COMPANY TOUR DOPPELMAYR PRODUCTION PLANTS MANUFACTURING QUALITY 2/3 DOPPELMAYR · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4/5 THE PRODUCTION PLANTS AT A GLANCE · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6/7/8/9 PLANT “HOHE BRÜCKE” · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 10/11 PLANT “GÜTERBAHNHOF” 120 YEARS OF ROPEWAY STANDARDS AN OVERVIEW OF DOPPELMAYR Since its foundation in 1981 LTW has Milestones been a member of the Doppelmayr 1892 Company foundation Group. Originally the global market by Konrad Doppelmayr leader in ropeway systems entered the technology of high-bay ware- 1937 First ski lift in Zürs, Austria houses in order to compensate 1953 First overseas commission seasonal fluctuations in production. Since then LTW has emerged as a 1972 First detachable gondola pillar of the group. 1976 First detachable chairlift The manufacturing of stacker cranes 1981 LTW foundation according to ropeway standards is one of the outstanding quality 1996 Michael Doppelmayr features LTW has to offer. Ingenious in 4th generation constructions and extremely fine 1998 First detachable 8-seater chairlift manufacturing tolerances guarantee exact material handling, even at 1999 First Cable Liner Shuttle in Las Vegas heights of 40 m plus. 2001 Doppelmayr Holding AG with integration of Doppelmayr today CWA Constructions SA/Corp. > Global market leader in ropeway 2002 Merger with Garaventa systems Seilbahnen AG > More than 14,300 installations 2002 First tricable and bicable ropeway implemented worldwide 2004 World novelty: first seat heating > Subsidiaries and agencies for chairlifts in 33 countries > Export into 87 countries around the 2006 World novelty: first ferris wheel world (Export content 80 %) Funitel, Galzigbahn/St. Anton am Arlberg, Austria > Employees worldwide approx. 2,200 2008 Longest tricable ropeway in the > Turnover approx. 620 Mio. EUR world: peak 2 peak gondola in Whistler Blackcomb, Canada 2010 Novel recovery concept for ropeways 2012 First urban ropeway in London 2/3 DOPPELMAYR · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4/5 THE PRODUCTION PLANTS AT A GLANCE · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6/7/8/9 PLANT “HOHE BRÜCKE” · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 10/11 PLANT “GÜTERBAHNHOF” EXPERIENCED QUALITY OVERVIEW OF THE PRODUCTION PLANTS LTW stacker cranes and conveyor that high class certified materials system components come a long way such as sheets and tubes turn into before being able to be used by the warp resistant mast segments and customer. other component parts for LTW systems. More than 50 cranes on two Since 2002 the components spend an levels are there to support. essential part of the company-internal round trip in the plant “Hohe Brücke”, Assembly and pre-commissioning the biggest production plant of the Doppelmayr Group. Opposite the plant “Hohe Brücke” the plant “Güterbahnhof” is situated, In the plant “Güterbahnhof” located where LTW products as well as various opposite, the assembly of the compo- Doppelmayr components are com- nents and the pre-commissioning take plemented. place. Every stacker crane, every transfer car, Manufacturing according to ropeway every vertical lift including the electric standards and electronic parts has to pass an All Doppelmayr plants attach impor- intensive test run. tance to the highest quality and Only if all functions work perfectly, the safety standards for ropeway systems. devices are made ready for shipment Passenger transport demands ex- so that on site they only have to be set tremely close tolerances, specialist up by the LTW team and are able to knowledge of employees and approp- start running. riately reliable machinery always up to date. Karl-Heinz Zündel, Manufacturing employees. In order to pass on the PLANT DATA Lots of room for highest quality existing knowledge to the whole “Our production plants offer an Plant “Güter- company, we have integrated, besides bahnhof” Beside the pertinent office units, Plant “Hohe Brücke” ideal platform for all manufacturing 2 the training workshop, our own steelwork, mechanical manufacturing, Hall area/offices: approx. 18,000 m requirements of the Doppelmayr 2 occupational field into the production. storage area and preceding and Roofed open area: approx. 8,000 m Group. following services such as manu- Approx. 250 employees Plant facturing organization and quality We produce only highest quality, In total approx. 75 trainees are being “Hohe Brücke” Plant “Güterbahnhof” whether ropeway system, cable liner exposed to the latest manufacturing management are located in the plant Hall area: approx. 3,000 m2 or stacker crane. Our machinery is technologies before being integrated “Hohe Brücke”. Open area: approx. 5,000 m2 always up to date as well as our into the different departments.” On a floor area of 26,000 m2 approx. Approx. 30 employees 250 dedicated employees make sure 2/3 DOPPELMAYR · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4/5 THE PRODUCTION PLANTS AT A GLANCE · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6/7/8/9 PLANT “HOHE BRÜCKE” · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 10/11 PLANT “GÜTERBAHNHOF” PLANT “HOHE BRÜCKE” – MANUFACTURING 1 STORAGE AREA AND PRODUCTION SETUP Bar material > More than 1,000 items > Delivered in final dimensions Steel sheets > Material thickness from 4 mm to 130 mm > Leftovers from cutting are reprocessed Setup area > Order related picking of fitted components, preparation for steelwork Storage bar material Order related picking 2 MARKING AND CUT Marking and drilling facility > Clear marking of the individual components with an ID number > 3,800 bar water pressure Main entrance Manufacturing LTW Oxyfuel cutting equipment Only Doppelmayr > CNC controlled > Material thickness from 20 to 130 mm Plasma cutting equipment 1 6 11 Storage area and Welding area Training steelwork > Material thickness up to 40 mm production setup (tacking, welding, > Temperatures up to 30,000 °C adjusting, cleaning) Marking and drilling facility Oxyfuel cutting equipment 2 Marking and cut 7 Quality assurance 12 Training mechanical welded seams manufacturing 3 SURFACE PREPARATION Ball shot blasting 3 8 13 Surface preparation Annealing furnaces Mechanical > Removes scale and slag from the manufacturing sheets Belt grinder 4 Steel pre-fabrication 9 Robot for bullwheel 14 Test range and > Removes cutting ridge and sharp manufacturing measuring zone edges Troughed blasting system > Removes scale, rust and cutting burr 5 Welding robot 10 Manual bullwheel of small parts manufacturing Ball shot blasting Belt grinder 2/3 DOPPELMAYR · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4/5 THE PRODUCTION PLANTS AT A GLANCE · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6/7/8/9 PLANT “HOHE BRÜCKE” · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 10/11 PLANT “GÜTERBAHNHOF” 4 STEEL PRE-FABRICATION 11 TRAINING STEELWORK 12 TRAINING MECHANICAL MANUFACTURING Welding edge grinder Training area > Preparation of components to be > Area 300 m2 each welded (chamfering) > Fully equipped workplaces > Integration into the production, Sheet orientation tasks are order related > Bending sheet edges for welding, > Transfer of highly skilled knowledge adjusting bent sheets and latest manufacturing techniques > Trainees usually remain in the company or a subsidiary after completing their training Welding edge grinder Sheet orientation – Edge bending / adjusting Training steelwork Training mechanical manufacturing 5 WELDING ROBOT 13 MECHANICAL MANUFACTURING Welding robot Various CNC lathes and lathe milling center > 11 welding robot equipments for > Complete manufacturing of components small and large parts > Max. component size 15 x 2.5 x 2.5 m Various machining centers (drilling and > Max. component weight 10 tons milling) > 1 welding robot for occupational field > Up to five-axis construction > Cross linking of the machining centers 4 devices for treating large parts > Treatment of components with up to 16 m length, 4.5 m width and 3.5 m height > Tool depot with 120 spaces Welding robot for small parts Welding robot for large parts Drilling and milling center Cross linked machining centers 6 WELDING AREA 7 QUALITY ASSURANCE WELDED SEAMS 14 TEST RANGE AND MEASURING ZONE Workplaces for manual tacking, Testing hall and open test location welding, adjusting and cleaning > Measuring of various components > Special light concept, Wood-block with Zeiss measuring machine paving for effortless and back-friendly (3 x 2 x 1.5 m) or with a flexible arm working for large parts > Complete air exchange in the hall > Magneto-inductive testing (MT) area within 40 minutes Quality assurance welded seams > Visual testing (VT) > Magneto-inductive testing (MT) > Ultrasonic testing (UT) Worker-friendly designed welding area Ultrasonic testing of welded seams Open test location with Zeiss measuring machine Crack detection of components 2/3 DOPPELMAYR · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4/5 THE PRODUCTION PLANTS AT A GLANCE · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6/7/8/9 PLANT “HOHE BRÜCKE” · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 10/11 PLANT “GÜTERBAHNHOF” PLANT “GÜTERBAHNHOF” – ASSEMBLY C LIFTING