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ThyssenKrupp System EngineeringCorporate (without Divsion)
ThyssenKrupp System EngineeringDrauz Nothelfer I Krause I EGM
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ThyssenKrupp System EngineeringCorporate (without Divsion)
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ThyssenKruppSales 53.4 billion € • EBT 3.128 million € • 199.000 employees
Umsatz 2007/08; Mitarbeiter: 30. Sept. 2008; gerundet
SteelAmericas
SteelEurope
TK Steel Europe• Steel Europe • Processing
ServicesElevator
Nirosta
AST
NewStar
Mexinox
Stainless International
SKS
VDM
Stainless International
Materials Services
Elevator Technology
Plant Technology
Components Technology
Marine Systems
CSA
CompassMetals Services Special ServicesIndustrial Services
UhdePolysiusFördertechnik
System EngineeringTransrapid
Rothe ErdeBerco
CamshaftsSteeringForging GroupBilstein-GruppeWaupaca
HDWBVNBVSS
CENESEAMEAMSAP
ES/PBBAccessibility
Division Materials
Division Technologies
ThyssenKrupp: Focused Industrial Group With Two Pillars
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ThyssenKrupp System Engineering - Organization
Drauz Nothelfer
Forming Dies
Josef Görgen
Krause / EGM
Testing Solutions
Peter Kohlwig
Krause
AssemblySystemsJean-Luc Guyon
Drauz Nothelfer
Body-in-White
Josef Görgen
Drauz Nothelfer
Part Production
Bernd Becker
•Engine testing
•Transmission
testing
•Axle testing
•Measuring
machines
•Engine assembly
•Transmission
assembly
•Axle assembly
•Body-in-White
•Final assembly
•Tools & Dies
•Prototypes
•Body assembly
•Hydroforming
3 Brands, 4 Continents, 11 Countries, 4000 People, 800 million € Sales
ThyssenKrupp System Engineering
Bernd Becker (CEO) Uta Anders (CFO) Martin Hilbig (CHRO) Bernd Becker (CEO) Uta Anders (CFO)
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Div
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Solu
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Motor / Transmission / AxlesTurnkey solutions for test systems
End of Line Test bench
Function & NVH test bench• Engine• Transmission• Axle
Complete test areas
• Dimensional measuring• Part control• Leak test• ect.
Measuring technologyHardware
Measuring technologySoftware
Component testing and integrated quality assurance (IQA)
Test areas
Measuring computers• Decentral measuring electronic DME• Programmable measurnig electronic PME Sensors• Laser
UPS 32
Extensive test applications
UMSDimensional measurement andIQA
• Simultaneous Engineering• Training• Production support• Retools• Maintenance• Spare parts• etc.
Service
Satisfied Customers Are Our MotivationTesting Solutions – Product Range
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Test bench for dual clutch transmission
Test bench for Diesel engines
Test bench for differential
• Function test (mechanical, electrical) at nominal speed and torque• Noise vibration harshness (NVH)• Park pawl test• Determination of clutch characteristics• Diagnosis of TCU and CAN bus simulation
• Combined NVH and balancing with up to 40 % reduction of investment costs• Initial breakaway torque, drag torque, ratio test, differential test • Noise vibration harshness (NVH)• Balancing of pinion flange
• Engine function test (mechanical, electrical) in unfired, torqued mode• Engine mechanic test (crank – cam shaft)• Common Rail Test with max. system pressure • NVH test• Test of engine sensors and actuators
Satisfied Customers Are Our MotivationTesting Solutions – Selected References
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Automatic Stations
Transport Systems
• Friction roller conveyor - horizontal - vertical - up to max. 2000 kg• Flex link conveyor (KSR)• Components (modular)
• Assembly operation• Tightening and press-in operation• Sealant application• Measurement and adjustment
Manual Stations
• Simultaneous Engineering• Instruction/Training• Production attendance• Modifications• Maintenance• Spare parts
Service
Engine / Transmission / Axle Assembly Turnkey Powertrain Assembly Systems
Service
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Syste
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Pallet Systems (Pallet, Adapter)
Assembly Systems
• IMS+• Multi-adapter system - flexible use - modular design
• Highly flexible• Ergonomically designed• Modularly extendable
Complete assembly systems for engines, transmissions and axles including measuring technology and testing solutions from one source
Why the Total Is More Than the Sum of Many PartsAssembly Systems – Business Activities
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•Flexible ergonomically designed manual work stations
•Adapter/pallet concept for further engine types prepared
•Output up to 300.000 engines/year
•Ideal for “low cost” locations
•Automatic assembly line for engine, cylinder head and final dress
•Automatic valve-lash adjustment
•Automatic engine function test and leak test
•Standardized stations•Different cylinder head
versions on one assembly line
•Space allowance for integration of additional product variations
•I3-I6 cylinder
•Overall responsibility for complex controlled processes
•Early fault detection•Optimal work station layout•Fuel-saving future
technology
•Flexibility: In-line 4-cylinder up to V12 engine
•Modular concept•Output: 10.000 up to
500.000 engines/year
•Highly automated assembly and test facilities for 5 worldwide production locations
•Same quality at all locations•Global project management by
utilization of 5 TK Krause locations
Navistar / 12.4 L I6 Truck EngineFord Commonality / Global System Supplier for 10 Assembly Lines
Renault / Semi-automatic Engine Assembly SystemVolvo Car / Fully automatic Cylinder Head Assembly
Volkswagen Double Clutch Transmission GM Automatic Transmission
Why the Total Is More Than the Sum of Many PartsAssembly Systems – Selected References
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Div
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Turnkey, customized body-in-white plants
Virtual process safeguarding at an early stage
•Framing stations up to 8 models• Robot framing
• Brazing, cutting, welding• Remote welding
• Tabletop hemming• Roller hemming• Hem dies
• Upgrade/Relocation• Plant optimization• Spare part service• Training
Car Body Manufacturing
General contractor for complete final assemblies
• Manual and automated systems•Roller technology
• Marriage assembly systems• Chassis equipment• Wheel assembly
Semi- and fully automated glass gluing and flange seal assembly
e.g. for bumpers, cockpit, frontend and center console
Final assembly technology
Planning – Virtual Safeguarding – Project Management - Commissioning - Service
Turnkey Sealer applications Marriage systems Window assembly systemsModule assembly syst.
Turnkey Digital factory Framing Hemming technologyServiceLaser application
How the Fascination With Car Design And Structure Is EmbracedBody-in-White – Business Activities
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Div
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Wh
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• Body equipment closures• Planning in Germany, local pro- cessing• > 40% local rate
• 3 sites: Ingolstadt, Neckarsulm, Changchun• Use of the Drauz Nothelfer plate technology for the application of door sealings
• 5 models, cycle time 55 sec.• Engineering in Germany• Co-operation with local suppliers• Local design and commissioning
• Industrialization of remote laser welding • Supplier for remote laser cell doors equipment in Sindelfingen and South Africa
• Realisation of side panel equip- ment in Wolfsburg, Brüssel and Mosel• Processing via all German Drauz Nothelfer sites
• System partner doors (tools and bodyshop) and side panel for Zaragoza plant• Quality responsibility for door module
Shanghai VW Santana 4000
Audi A4 / Door sealer application
Renault Logan Brasilien / Marriage
Mercedes C-Klasse / Remote laser welding
VW Golf V / Side panel
Opel Meriva /Doors and side panel
How the Fascination With Car Design And Structure Is EmbracedBody in White – Selected References
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Tools for serial production
System responsibility for assemblies up to complete bodies hand in hand with the division body-in-white
Tools - Components – Fixtures - Assemblies Tools for outer body parts and structure – all materials
Simultaneous Engi-neering, method planning, design
Individual operations/ value-added levels up to full outsourcing worldwide
Quality attainment of own and supplied tools
From individual components to o.k. assembly, respecively o.k. car body
e..g. digitalization,laser hardening/cladding, lean tooling standards
Preventive mainte-nance/maintenance, spare part management
Div
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Die
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Engineering Purchasing Tryout Matching Innovations Service
Prototypes
How To Form QualityForming Dies – Business Activities
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• 14 die sets e.g. longitudinal carrier
axle support• High strength dual phase materials e.g. DP 600, up to 2mm thickness• High quality requirements
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• System responsibility door assy.• Inhouse manufacture outer skin and inner panel• Sourcing in Eastern Europe and Asia
• Material aluminium / steel• Responsibility for doors, bonnets and tailgates/hatchbacks as assy.• Development tooling• Sourcing China
• Planning and consultation regar- ding components• Prototypes with production intent• Worldwide supplier management• Tryout in press shop• Integration of all TKDN sites in Europe and North America
• Manufacture and tryout of side panel tooling for Genk
Audi Q5 / High strength steel expertise
Jaguar XF / Closures as system supplier
BMW X5 / General contractor for about 700 tools
Ford Galaxy / Side panelOpel Corsa / System partner doors
• Consultation regarding component engineering• First sample parts• Prototype tooling• Small-series tooling• Welding equipment• Laser cutting equipment
Fendt
How To Form QualityForming Dies – Selected References
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Div
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Pro
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• Manufacture of low-weight and high-strength hydroforming parts for ultimate stress
• Manufacture of IHF tooling in own tool shop
Part Production
• From individual assemblies up to complete body in steel or aluminium
• Planning, design and commissioning of equipment and tooling by body-in-white and forming dies division
• Support in Simultaneous Engineering
Hydroforming (IHU)
Many of our competencies join in productionPart Production – Business Activities
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• Material aluminium• Serial components and equipment• Manufacture of about 160 assemblies per day
Porsche 911 / water tube IHF
Audi Space Frame ® / different IHF parts A8, TT, R8
• Material aluminium•Serial components and equipment • Patented sealing process for multi- chamber extrusions • Total forming process inhouse
Lamborghini Gallardo Coupe and Spider / Complete body
•Aluminium bodyframe construction
•Small series manufacture, about 10 bodies per day
•Outer skin expertise•Simultaneous Engineering
Porsche 911 und Boxster / Back panel lower for spare wheel
•Material steel•Manufacture of 150-200
assemblies per day
Mercedes S-Klasse / Main floor
•Material steel•Highly automated
manufacture with 400-500 assemblies per day
•Successful trials with Bondal plates
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• Material high-grade steel• Different cages from one modular tool• Multi-part production• Close limit inside component
Behr / Cage for heat exchanger in IHF
Many of our competencies join in productionPart Production – Selected References
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Drauz Nothelfer
Krause and EGM
Products and Services along the Automotive Value ChainDrauz Nothelfer I Krause I EGM
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Automation and Assembly Competence for AerospaceNew Business Unit Aerospace
• Process Planning and Simultaneous Engineering
• Management of complex turn-key assembly system projects as general supplier
• Design and commissioning of customer-oriented optimized modular assembly equipment
• Implementation and combination of proven production and assembly technologies
• Development and use of advanced joining and testing technologies
Airbus A350XWB ProgramSimultaneous Engineering for
automatedproduction equipment of• Outer Wing Box• Center Wing Box• Vertical Tail Plane • Horizontal Tail Plane
From Concept to Realization Selected References
Boeing 787Finishing of CFRP tools for front
spar andfront spar bond assembly
Airbus A400MDesign, manufacturing and
delivery of the inner and outer flap rack
Airbus - Next Generation Flaps
Development and Build of audit cells for
automated testing of integrated CFRP flaps
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Subsidiaries
Service branches
Commercial agencies
Global Company - Local Presence
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ThyssenKrupp System Engineering - Philosophy
• short decision-making channels• minimum number of interfaces• short reaction time• high degree of customer orientation
• cost reduction• quality increase• high system uptime• short delivery time• reduced maintenance and spare parts expenditure• high degree of reuse for
modifications/extensions
• Americas: USA, Mexico, Brazil• Eastern Europe: Poland• Asia: China• cooperation with local partners
Project-oriented organization structure with
Standardized, modular solutions to the advantage of our customers
Utilization and expansion of world-wide low-cost production locations
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ThyssenKrupp System Engineering - Customer ReferencesAmerica Europe Asia/Australia
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ThyssenKrupp System EngineeringCorporate (without Divsion)
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• Ford - Q1 Award• Best Factory Award• County of Saxonia Price for Quality• BMW – “7-series Partner” • GM - Supplier of the Year: Body Shop Equipment & Service• VW - Global Supplier Award• S-VW - Golden Prize for Best Commercial Performance (China)• Ford / Jaguar - Reliability & Maintainability compliment
• DIN EN ISO 9001:2000 Quality Management System• IQNet ISO 9001:2000 International Certification Network for Quality Management System• VDA 6.4 Quality Management System for production equipment• TS 16949 Quality System Management for the parts supply into the automotive industry• DIN EN ISO 14001 Environmental Management
Recent Awards Certificates
Awards and Certificates
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TKSE is well established in North AmericaNAFTA Region Overview - 40 yrs experience, 5 Sites, 100 Mio. $ Sales, 370 Employees
Chrysler SebringDecklid Assembly Cell with Lazer Brazing
Forming DiesTesting Solutions
Assembly Systems Body in White
Freightliner P3Turnkey Bodyshop for Aluminium Cab, Saltillo, Mexico
BMW X5Engineering, Sourcing, Matching and Launch management
Ford D3XEngine Assembly on a convertible & globally common system architecture
GM 6RTransmission Sub-assembly, Assembly & Test for Europe, Mexico and the U.S.
GETRAG RDM 646Combined Balance & NVH End-Of-Line Test Stand for Rear Axles
Selected References
Detroit, MI - Auburn Hills
12,600 sqm 213 employees
- Janesville, WI: 232 sqm - 14 employees
- Huntsville, AL: 836 sqm - 13 employees
- Greer, SC: 520 sqm - 5 employeesQuerétaro, Mexico
3,600 sqm89 employees
Sales & Service Sites
Site Map
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Fast Growth in Asia Far East Region Overview
Forming DiesTesting Solutions
Assembly Systems Body in White
Site Map
Selected References
ThyssenKrupp System Engineering (Shanghai) Co., Ltd
Gaodong Facility (Northeast of Shanghai)
- 1400 sqm in total- 25 direct employees- 20 contractors
Sales and Service Sites in India, Korea and Japan
Commercial Agencies
S-VW FabiaFraming and Closure weld lines (China)
Tata ACE MinitruckEngineering and Turn-Key Bodyshop (India)
Opel Meriva NewSourcing of door dies(Korea)
Tata Small CarEngine Function Test (India)
VW TSTransmission Assembly Line (China)
KOEL Transport system, pallets and verification stations (India)
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Site Map Selected References
ThyssenKrupp Production
Systems Ltda.,Sao Paulo, Brazil- founded in 1973- 40 Mio. € Sales- 125 employees- 15.000 sqm shop floor
- 35.000 sqm in totalFilial Site in Buenos
Aires, Argentina
Testing Solutions
Body in White
Mercedes Class C coupé and Class ATurn-Key Bodyshop, Juiz-de-Fora, Brazil
FIAT Fire MotorEngine function test, Belohorizonte, Brazil
VW new Gol familyTurn-Key Bodyshop, Taubaté and Anchieta, Brazil
Ford TruckChassis line, São Bernardo, Brazil
Assembly Systems
VW power train EA-111Powertrain line, São Carlos, Brazil
Top League of South American Production Equipment SupplierSouth-America Overview
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