWAY Lejeune, North Carolina. The demonst- bust portable runway solutions, which in new markets.” Info ration included the Heavy Ground Mobi- include Helicopter Landing Mats (HLM), Rachael Williams

FAUN TRACKWAY are pleased to an- to prevent heavyweight vehicles from Ireland is one of the five parti- nounce our continuing support for becoming bogged down and protect cipating nations in the Nordic the Irish Defence Forces through an valuable military assets. Comprising of Battlegroup, which alongside extension in the relationship which aluminium matting that can withstand Sweden, Finland, Norway and will see us further bolster its capa- repeated loads of tracked and wheeled Estonia supplies soldiers to bilities in challenging environments. vehicles of up to 70 tonnes, 50 m of the European Union in crisis HGMS track can be laid by two men in situations, so there’s a poten- The Irish Defence Forces made its first less than six minutes. tial that our system could be purchase from us in 2009, and the troop deployed in humanitarian and has recently shown its long-term com- In extending its order for HGMS tech- disaster relief missions. FAUN mitment to FAUN TRACKWAY by sig- nology, the Irish Defence Forces has TRACKWAY has long been ning a contract for an additional order of strengthened its stock and increased on- recognised as a developer of our world-leading Heavy Ground Mobili- the-ground efficiency. Under the new quality and innovative glo- ty System (HGMS). For modern defence deal, the force will now own 500m of bal mobility solutions and it’s forces it’s crucial that they’re able to our aluminium TRACKWAY and HGMS thanks to our strong pedigree traverse challenging terrain and diver- laying and recovery equipment. in engineering and manufac- se territories without difficulty. Portable turing that defence forces con- roadway solutions like HGMS will help Rachael Williams tinue to invest in our systems. 98 ZOELLER 99 KIRCHHOFF GROUP

Technik entscheidet. 98-103 K›MOBIL 41 // ZOELLER

Q 2

After 34 years, Manfred Zöller is retiring and handing over to Dirk IJfs.

sumption and also reduce CO2 emissions and noise. This means that our customers will be in a position to pro- ceed with waste collection during off- peak times as well, without disturbing either residents or the environment. Dirk IJfs is confident that the ZOELLER 101 Group will be proactive with developments such as this in the future.

Farewell to Manfred Zoeller Manfred Zöller’s retirement in April 2013 saw the end of an era for ZÖLLER-KIPPER GmbH. In his 34 years as Director International Sales of the %% Group, Manfred Zöller succeeded in After 34 years Manfred Zöller leaves ZOELLER group an Dirk IJfs took over his role winning key projects, contributed to the growth of the company and helped shape the waste management ZOELLER dealer RG Techo takes part in WasteTech. There is a new but familiar face at sure loyalty and always offer custom- industry. He had the gift of winning the Export Division of ZÖLLER-KIPPER ers the best possible products for their people over with his manner and his GmbH. Dirk IJfs is the new leader of tasks. Over the last few years, our principles. As Managing Director he Export Management. The Dutchman aim in Denmark has been to achieve built up subsidiaries in Great Britain, has been working for the ZOELLER a good market share. This aim could the Netherlands, Spain and France. At WasteTech in Moscow from 28 - 31 A particular attraction for visitors was fication and weighing system. Dirk Group since the end of 2009, and be- only be achieved with high quality in- He achieved a great market share in May 2013, our Russian dealer RG Techo the MEDIUM XL SK200 with integral IJfs, Export Manager of the ZOELLER fore that he was actively involved in novative products, together with a these countries. The management of presented the latest products from washing facility for waste containers. Group, was very satisfied with the way the waste management industry for high standard of service.” the KIRCHHOFF Group and the entire ZÖLLER-KIPPER GmbH. WasteTech (In- Up to now there has been nothing the trade fair progressed: “A thorough twelve years. At the end of 2012 Dirk ZOELLER Group extend their thanks to ternational Exhibition of Waste Man- comparable on the Russian market. triumph and success. Compliments to IJfs took over the position of Export With electric power take-off (e-PTO), Manfred Zöller for his dedication and agement, Recycling, Renewable En- Another highlight was the MINI SK200 the RG Techo Team!” Manager, relocating his office to the Dirk IJfs sees this as one of the most wish him all the best and good health ergy and Environmental Technologies) on a Mercedes-Benz ATEGO chassis. company headquarters in Mainz. IJfs important developments in recent for the future. is the largest trade fair of this kind in For more information see: welcomes this new challenge and has times. With e-PTO, energy (for exam- Russia and CIS States (Commonwealth This small, compact vehicle is the ideal www.waste-tech.ru specific ideas about his future work. ple wind energy) will be stored in lith- Volker Schröder of Independent States). Under the ban- solution for waste collection in the Together with dealers, his aim is to in- ium batteries. This energy will be used ner “ZOELLER’s five years in Russia“, narrow Russian streets overrun with Krzysztof Sosnowy tensify long-term customer relations. for set-up and lifting operations dur- RG Techo presented six of the latest parked cars. The product range was Dirk IJfs says “we can only achieve this ing collection. This will firstly achieve technological advances in the waste completed by a new waste collection aim by working together. We must en- up to 30 percent savings in fuel con- management sector. vehicle with GPS and a bin identi- K›MOBIL 41 // ZOELLER ZOELLER // 41 K›MOBIL

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Cape Town is a place of natural beauty with mountains, alongside the most beau- tiful beaches and vineyards, as well as being the location of the offices of ZOELLER’s subsidiary, Mechlift (PTY) Ltd.

Tourists generally see Cape Town and tion of South Africa of 81 million still In 1992 as a competitor to ZÖLLER- other major towns in South Africa as uses the black-bag system, while some KIPPER GmbH, Mechlift (PTY) Ltd very modern and western-orientated, residents have no regular waste collec- started production of its own lifters. but socially deprived areas are still rife. tion service.Mechlift, a ZOELLER sub- At that time the ZOELLER Group was Photo top left: The Mechlift (PTY) Ltd. team | Photo bottom left: the 102 In the towns, some four million waste sidiary, gives an insight into life there still the only supplier in South Africa. 103 workshop team | Photo right: A ROTOPRESS with Mechlift lifter containers are cleared every week and the daily tasks and challenges Importing products from Europe some from around 800 waste collection ve- when European technology comes up 10,000 kilometres away was, how- hicles. But the majority of the popula- against conditions in Africa. ever, not only cost-intensive but also

time-consuming, especially when it cated. This is why Mechlift’s philoso- of waste management companies. came to swift supplies of spare parts. phy is “Simplicity is the ultimate so- Training is increasingly regarded as an In 1996, both companies therefore phistication”. essential constituent of modern com- decided to join forces in future. The pany policy, to ensure that personnel ZOELLER group has had a 51 percent Mechlift offers a range of five differ- are properly trained and supported. holding in Mechlift since that time. ent lifters, tailored to suit local conditions of use. Products are marketed Gerald Dorrington The waste containers most com- in a type of Internet shop, and there monly found in South Africa are is always a sufficient stock of spare 240 litre wheeled bins. These bins are parts based on the selected number not cleared with vehicles or lifters built of products. Mechlift also handles the to European standards, however. With After-Sales service for customers. The an unemployment level of 40 percent, market share is 90 percent. the focus is on job creation measures. The crew of a waste collection vehicle But the South African waste manage- generally consists of one driver and ment sector has now moved into the four other operators to pick up the modern age. Mechlift has developed a bins or bags. There is virtually no auto- lifter data monitoring program for the Info mation of work procedures. The lifters iPad. With the “LiftLogger”, the lifter have simple circuits and servicing work performance can be read off and dis- is handled by mechanics or welders. played on the Internet. The new sys- For further information Personnel are generally poorly trained tem has gone down well in the market see: www.mechlift.com and unfortunately often poorly edu- and has changed the way of thinking The company headquarters of Mechlift (PTY) Ltd. in South Africa www.liftlogger.com 18th volume | Issue 41 | June 2013 18 th

volume | Issue 41 June 2013 K›MOBIL THE KIRCHHOFF GROUP MAGAZINE

We wish you a great summer season.