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glück auf · 1/2011 · Extraits en langue française ........................... 1 glück auf · 2/2012 · Extracts in English .......................................... 1

Merely a question of time GMH Group · The proportion of women employed in the GMH Group is increasing constantly. And the GMH Group creates conditions which support women in their careers and help them achieve success.

I t is meanwhile an established fact that women at work –

whether in the industrial or com-mercial sector – are usually very well qualified and thus provide significant added value for the employer. Women are therefore warmly welcomed by the GMH Group.

This already begins in the acquisition of junior employees. By means of participation in Girls’ Day, specific approaches to (prospective) academics, training of women in technical profes-sions or involvement of qualified mothers who are currently not in professional employment, com-panies of the GMH Group show clearly where they stand.

Long-term and reliable inte-gration of women at the work-place can only be successful, however, if the employer knows about the challenges involved in combining work with family life, and also accepts them and pro-vides appropriate working condi-tions. GMH Group companies are well aware of this.

Many of our companies, therefore, already offer flexible working hours, mobile work places (home office), individually tailored possibilities to return to work after maternity leave, care and supervision of schoolchil-dren during school holidays or even family support periods, to

mention just a few examples. The same fundamental principle applies to all these companies, as it does to Harald Schartau, Man-aging Director for Human Re-sources and Personnel Manager of Georgsmarienhütte Holding: “We will never put obstacles in the way of a qualified woman. On the contrary. Should there be any in her way, we will remove them.”

The proportion of women em-ployed within the GMH Group is not regulated by quotas, because Harald Schartau does not con-sider such a measure to be neces-sary: “Not only because women are welcome here. We also have an equal treatment system with regard to recruitment, pay and career opportunities.” Indeed, Kranbau Köthen is a good exam-ple of how other GMH Group companies think and act in a similar way because the crane construction company has re-cently been awarded the title of “Family-friendly business”.

For many decades steel pro-duction and processing was considered an exclusively male domain. Well-developed mus-cles and good stamina were the principle qualities required on the shop floor, whilst rough language and manners prevailed in the office. Today, however, a look into the production facili-ties and offices shows that times

have changed. Increasingly frequently jobs in these areas which used to be done by men, also at management level, are now held by women. Statistics prove that this impression is correct.

Against such a background, it seems almost superfluous to mention that almost 800 of the approximately 11,000 employees of the GMH Group – in other words almost 7 percent – are meanwhile women. However, the proportion of female train-ees is almost twice as high, at 11.6 percent. And in the GMH Group’s current junior trainee programme, seven of the 31 par-ticipants are women – represent-ing a proportion of 23 percent. Furthermore, by comparison with other Group companies, the quota of women employed by Georgsmarienhütte Holding is the highest at 47 percent.

Nevertheless, despite the in-creasing proportion of women within the GMH Group, no woman has ever progressed to the management level of a GMH manufacturing company.

“But that is about to change. Very soon a leading managerial position is going to be occupied by a woman“, says Harald Schar-tau, looking confidently to the near future.

ikw

EdItorIal

Dear Colleagues,

Which team has won the Euro-pean football championships? By the time you read this, you will already know. As this edi-tion of glückauf goes to print, however, the answer is still in the clouds. As far as some issues are concerned, it is quite simply a question of time. This certainly applies with regard to the many optimisation projects within the GMH Group, about which reports are included in this edition. Here also a period of time is required before the extent of the benefits can be realistically assessed. And if there aren’t any? In contrast to the European championships, it is always possible to make a fresh start.

Editorial team

»Success needs us all«Illustration: lutz Mathesdorf

glück auf2/2012

Extracts in English

The newspaper for employees, customers and friends of the GMH Group


that’s us

Security of supply and processing expertiseGMH Group · Reliable partner and service provider: The value chain begins with the Raw Materials Recycling business unit.

W ithout scrap there is “nothing doing” in the melt shops and foundries of the

GMH Group. This secondary raw material, which is fundamental to the steel and found-ry industries, is procured by the companies of the Raw Materials Recycling business unit for the production processes of GMH Group members and numerous customers national-ly and internationally, and is processed using wide-ranging, state-of-the-art technologies.

Rohstoff Recycling Osnabrück GmbH and Adolf Ellermann GmbH were taken over by GMH Holding GmbH in 1995. Rohstoff Recy-cling Dortmund GmbH was founded in 2001.

In Osnabrück, Dortmund, Mülheim/Ruhr and Krefeld, steel scrap and residual iron are processed in special-purpose installations at sites totalling 140,000 m2 in area - large enough to accommodate around 14 football fields.• The harbour-based site in Osnabrück in-

cludes a press for the briquetting of grind-ing swarf and steel turnings, in addition to two alligator shears, a baling press, and an NF separation installation with attached float-sink plant.

• The site at Dortmund harbour processes heavy, large-volume scrap with the aid of two drop-ball crushers, three hood- enclosed burning chambers, a under-ground blasting chamber and a scrap shear. Two rented drop-ball facilities for crushing pig iron skulls and engineered castings are additionally available in Mülheim/Ruhr.

• In Krefeld a screening plant processes sepa-rated scrap for its ferrous metal content.Used for handling the scrap prior to its

transportation by road, water and rail are 19 mobile excavators, two slewing cranes

and two gantry cranes.

The range of activities of the business unit’s 176 employees goes far beyond processing the secondary raw materials and sup-plying to the Group companies, however. The international marketing of scrap, of residual iron from the metallurgical and steel industries, of NF

metals and of alloyed scrap grades also plays a major role as do, equally, the business of collecting discarded secondary raw materi-als, and consulting, disposal, hire crushing and screening, demolition, logistics and slag management services.

The Raw Materials Recycling business unit thus offers an extensive portfolio relating to the supply of scrap materials, including industry-specific services for steel mills and foundries of the GMH Group as well as other national and international customers.

mk

photos: Felix treppschuh

View of the company premises of Rohstoff Recycling Osnabrück GmbH

Special scrap“Special scrap” encompasses materials such as rolls, dies and moulds. Metallurgical by-products, by comparison, come about in melt shops and comprise either pig iron or steel. Rohstoff Recycling Dortmund GmbH crushes such materials - generally delivered as large, heavy and solid entities - in its own processing installations into sizes suitable for charging.Examples of the wide diversity of materials that are processed include pig iron and steel skulls in various sizes, castings in the form of automotive industry dies, cast metal ingots from the steel industry, and steel rolls.

torch-cutting chambers. To re-duce the size of large-volume scrap, Rohstoff Recycling Dortmund GmbH operates three hood-enclosed torch-cutting chambers facilities equipped with a modern exhaust-air cleaning system. Such a facility comprises a roofed-over and encapsulated area within which heavy scrap is cut up into chargeable sizes using industrial torch-cutting equipment. Holes are burned into the pig iron skulls and rolls by means of oxygen lances in preparation for blasting. During such work the personnel are located outside the enclosures and thus protected from flying sparks and torch-cutting fumes. All the hood enclosures are connected to a modern filter system, with a slightly neg-ative pressure being maintained within the enclosures. Around 770 filter bags ensure that no dust finds its way into the environment. This extraction system uses state-of-the-art filter techology, cleaning approximately 140,000 m3 of exhaust air per hour. The mass flows that develop in the process lie well within the limits stipulated in Germany’s 2002 “TA-Luft” air quality requirements.

Detonation chamberThe underground blasting chamber is a reinforced-concrete monolith that is fed by a crane with materials that are to be reduced in size, such as rolls and pig iron skulls. Blasting holes are cut into the materials beforehand in the hood-enclosed torch-cutting facilities and packed with explosives and a fuse. The deto-nation chamber is then closed off by means of a traversible cover (weight of the cover: 360 t) to prevent any objects from being hurled unhindered from the chamber. Once the cover is in place, a master blaster electri-cally triggers the detonation from a remote location. Rohstoff Recycling Dortmund GmbH uses cartridge explosives for this process.


lEad artIClE

Proceeding cautiously“Since politicians are not creating reliable underlying conditions for the energy sector, we will have to pursue our corporate philosophy more scrupulously than ever.”

In the international economic and financial crisis, politicians have often repeated the

slogan “We’re proceeding cautiously”, out of uncertainty as to which bad debts would appear next in the banks’ accounts, how the markets would react to this and how the dimin-ishing confidence in the financial world would continue to weaken the real economy.

The consequences of these uncertainties are continuing to have effects throughout the world, but in Germany, at least, economic per-formance has reached pre-crisis levels. We have the highest number of employees paying into Germany’s social insurance programme since reunification.

Nevertheless, there are new storm clouds appearing on the horizon, so it is now up to the companies in this country to say “We’re proceeding cautiously”. Not just because we cannot guess how the markets are going to develop but also because underlying political conditions are becoming visibly more incalcula-ble – at German as well as at European level.

The national debt crisis within the euro-zone, European energy and climate policies and the energy u-turn in Germany are the three main issues on which politicians are failing to demonstrate any resolve or clear perspectives. Thus they are making it extremely difficult for private sector companies – the energy-intensive ones in particular - to make any long-term plans.

Whilst we have been talking about a “two-speed Europe” to date – namely the EU mem-ber countries using the euro as their common currency and those still using their national currencies, there are now also signs in the euro states of domestic and incalculable dynamics. Governments which are committing themselves rigorously to consolidating their budgets are being voted out of office one after the other – as we have recently seen in France as well as Greece. Or they are watering down their sav-ings targets in anticipatory obedience to their voters’ wishes – for example Mario Monti in Italy, who again cancelled an ambitious debt-brake in April. The – only half-hearted – efforts at saving are now to be supported by a growth pact.

However, if it is to be financed with new debt, in other words, if we are not talking about more state-financed economic stimulus packages, only structural reforms will be left to stimulate the weak economies in the coun-

tries affected by crises and reduce government expenditure. In concrete terms, we are talking - for example - about whether the French will keep their state-mandated 35-hour working week, whether the Spanish will adhere to their extreme job-protection legislation and whether the Greeks can continue to afford an inflated state apparatus with massive personnel costs.

In Germany some of these questions have already been answered with the employment market reforms of Agenda 2010: unemploy-ment market benefits and social welfare benefits have been combined, the long-term unemployed have had to accept considerable cuts in these benefits, the instrument of mini-jobs has been created, and employment agency work regulations have been liberalised. The instrument of short-time working came later in order to keep German companies flexible and competitive during the economic crisis as well.

It is due far more to the significance of me-dium-sized companies in Germany’s economy that we are comparatively robust from an eco-nomic point of view: small and medium-sized companies are world leaders in many areas with their highly specialised products and they also combine to provide over half of all jobs subject to compulsory social insurance contributions. Businesses such as the GMH Group are firmly integrated into industrial value chains and can act independently of financial markets (and were indeed vilified as “old economy” before the crisis precisely for this reason).

This German medium-sized sector is the anchor of stability in the crisis and part of the industrial base for growth and prosperity. In Greece, Italy or Portugal you seek such struc-tures in vain. For this reason in particular it remains to be seen whether the debt-ridden euro-states can succeed in consolidating their economies with ambitious structural reforms or whether they will continue to fall into the downward spiral of new debt, higher taxes and hence sinking competitiveness.

In order that we, too, as member companies of the GMH Group, can continue to make use of this stabilising function, a few clarifications are required from politicians, in particular a clear commitment to Germany as an industrial location. The additional gigantic burdens that threaten the German steel industry are a result of emissions trading by the EU, the German Renewable Energies Act levy, higher energy taxes and increased electricity costs due to the

energy u-turn. These are uncertainties that make “proceeding cautiously” necessary.

Major investments must be held back until reliable basic conditions in energy and climate policies prevail. Should all foreseeable burdens actually come about in this manner, invest-ments in Germany as an industrial location could be economically difficult from a business point of view and could only be justified with a very carefully calculated sense of proportion. With a view to European policies, the main is-sue is emissions trading. The cries to increase the price per tonne of emission rights - which has dropped to less than ten euros at the cur-rent time - by having the EU take certificates off the market, are becoming increasingly louder. At the same time it is certain even now that the price will rise considerably from 2013 due to the fact that fewer certificates will be traded when that period begins.

In order for German companies – in the energy-intensive steel industry in particular – to remain competitive, we need a rapid imple-mentation of compensation for national elec-tricity prices into national law, as was decided by the EU in May. With compensation restricted to 85 percent of electricity price increases and to 75 percent from 2019, as provided by the EU, we will be able to compensate for our in-ternational competitive disadvantage – but not completely.

The energy u-turn and its related, ambitious aims are, on the other hand, an exclusively Ger-

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Photo by courtesy of the GMH Group


man issue. Even after the phasing-out of nuclear power, the future supply of power is intended to be environmentally friendly, guaranteed and economical. We do not need to worry about the environmentally friendly aspect – the Ger-man Renewable Energies Act - an Act for accel-erating the expansion of the German electricity grid and an Energy and Climate Fund to finance the energy u-turn - will take care of that.

However, the question of secure supply re-mains open to debate. How can the expansion and stability of the German electricity network be guaranteed if, at the same time, the share of renewable energies – the availability of which fluctuates – is continuously increased and an extensive source of base-load electricity is lost?

The question of economy is equally uncer-tain. There are no reasonable data on how far the electricity prices may vary by comparison with the international level and from which point they become a competitive disadvan-tage. Nor is there any consensus on how an affordable energy supply can be guaranteed in practice.

Germany needs a plan in which all three aims of national energy policy – environmen-tally friendliness, secure supply and economy – are treated equally and aimed for in a similar manner. A clean yet insecure energy supply is equally as worthless as a secure supply that is unaffordable for either private households or industry.

So far, no solution to these uncertainties is in sight – either at national or at European level. As long as we are unable to rely on clear under-

lying conditions from politicians over the long term, we will be forced to concentrate all the more on our own strengths: producing flexibly and close to customers, not taking any incalcu-lable risks and – instead – pursuing sustainable growth for all the member companies in the GMH Group.

Because, even if we are obliged to “proceed cautiously” from a political perspective, this company philosophy still provides us with a proven and reliable compass.

Glückauf

tHE oWNEr’S VIEW

What is required for the championship?Dear GMH Group employees, dear glückauf readers,

The Euro 2012 in Poland and the Ukraine is in full swing. There is hardly anyone who does not share the excitement and thrills with their favourite team and generally enjoy the summer spectacle. And even those who normally are not completely “football crazy” may well feel astonished at how such sporting competition brings people together and inspires them with overwhelming enthusiasm for the event.But what does a team need in order to achieve success? What preparations are required in or-der to compete against the crème de la crème? These are exactly the questions which we also ask ourselves within the GMH Group if we want to play in the highest league.

In the European Championship, the teams compete to master the round leather ball at the highest level technically, to combine strategy with fighting spirit and, in doing so, also to project themselves well and with sportsmanlike appeal. The one that invests the greatest effort – mentally as well as physically – in the training camp and then reproduces these efforts on the field in the actual matches will have the best chance of success. On the pitch the line-up must be right, the rules of fair play are to be observed towards opponents as well as fellow players – but each individual’s playing style must also involve a certain assertiveness.

Within our group of companies everything revolves around the basic materials of steel, iron and also aluminium. We are exposed to global competition in the manufacture and process-ing of these materials. You, dear employees,

work every day on making our processes more efficient and our products even better, lighter wherever possible and even more resilient, and putting them to use in even more intelligent applications. Sporting and technical ambition are rather similar in this respect.

Instead of the training camp we have our know-how, which has been acquired over many years, and the constant transfer of skills and knowledge. Nevertheless, constant self-criticism is necessary – to look at ourselves carefully and scrutinise how we work, to reflect, and if neces-sary learn from others about where and how we can become even better.

We need a team which covers all the re-quirements: older members who lead and share their experience and younger persons who are hungry for success and introduce a new approach. In the areas of mobility, energy and mechanical engineering we are already market leaders with a number of our products, in some cases even at global level, and we are able to react quickly and flexibly to the wishes of our customers, whom we support as a reli-able partner – all of which is a reflection of the fact that we do our homework well and are well positioned.

However, success like this is always only of snapshot value. The business world is dynamic and such success must always be defended anew which means we must re-define ourselves constantly and inspire new confidence. That is the team spirit of the GMH Group: We want to play at the top, become champions in our field.

We see this not as a one-off target but as a per-manent task.

In order to accomplish it there must be fair play in our dealings with each other. In con-trast to large conglomerates, this means that the employees in our companies must pass the ball on or accept an unexpected ball now and again and always think a step ahead of our “op-ponents”.

But the most important thing is: in the long term no-one is successful alone – the team lays the foundation for success. And we want to share this success fairly with each other when-ever it is achieved. Everybody deserves to have a share.

Glück auf!


q Continued from last page


Strong joint representationGMH Group · Hanover Fair 2012: Nine companies of the Group presented themselves as competent partners for the energy sector in the context of the “Energy” flagship fair.

P resent expertise in “young” as well as “old established”

sales fields, strike up customer contacts and further increase the level of awareness of the GMH Group – these were the objectives which nine companies of the GMH Group wanted to achieve at the five-day Hanover Fair. The fair, which is considered to be the most important technology event in the world, took place from 23rd to 27th April and its gates were open not only to trade visitors but also to the general public.

This year the fair was divided into eight flagship fairs which all made a convincing impression with their diversity of topics. The most important technologies and innovations from varying fields of industry were displayed over an area of more than 150,000 m2. The GMH Group naturally had to be there too.

Nine companies of the Group (see box) presented themselves with numerous impressive and heavy-weight exhibits. Their fair stand was located in Hall 27 on the former Expo site. This building also accommodated the flagship “Energy” fair, one of the core themes of which was “re-newable energies“.

The GMH Group was thus located in the direct vicinity of sector giants such as GE Energy, Enercon and Vestas and conse-quently there were large numbers of visitors in this area of the huge fair site – which enabled the GMH companies to present themselves very effectively to potential customers. WeserWind exemplified the GMH Group’s involvement in the “Renewable Energies” sector. The company showed off its capabilities in the development, design, construc-tion and assembly of windproof and weatherproof foundation structures for offshore wind farms. The tripod model, which is 1.5 t in weight and 5 m in height, was a good eye catcher and attracted lots of fair visitors to the fair stand. But expertise in

wind power was not everything that the GMH companies had to offer the 195,000 visitors to the 2012 Hanover Fair. Its know-how in other areas of energy gen-eration met with just as much interest. Numerous exhibits provided impressive evidence of its wide range of products, in-cluding a cast steel Kaplan blade (Pleissner Guss) for hydroelectric plants and a forged connecting rod (Wildauer Schmiedewerke) weighing 850 kg for large en-gines.

During his tour of the fair the Minister of Economics of Saxony, Sven Morlok, also visited the GMH Group stand. Hartwig Kockläuner Managing Director, Holding, Market & Purchasing) and Michael Schiller (Manag-

ing Director, Schmiedewerke Gröditz) used this opportunity to discuss the energy policy in Germany with him as well as the general economic development at the Gröditz location. The Min-ister of Economics and manag-ing directors were in agreement: energy policy in Germany will have a significant influence on the future competitiveness of the energy-intensive and export-oriented GMH companies.

Ultimately, the benefits of the fair extended beyond the numerous talks with current and potential new customers. The joint presence helped, in

particular, to provide a stronger perception of the range of capabilities offered by the group of companies as a whole. Thus a lot of stand visi-tors showed great inter-est in the numerous

companies which are behind the red signet of the GMH Group. A logical consequence was that in many cases Group companies were able to establish contact with other Group companies on behalf of their customers. In this way customers were often able to find further suppliers and prod-uct lines from the range on offer within the GMH Group.

A further positive image effect ensuing from the constellation at the Hanover Fair was that the group of companies as a whole as well as individual Group com-panies attracted the attention of many qualified persons, includ-ing university graduates. This contributed to an even clearer perception of the GMH Group as an attractive employer.

Now that the event is over, the fresh impetus which the Hanover Fair has created must not be allowed to simply ebb away. Our aim must be to revive it again at future trade fairs in or-der to further improve the posi-tive image of the GMH Group amongst the qualified public.

Maren Dependahl

Who all was there?The following companies of the GMH Group were represented at the Hanover Fair: Schmiedag, Wildauer Schmiedewerke, Walter Hundhausen, Friedrich Wilhelms-Hütte Eisenguss, Pleissner, Pleissner Guss, Stahlguss Gröditz, IAG MAGNUM and WeserWind.

Facts date: 23rd to 27th AprilNumber of exhibitors: 5,000 from 69 countriesNumber of visitors: approx. 195,000Visitors from abroad: approx. 50,000this year the Hannover Fair accommodated eight international flagship fairs: Industrial Automation, Energy, MobiliTec, Digital Factory, In-dustrial Supply, CoilTechnica, IndustrialGreen Tec and Research & Technology.

Photos by courtesy of the GMH Group

Over two levels: the busy fair stand of the GMH Group.

Exchange of opinions (from left to right): Michael Schiller, Minister of Economics Sven Morlok and Hartwig Kockläuner.


Bigger stand came at the right timeGMH Group · Excellent timing: Wire 2012 in Düsseldorf achieved a new exhibitor and visitor record. The companies of the GMH Group were perfectly prepared for the large number of visitors.

F rom 26th to 30th March, 1,314 companies from all over

the world provided information about their latest machines and products. Amongst them were eight companies of the GMH Group: GMHütte, GMH Blank-stahl, Stahl Judenburg, MVO Metallverarbeitung Ostalb, Wista Stahlhandel Witten, Heinrich Geissler, J. A. Bäuerle und ESB.

But was this Wire event really appropriate for the GMH com-panies? At first glance it might seem that it was not because “wire” as such is not one of the GMH products. Nevertheless it is a tradition for producers of rolled bar steel from Germany and Europe to exhibit at this event. Accordingly, in Hall 12, where the GMH companies had their stand, a lot of our competitors were also present. This really was the venue where all the names and faces of the industry congre-gated.

The companies of the GMH Group were optimally prepared for the trade fair. A newly de-signed stand with a total area of

165 sq m constructed over two levels provided sufficient space for holding detailed discussions with regular customers as well as making new contacts. The “Messe” forum offered the op-portunity to discuss current subjects and new market trends or – very popular this time – to exchange information between Group members.

It soon became obvious that the expansion of the stand had

been very necessary. Not only be-cause an additional GMH com-pany, ESB, had joined the team of exhibitors. There was also a remarkable increase in the num-ber of visitors to the stand. Thus, particularly around lunchtime, there was not a single space free on the second level.

A substantial increase in the number of international fair visi-tors was also registered. This may well have been due – at least in

part – to the new catering con-cept. “Food et Event”, a company from Osnabrück, provided an all-round service and was respon-sible for the culinary delights.

ESB, as a first-time exhibitor, had a very successful time ac-cording to sales manager Frank Swierzinski: “In our opinion, after the Stahlmesse, the Tube & Wire dual trade fair is the most important and most popular fair in Europe. The principal objec-tive was to offer our customers, project partners and potential future clients a platform for per-sonal contacts.”

The response from ESB cus-tomers was positive, as was also underlined by the number of redeemed vouchers and ap-pointments on the stand. Frank Swierzinski: “At the meetings, prices were discussed, projects elaborated, or the opportunity was simply used for contact and social exchange. ESB had defined the tube industry as a customer group for round, continuously cast products. Although we, as the GMH Group, were actually exhibiting at the Wire event, within the scope of this dual fair we also wanted to be visible for visitors to the Tube exhibition.”

Furthermore, the fact that En-gineering Steel Belgium has defi-nitely decided to exhibit again at the Wire event in 2014 is due to the stand team, excellent organi-sation and a fantastic stand de-sign. Preparations for April 2014 are already in full swing. Then there will be a reunion at Wire 2014 in Düsseldorf.

Andrea Busch

traVEl tIPS – PrESENtEd By lEoN raduNoVIC

airlines are also in actionSaS: Europe’s most punctual airline. Scan-dinavian Airlines has now been distinguished by Flightstats as the most punctual airline in Europe for the third time in succession. With a punctuality rate of 88.22 percent on all flights, SAS occupies third place worldwide amongst all major scheduled airlines. In fact the punc-tuality rate has even increased by comparison with 2010 (86.47 percent). The data is based on punctuality statistics recorded by Flightstats which analyses more than 150,000 scheduled airline flights per day.

lufthansa: First Boeing 747-8 Intercontinen-tal. Lufthansa is the first airline in the world to receive the passenger version of the Boeing

747-8 Intercontinental. Back in December 2006 the airline ordered 20 new jumbo jets and se-cured an option on another 20. The new jumbo is not only 5.60 m longer but also equipped with the latest generation of wings and en-gines. Fuel consumption is thus significantly lower than in conventional aeroplanes used on long-haul flights. The CO² emission of the new series is approximately 16 percent lower than that of the B 747-400. On 1st June the world’s first passenger version of the Boeing 747-8 will fly from Frankfurt to Washington D.C. Other flights to the USA and to India are planned.

united/Continental: Last stage in the merger. The two US airlines United and Continental

actually combined forces back in 2010. Since then the new United has not only become the world’s leading airline, it is also the biggest in the world. Already since spring 2011 passengers have been able to recog-nise a homogeneous outer appearance and coordinated procedures as well as match-ing service features on the ground and in the air. In March, the last stage of the merger was completed, and ever since the two airlines have been operating exclusively under the name “United Airlines”, meaning that United flight numbers only are used.

photo: Senator reisen

The second level provided an oasis of calm amidst the bustle of the fair. This was a good place to talk in a relaxed atmosphere.

photo : oliver Santelli


the cheerful artistAfter a long professional life extending far beyond normal retirement age, Nikolaus Schuck is devoting himself to painting again. A visit to his atelier in Osnabrück.

a professional career as an economist and artist – is it

possible to combine both at the same time? Looking at Nikolaus Schuck’s career, it seems that this can only be done to a limited ex-tent. For many years he was only able to pursue his artistic work in small doses to provide some equilibrium in his busy profes-sional life.

Nikolaus Schuck painted his first pictures as a child during the Second World War. His motifs, as he remem-bers very well, were mostly burning houses. This probably helped him to cope with his terrible war-time ex-periences. A few years later, as an altar boy, he painted the Stations of the Cross.

He achieved his first success in a painting competition on the subject of transport

safety. He was awarded first prize for his picture entitled “Berliner Luftbrücke” (Berlin Airlift).

After passing his school-leaving examination, Nikolaus Schuck’s painting activities ceased for a number of years. Following university studies in economics, he began his professional career in the steel industry. It was not until the late 1970s – during this time he was an authorised signatory at Krupp

– that he took part in a painting course at the community college (Volkshochschule) in Bochum.

During this course his pas-sion for painting was rekindled. Encouraged by a colleague, he exhibited his pictures for the first time at “Café Zürich” in Bochum, where he immediately sold ten pictures. On the basis of this success further exhibitions followed.

When Krupp’s forging works merged with Klöck-ner in 1984, Nikolaus Schuck moved to Osna-brück as sales manager and later to Georgs-marienhütte, where he became managing director in 1993. From this point onwards at the latest, his profes-sional commitments al-lowed no more time or leisure for painting.

Nikolaus Schuck retired from the board

of managing directors in 2000. This was not to be the end of his working life, however. He remained chairman of the super-visory boards of several forging and casting businesses belonging to the GMH Group of companies. Nevertheless, he was able to ded-icate more time to his painting. He brushed up his knowledge in courses at the art academies of Bad Reichenhall and Münster. Since 2003 Schuck has held regu-lar exhibitions of his work in Osnabrück and beyond.

tHE art ISt

Nikolaus Schuck1937: born in Berlin 1963: Diplom Volkswirt (degree in economics) Freie Universität Berlin1963-2000: employment in the steel industry, finally as Managing Director at Georgsmarienhütte GmbH Since 2005: art education at the academies of Bad Reichenhall and TrierSince 2005: chairman of Kunst- und Kulturstiftung Georgsmarie-nhütte Since 2006: chairman of Kunst- schule Paletti Georgsmarienhütte Nikolaus Schuck lives and works in Osnabrück.

Continued on the next page q

photos: mk

Not only productive in his profession, but also in his leisure time: Nikolaus Schuck surrounded by a selection of his paintings.


His favourite motifs are hous-es and landscapes. Most of them are located in Tuscany and other southern countries. The light and colours are so wonderfully inten-sive there.

Back at home he recalls the motif and/or the draft of one or more pictures – the structure, the composition, the colours – which he has stored in his mind and creates the actual painting in his Osnabrück atelier. His works oscillate between realism and abstraction.

He uses acrylic paint for most of his pictures. Furthermore, he sometimes includes materials such as sand, gravel, cardboard, scale (decades of work in the steel industry become evident here!) or textile fabrics. In former years he used to simply whiten a picture which did not seem

to work out as planned and started anew. Today he often lets excerpts of the “original” shine through, a method which lends additional depth to his pictures.

Like most artists, Nikolaus Schuck also has his role models. Principal personalities here are Lyonel Feininger, Karl Schmidt-

Rottluff and Anselm Kiefer. He is, however, also inspired by other German and French expression-ists.

In addition to his passion for landscape painting there is an-other artistic technique of which Nikolaus Schuck has an impres-sive command: he loves draw-ing caricatures. He held his first exhibition of caricatures entitled “Rasend dünkt mich, wer am Wein nicht Freude hat – Euripi-des 480 B.C.” at Bistro Steinwerk Osnabrück in 2004. Much to the pleasure of his friends and for-mer colleagues, who also greatly enjoyed viewing illustrations of their own persons.

mk

Increase efficiency, decrease requirementsGMHütte · Successful application and a special award: steel maker invited to Schloss Bellevue for the “Week of the Environment”.

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GMHütte compiled a study entitled “Simulation-based Study on the Use of Exist-ing Waste Heat Sources”, the method of which will proba-bly also be of interest to other companies. An independent jury selected the study for presentation on 5th and 6th June within the scope of the “Week of the Environment” in the park of Schloss Belle-vue – with GMHütte being the only steel maker represented. The fact that the project was selected by the jury from so many applications is a special distinction in itself. It con-firms it as being one of the best projects demonstrating in a practical way, with innova-tive approaches, that ecology, economy and social consid-erations are compatible. The “Deutsche Bundesstiftung Um-

welt” (German Foundation for the Environment) and the “Bundespräsidialamt” (Of-fice of the Federal President) are joint organisers of the “Week of the Environment”. During this week around 200 medium-sized companies and organisations presented their ideas, innovative projects and developments as well as pro-posals for implementation. In total around 12,000 visitors, including many prestigious representatives from industry, politics, academia and society, were invited to the event. But what exactly did the GMHütte study deal with? glückauf interviewed Reimund Laermann, GMHütte’s Direc-tor of Energy Management, in order to find out more:

glückauf: Mr Laermann, what was the main topic of the study?reimund laermann: Being a steel maker, GMHütte belongs to one

of the most energy-intensive sectors of industry. It is therefore important to exploit the full energy-saving potential and this is why GMHütte started a project on the structured assessment of its waste heat potential. The ob-jective was to discover so-called heat sources and heat sinks on the works site and in the works

buildings, to assess them and evaluate the possibility of utilis-ing these energy sources.

How did you proceed?laermann: In order to assess this energy potential from a techni-cal and economic point of view, we had to prepare a simulation-based study. But initially we observed the processes in all sections of the company in order to localise heat sources and heat sinks. The particularly difficult part was subsequently to evalu-ate their potential for use, be-cause this potential is influenced by many factors – the course of time, the quantity of waste heat, the carrier medium, the tempera-ture level as well as spatial condi-tions and distances between the places in question.

So how great is the potential?laermann: We have more heat sources than heat sinks in our location. But with the present state of technology, the majority of them are still not economi-cal to use. On the basis of the knowledge acquired, we then developed a holistic heat con-cept. While doing so, different possibilities for use, such as con-version into electricity, cold gen-eration or heating purposes, were investigated.

First you simulated and then evalu-ated these possibilities for use.

q Continued from last page

Current exhibitionPaintings by Nikolaus Schuck are exhibited at Diakoniestift am Westerberg (Osnabrück) from 14th June 2012.

Reimund Laermann


Nikolaus Schuck’s pictures oscillate between abstraction and realism. He has already held numerous exhibitions, not only In Osnabrück and surrounding area but also elsewhere in Germany.


laermann: That’s right. In this way we were able to simulate all possible process contexts and operating conditions. In this case steam was selected as a carrier medium, along with an electricity generation process and optional steam storage. The mechanisms are applied to the model through the use of physi-cal modelling and by using tech-nical parameters of the real case in question. On the basis of the data provided,

the programmed calculations are carried out as a function of time, continuously, and in real time. The results of the simulation runs can thus be evaluated pre-cisely from a technical as well as an economic point of view.

And with regard to the net results, what does this mean in concrete terms for GMHütte?laermann: The waste heat potential should be used on a decentralised basis

for generation of electricity with the aid of a suitable conversion technology. However, they must be interconnected intelligently in order to reduce energy loss.

Did the simulation method used prove successful in your investiga-tion?

laermann: As far as the “steel production” application is con-cerned, the simulation-based study can certainly be applied successfully – although it in-volved the evaluation of a wide variety of process steps. And, of course, it became clear in the course of the project that some concepts, which at the outset promised to be successful, were in fact impossible to implement, either from a technical or an eco-nomic point of view, or both.

Can other companies in the indus-try also make use of this simulation method?laermann: Definitely. In the case of complex production processes and different heat requirement profiles, simulation is a core method for modelling current heat situations, for illustrating potential, and for supporting the development of measures. It is not possible to investigate such intricate relationships on the ba-sis of static observation.

Thank you for talking to us.

Annealing furnaces 21-24

Furnaces 63

Continuous caster

District heating North

District heating East

Ladle furnaces 1+2

Oxygen plant

Media centre

Electric furnaces

Ingot store

Condensation from exhaust gas boilers

Slag

District heating West

Rolling mill

Comparison of heat quantities at GMHütte

theoretical waste heat potential heat requirements unused surplus available

Vacuum degasser

The plant overview with potential bars illustrates the situation clearly. Here heat sources and heat sinks were identified. The aim of the simulation is to show how these can be used.

source: GMHütte

Would you have known?

Heat sinkA component with high heat con-ductivity and in most cases also high heat capacity is described as a heat sink. In building services engineering, heat sinks are used as a synonym for heat losses be-cause they lead to a higher heat-ing or cooling requirement.

The GMH study met with great interest (from left to right): Henning Schliephake, Clemens Lammerskitten (Member of the Regional Parliament of Lower Saxony), Frank Leischner (Limón GmbH), Reimund Laermann and Wolfgang Schmidt


glück auf · 1/2011 · Extraits en langue française ......................... 10 glück auf · 2/2012 · Extracts in English ........................................ 10

all in the same boatGMHütte workshop promotes mutual understanding and teamwork.

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Safety officers are the foreman’s right-hand men as far as industrial safety is concerned. Their job is to detect hazard areas and help to eliminate them, to investigate and process accidents and, above all, to act as a link between supe-riors and colleagues. In order to support the team building process and promote cooperation on a partnership basis within the sphere of occupational health and safety management, a number of foremen and safety officers have now taken part in a workshop. glückauf spoke to foreman Heiko Jesse and safety officer Thorsten Biewald from the rolling mill.

glückauf: A workshop on the subject of team building – that sounds as if in-fighting used to be the order of the day.Heiko Jesse: No, it was never as bad as that! After all, we have known each other since we were at school. There was only one year between us during our apprenticeship and we have also been working together in the rolling mill for quite a long time.thorsten Biewald: Heiko has been shift su-pervisor in the rolling mill for five years and six months ago he was also appointed safety officer for this shift. It is a big advantage that we already had a well-established working relationship.

So was the workshop superfluous?Jesse: The aim was not only to become a team, but also to evaluate the team, to get to know its structures – and detect the weak

points in our collaboration and eliminate them. Biewald: Within the scope of a so-called team diagnosis we took a careful look at how we work together with one another, how we speak to each other, who plays which role. On the basis of specific exercises we then refined our team work.

What did you find particularly difficult?Jesse: The feedback session. To get feedback from the other person, to let them finish what they were saying, not to interrupt with my own point of view – that was difficult for me. Biewald: We like to discuss things in our eve-ryday work, even controversial issues, and at great length. But we always arrive at a solu-tion which suits both parties.

You want to jointly implement an occupational safety project. Which one? Jesse: We call it “3 storage locations for stripping plates”. These plates weigh be-tween 20 and 50 kilos. We need them at the roll stands. Unfortunately until now they have just been left lying in different places – a potential accident hazard should anyone stumble over them.Biewald: Going by the motto “Everything in its right place”, we created three locations for our colleagues to put the stripping plates. It already works quite well on our own shift. We now only have to improve the coopera-tion throughout all the shifts. There are some colleagues whom we very seldom see due to the different shifts and so it is diffi-cult to make arrangements with them.

Many thanks for this interview.

a premiere in safetyGMHütte · A woman is now responsible for occupational safety.

Natascha Volkmann is GMHütte’s first female safety officer. She works in the

fitter’s section of the finishing shop and is looking forward to her new, additional task: “For a long time now I have wanted to become actively involved in shaping the safety culture in our works. I believe I am capable of addressing my colleagues, draw-ing their attention to unsafe behaviour or praising them in connection with positive issues.”

Hans-Günter Randel, finishing shop manager, shares her opinion: “We have re-defined the role of the safety officer at GMHütte, upgraded the position and given more responsibility to the persons con-cerned. This development has meant that we have had to appoint some new safety of-ficers. I immediately had the idea of involv-ing a woman.”

He is also convinced that Natascha Volk-mann will carry out her new role very suc-cessfully: “She will establish good contact with her colleagues and thus have a very positive influence on the safety culture. Col-leagues will take her comments and instruc-tions seriously.”

Natascha Volkmann believes in the positive influence of women on male col-leagues: “When I discuss technical problems with my male colleagues, these conversa-tions always take place on a factual and business-like level. I am listened to and my comments are taken seriously. It subse-quently becomes obvious that everyone is trying that little bit harder. Why shouldn’t the same apply in the context of occupa-tional safety?”

Another advantage is that, as a fitter, Natascha Volkmann gets to see a lot of dif-ferent workplaces in the finishing shop and meets colleagues on all the shifts there. She thus has a good chance of discovering safety deficiencies and convincing as many col-leagues as possible about the benefits of safe behaviour.

hgr

photo: vl

Safety officer Thorsten Biewald and foreman Heiko Jesse from the rolling mill


a touch of HollywoodESB · Computer animation cannot always replace reality: Steelworks served as the impressive setting for a new film.

on 17th April the steelworks of Engineering Steel Belgium

in Seraing were converted into a film set. The reason was the making of “L’Ecume des Jours”, a new film by Michel Gondry. The French director, who won the Oscar for the best original script in 2005 for his film “Eternal sunshine of the spotless mind!”, has worked in the past with top stars from the music industry such as the Rolling Stones, Paul McCartney or Björk. His last film (“The Green Hornet”) with Hol-lywood stars such as Christoph Walz or Cameron Diaz reached the top of the international cin-ema charts. “L’Ecume des Jours” is based on the novel of the same name written by Boris Vian in 1946 (English title: “Froth on the Daydream”). It tells the story of Colin (Romain Duris), a wealthy young man, and his financially not so well-off friend Chick (Gad Elmaleh). Despite his own wealth, Colin rather envies his friend on account of his girl-friend, Alise. His desire for love grows.

Then he meets Chloé (Audrey Tautou), whom he marries

shortly afterwards. During the honeymoon, however, it already transpires that Chloé suffers from a rare disease. A water lily is growing in her lungs …

During breaks in the shoot-ing, several ESB employees took the opportunity to talk to the

actors and other members of the crew and take some souvenir photographs.

In addition to the beautiful Audrey Tautou (“Amélie”, “The Da Vinci Code”) and Romain Duris (“Dans Paris”, “Heart-breaker”), Omar Sy was involved on the steelworks film set. He should be particularly present in the minds of cinema fans because he starred in the film “The Intouchables”, which has recently been highly acclaimed at international level. Omar Sy has already been awarded several prizes for his role in the film.

“L’Ecume des Jours” will run in the cinemas in 2013. And, of course, there will be plenty of ESB colleagues in the audience.

Michael Schmak

photos: Michael Schmak

Leading actors Audrey Tautou and Romain Duris

“Green manikins” ensure bizarre scenery: filming in the steelworks.

Good ideas score againGMHütte · IdeenManagement awarded “DeutscherIdeenPreis 2012”.

For the second time in suc-cession, GMHütte’s Ideen-

Management scheme has been awarded a prize by Deutsches Institut für Betriebswirtschaft GmbH (dib).

It achieved third place in the “DeutscherIdeenPreis 2012” in the “iron and metal industry” category, and was thus beaten only by WESO-Aurorahütte GmbH of Gladenbach (Hesse)

and Mann + Hummel GmbH of Bensheim (Hesse).

“This award is a great success for us because it proves that our IdeenManagement scheme func-tions very well”, comments Ralf Kübeck who is responsible for GMHütte’s IdeenManagement.

After all, the company was able to maintain the good position it achieved last year. “Now our aim is to progress one step higher

on the winners’ podium”, said Kübeck with a view to the goal for 2013.

dib awards the “ DeutscherI-deenPreis“ to companies and individuals for outstanding com-mitment and success in connec-tion with creativity, innovation and responsibility. The awards are classified into six categories, one of which is “Best Idea Man-agement” (basis: participation in the dib-Report 2012). They were presented at the annual confer-ence of the dib-Forum Idea Man-agement in Dresden.

The jury of high-ranking members included executives from industry, politics and sci-ence. Fundamental criteria for the award are the degree of inno-vation, transferability, as well as added socio-cultural, economic and ecological value.

mw

Ralf Kübeck after receiving the “DeutscherIdeenPreis 2012”

photo: dib


lots to do – but also something specialGMHütte · Memories of the highlights will still be cherished long after Clean-up Day 2012.

G reen and flourish-

ing, but get-ting a little out of hand, even at GMHütte. The annual Clean-up Day again offered the opportu-nity to bring the fast growing greenery back under control and also to do some of the other jobs for which there is never enough time in everyday business. At the beginning of May around 300 volunteers (employees, pension-ers and business partners) came early on a Saturday morning to put the plans into action.

A variety of projects were tackled in mixed working groups. All around the car parks, produc-tion facilities and office build-ings bushes were pruned and weeds removed. On this occa-sion also rubbish was discovered which was correctly disposed of straightaway. Luckily the rain eased off during the course of the morning – which made the work easier and also lifted the spirits.

As always there were some highlights which deserve special

mention. For example,

colleagues from the rolling mill paved the area in front of their building – with the GMH logo! And since

that day another large GMH logo has been on display at the bend near the heat treatment facili-ties. It was created as part of this year’s “women’s project”.

The slope there had been basi-cally cleared beforehand so that on Clean-up Day only the re-maining stones, branches, roots and other stubborn debris had to be removed before the female colleagues were able to start posi-tioning plants in the form of the GMH logo. Light gravel stones create a background contrast.

The managing board was very pleased that so many employees had again come to work volun-tarily in their free time. Many business friends of GMHütte were also a great help, however. They had not only come with their own hard-working hands, but had also brought along lor-ries, wheel loaders and excava-tors to deal with the rubbish col-lected and other heavy transport loads.

For some time now GMHütte has commissioned companies to maintain the grounds and build-

ings throughout the year. The traditional Clean-up Day still makes sense, however. Not only because of the bonding effect it has and the symbol of loyalty to the company. It is also a day when individual ideas can be implemented, such as the paved area in front of the rolling mill. The new paving had become necessary, but the logo was a vol-untary addition – an extra touch that gives the place something special. At the end of Clean-up Day everyone was delighted to enjoy some delicious goulash soup.

vl

photos: vl

The “women’s project” is one of the highlights of Clean-up Day. They “planted” the GMH logo in natural form on the slope near the heat treatment facilities (from left to right): Thorsten Kurz, Christina Battmer, Birgit Diestelkämper, Cornelia Börger, Claudia Riesenbeck, Christa Krick, Monika Friebe, Marvin Kurz, Katharine Hügelmeyer, Andrea Bruns, Silke Flaspöhler and Andrea Frank.

Labour Direc-tor Felix Osterhei-der demonstrates the attractive blue electric scooter, the prize

on offer for the next IdeeM draw.

Made a joint “attack” on the greenery: Jianxiong Deng (back row), Axel Stüber (front), Vadim Rembold (back, intern-ee), Heike Witte, Ingo Kolm, Reinhard Frau-enheim and Thomas Wurm.

Above – Hung pictures by Angelika Walter to embellish the newly deco-rated office hallway of BGG (left to right): Jens Melcher, Lukas Brock-meyer and Tom Schöne.


Putting systems to the testBous · Before its quality, environmental and energy management systems were “officially” certified, the steel maker held an “in-house” rehearsal for the real upcoming event.

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In March, Stahlwerk Bous completed its annual in-house audit with the assistance of consultants proTerra Umwelts-chutz- und Managementbera-tung GmbH. On the agenda were its quality, environmen-tal and energy management systems. External auditors Anton Backes and Daniela Jakoby took a really close look at the company’s operat-ing processes and procedures. Only then was the green light given for the official audit, which was conducted by TÜV Saar Cert. Armin Hans (Head of “Industrial Safety, Environ-mental Protection and Energy Management”) reports on the findings of the audits in an in-terview with glückauf.

glückauf: Bous has also put its faith in external auditors in the past where in-house audits are con-cerned. Why is that?armin Hans: Experience has shown that such audits are sim-ply rated more highly by the employees. An audit conducted

by external person-nel is taken more seriously than one done by company employees who are otherwise in charge of instruc-tion and training. Our employees take the presence of the company’s own environmen-tal and energy management of-ficer for granted. Auditing by external auditors breaks with such routine.

The in-house audit took place at the end of March. Did it go smoothly?Hans: You could say that. The maintenance shop, vehicle workshop, electrical workshop, segment workshop, continuous casting facilities and melt shop

were audited strictly according to the audit plan. The auditors also carried out a precise assessment

of the laboratory, engineering of-fice, purchasing department and warehouse. A focal point in this regard was the documented pro-cedure for “procurement”. This is important for the purchasing of charge, raw and indirect ma-terials as well as fuels, lubricants and coolants, and also for the procurement of energy-relevant

equipment and resources. Training courses, operating in-structions and the handling of hazardous materials were also audited.

What were the findings?Hans: That we were much better compared with the year before.

That was undoubtedly a good basis for the official audit due in April. Who conducted it?Hans: TÜV Saar Cert. Ursula Wolff and Albert Lucas audited the environmental management system, and Herbert Conrad and Manfred Mateiko the energy management system.

And what was the outcome?Hans: A differentiation has to be made in this connection: During auditing to DIN EN ISO 9001, the daily schedule was completed without any major incidents and shortcomings. During certifica-tion to DIN EN 16001:2009 and DIN EN ISO 5001:2011, the one or other possibility for improve-ment was found after all. They were mentioned in the audit report.

And how would you sum up the au-dit personally?Hans: All in all, a positive devel-opment of our environmental and energy management systems is to be noted. This will also con-tinue – if all employees continue to work motivatedly together and are interested in, and recep-tive to, new challenges.


Positive developmentMa · Continuing demand for rolled colliery sections

Mannstaedt is evident in underground mining, too. Trough sections from

Troisdorf, for instance, are needed for the extraction of hard coal removed at the face. Mannstaedt has been rolling them in a broad range of types now for several decades.

A special role is additionally played by the “TH40 = W 09.006“ section, which is a trough section used for flexible roadway or tunnel supports (also referred to as yielding arch supports). It was re-included in the product catalogue in 2009, and deliveries were made again for the first time in early 2010.

The rolled trough profiles are sent to Bo-chumer Eisenhütte, where they are quenched

and tempered or otherwise heat-treated. They are then shaped to the radii that the end user re-quires. Below ground the curved trough profiles are assembled in overlapping arrangement and joined together by means of fish plates. Depending on the design, the support segments used for yielding arch supports can slide into one another, thus allowing the supports to withstand the roof pressure within certain limits without being destroyed.

Sales of the trough sections have shown a very positive development since 2011.

Mannstaedt is also looking to include other sizes in its product catalogue and is currently holding exploratory discussions with Bo-chumer Eisenhütte on the subject.

Dieter Tondar

Gerhard Schmitt shows Albert Lucas and Ursula Wolff test reports relating to electrical plant and equipment.

Armin Hans

photo: armin Hans

Trough sections from Troisdorf: a prime example of roadway supports.




International flairSWG · 19th International Students’ Day of Metallurgy in Freiberg

the 19th International Stu-dents’ Day of Metallurgy

(ISDM) took place from 15th to 17th March and, after a period of four years, the venue of this event was again TU Bergakad-emie Freiberg. The conference objective is a scientific exchange between universities.

The ISDM programme was correspondingly varied. The event was attended by approxi-mately 250 students and post-graduates of metallurgy and related disciplines from 19 uni-versities who had plenty of op-portunities to attend lectures or to present and discuss their own research work. Furthermore, in-teresting excursions and a variety of opportunities to talk to rep-resentatives from companies in-volved in the sector were offered. The 3-day conference in the silver-mining location of Freiberg

was completed by two successful evening events. They provided an ideal setting for students and company representatives to get to know each other in a relaxed atmosphere.

The shortage of skilled person-nel is now also noticeable in the metal industry. Within the scope of a 2-day company contact fair, therefore, the Students’ Day of-fered around 30 companies the chance to present themselves to students as potential employers. The fair was held in the “Neue Mensa” of TU Bergakademie Freiberg.

Schmiedewerke Gröditz (SWG) also had its own stand at the event. Engineers from different SWG departments and colleagues from the human resources department answered a wide range of questions relat-ing to internships, final dis-

sertations and how to join the company.

Employees of Pleissner Guss were also present at the stand. The GMH Group was thus able to present itself from a different aspect – and show prospective metallurgists also other job op-portunities and future perspec-tives.

jp

How it all beganThe first Students’ Day of Metal-lurgy took place in 1993 – in response to an initiative launched by metallurgy students at the German speaking universities of RWTH Aachen, TU Berlin, TU Clausthal, GMU Duisburg, TU BA Freiberg and MU Leoben. The conference has expanded tre-mendously over the years as the number of participating universi-ties has increased. In 2012, par-ticipants from 19 universities all over the world were welcomed. A platform for ideas and discussions has meanwhile been established, involving a different host univer-sity every year.

photo: Stefanie Hoffmann

Source: Verein Metallurgiestudenten zu Freiberg e.V., Marcel Schlenkrich

More pressure for academiaSWG · New 10 MN forming press inaugurated at the Institute of Metal Forming.

a t the end of March, MEFORM 2012 took place at the Institute of Metal Forming of

TU Bergakademie Freiberg. The focus of the conference, which is held once a year, was this time on materials development and mas-sive forming. Almost 200 national and inter-national forming technology experts, among them four engineers from Schmiedewerke Gröditz (SWG), spent three days discussing challenges and latest developments in these fields.

A highlight of this year’s symposium was the inauguration of a new universal forming press at the host institute. The 10 meganew-ton press is installed in an experimental facil-ity there. It is capable of carrying out differ-

ent forming processes and of systematically testing new work pieces. It is also designed to provide students of forming technology with greater practical experience and to improve the cooperation between industry and aca-demia.

The funding for the investment, costing 2.33 million euros, came from the German Research Foundation (Deutsche Forschun-gsgemeinschaft), the federal state of Saxony, the Central Innovation Programme for Medium-Sized Companies, TU Bergakademie Freiberg, as well as sponsors and industrial interests. Schmiedewerke Gröditz also con-tributed toward the new forming press. It produced and machined the base plate in

Gröditz, then donated it. Schmiedewerke thus plays an important part where research in Freiberg is concerned. It will, of course, also benefit from the diverse research possi-bilities that the new press opens up.

Ralf Schreiber

The new 10 MN press at the Institute of Metal Forming of TU Bergakademie Freiberg

photo: Stephan reichelt

Above: SWG colleague Igor Karase-vich (quality engineer, ring rolling mill) advises a participant at the ISDM company contact fair.

Below: Group picture of ISDM participants


thorough structural overhaulSWG · Re-organised Technology activities place even greater emphasis on the customer.

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Thursday, 1 March 2012 was a special day for Schmiedewerke Gröditz (SWG). Since that day, namely, the company has been adopting new approaches. To support its customers even better, SWG has thoroughly re-organised its Technology activities. glückauf interviewed Robert Kühn, Managing Di-rector Technology, and Bernd Kresinsky, head of the newly created Centre of Excellence, on the reasons for this and on how the re-structuring has gone.

glückauf: How did you go about the re-organisation? And what was the aim of it? robert Kühn: Quite generally speaking, it had to do with ful-filling customer and market requirements even better than before. We got started with a preparation project in which we analysed all the in-house pro-cesses that a forged product goes through. This meant that the analysis encompassed not only the flow of production but also customer support, cost estimat-ing, order processing, product and process development, pro-cessing of complaints, and other aspects.

Who took part in this analysis?Bernd Kresinsky: Personnel from the production shops, from mar-keting and sales, from quality management, and from Applica-tion and Process Engineering. After mapping the actual situa-tion, they developed a number of ideas and proposals on how to modify and improve operating procedures to meet the aims in mind.

And what was the aim of this anal-ysis or these process studies? What was particularly important?Kühn: We had a whole number of aims that were not only of a technical nature. Firstly, to cre-ate procedures and matching structures that are as efficient as possible for the processing of enquiries, orders, as well as cus-tomer queries or complaints, and which promptly make it easy for us to realise also new products or comply with unusual customer requirements. Secondly, we want lessons learned from ongoing production – both positive and negative – to help our processes to develop further as smoothly as possible. A self-learning pro-duction establishment, if you so wish. Kresinsky: This also means putting technology faultlessly into practice. We’re looking to adopt a double-check principle throughout the process chain. To us, fulfilling orders means being good, fast, and punctual, and that we cannot afford any un-planned delays. Kühn: And ultimately there was the important question of how do we identify the products and technology trends on our mar-kets of tomorrow at an earlier

stage, prepare better for them, and help shape them more ac-tively?

Did you also touch upon personnel issues with these proposals?Kühn: Once the new procedures were clear, suitable re-structuring then followed. And it is in this regard we also made very impor-tant personnel-related decisions, of course. There are now, for in-stance, technical customer advi-sors for individual product fields. The main focus of their work will be direct contact with the customer and technical advice on individual applications. They will also identify what customers expect of products from Gröditz in future. They will work in close cooperation with our marketing and sales people. Kresinsky: Occupying ourselves so intensively with these opti-misation proposals and with the analysis of weak points led to yet a further fundamental decision: to create a Technology Centre of Excellence, where the Order Cen-tre, Process Engineering and Ap-plication Engineering will now be concentrated.

Who will be in charge of matters there?

Kühn: Bernd Kresinsky, previ-ously manager of forging and machining activities. He will have overall responsibility for the Centre of Excellence. Within the Centre he will also be head of Application Engineering. The Order Centre will be managed by Birgit Salega, and Process Engi-neering by Stefan Lachmann.

Congratulations on your new posi-tion, Mr. Kresinsky. What functions will the Centre of Excellence have?Kresinsky: A large number of activities will be concentrated there. The Order Centre will be responsible in future for the one-stop processing of all technical enquiries and orders and ensure a smooth flow of information, also during production. Process Engineering will be responsible for setting and developing the technological parameters for the melt shop and ESR unit, for the forging and heat treatment facilities, and for the machine shop. And the focus of Applica-tion Engineering’s work will be on product development and support for new products.Kühn: The Centre of Excellence will thus be, so to speak – as the name also implies – the tech-nological core for the strategic development of the company. But we haven’t stopped there. The forging/machining activi-ties have also been re-organised. There is now Forging/Heat Treat-ment, headed by Ralf Schreiber, and the Machine Shop, headed by Torsten Ulrich.

How do the personnel concerned stand with regard to the re-organi-sation?Kresinsky: They all want to im-prove upon the positive results we have achieved so far. And they want to minimise any weak points that might come to light when realising customers’ stead-ily more exacting requirements. Kühn: In which respect, one thing is absolutely clear: Only if we continue to improve our products – and have an optimum cost structure and competitive delivery times – will we be able to take Schmiedewerke Gröditz forward on a sustained and posi-tive basis.


Robert Kühn Bernd Kresinsky



Multi-tasking talentSchmiedag · New FARO measurement arm efficiently performs a multitude of tasks.

I NtErV IEW

In March, Schmiedag was able to put a 3D measurement arm and laser scanner manufac-tured by FARO Europe GmbH & Co. KG into service. It will enable the company to pursue new production routes. In an interview with glückauf, Uwe Dannen (Head of Tool Engi-neering) explains which ones.

glückauf: What capabilities does the new measurement arm offer, Mr. Dannen?uwe dannen: More than you would expect at first glance. First and foremost, we are able to carry out all tool and die geom-etry measurements with the new measuring system, which is of portable design!

Who is responsible for operating it?dannen: The personnel from the Quality As-surance, Tool Engineering and Finishing depart-ments. They have completed a three-day train-ing course so as to familiarise themselves with how to operate the measurement arm and use the software.

How does the new technology work?dannen: The measuring points are recorded by tactile means – in other words, by touch – or the component surface is scanned. These measurement data are then

transmitted wirelessly by WLAN from the measure-ment arm to the data analyser. There they

are processed further by a soft-ware tool. The software is able to generate a polygonal model from the measurement data and do a comparison with the 3D CAD geometry.

And what is done with this target/actual comparison of the geom-etries?dannen: The data can then be output in the form of a first-piece inspection report or as a false col-our photo.

What was the reason for Schmiedag deciding on this new technology?dannen: Our primary aim has been to reduce, by 50 percent, the time required to produce first-piece inspection reports.

However, we derive a much greater benefit from it in tool engineering and in the regenera-tion of tools and dies because, by scanning the used die cavi-ties, we are immediately able to identify the worn cavity areas – which will significantly reduce the amount of corrective main-tenance work we have to do in terms of partial repairs. Together with the reduction in work-intensive manual engraving after milling, this will lead to a consid-erable cost benefit in tool engi-neering. We are already using the measurement arm to assess dies. When doing a tool calculation we are thus able to calculate pre-cisely, taking the tolerances into account, what number of pieces per die we can expect.

Are there any other areas of use?dannen: We are also planning to use it for the geometry scanning and CAD reverse engineering of old dies.

How will that be done, and what benefits will that yield? dannen: We will scan-in the old copy models or die cavities and, using the software module, generate a 3D reverse-engineered image. Once the surface data have been transferred to the CAD programme, it will be possible to generate a volume model that can also be modified in design if necessary. There are also plans, though, to digitalise all old as well as hand-produced dies using the new technology.

The amount of work involved will probably be enormous. Will it also be worthwhile?dannen: The effort involved will be justified and worthwhile, of course, for our customers.

Why is that?dannen: We could then also sup-ply them with constantly high quality where spare parts are concerned.


photo: uwe dannen

The new measurement arm in operation: Emir Ribic (left) and Thorsten Thurn measuring a die half for a pump casing.

Uwe Dannen (Head of Tool Engi-neering)

photo: thomas Irmscher


Clamps and jawsSchmiedag · KAIZEN optimises new forging line a step further.

In glückauf 4/2011, Schmiedag in Hagen reported on the upgrading of its H16 forging line, involving a new method of heating, full automation and longer tool life. There have been further modifica-tions in the meantime. Karl-Günter Kruska (foreman in the closed-die forging shop) gives details:

One outcome of upgrading our forging line has been that au-tomation has led to the use of two KUKA robots. They handle the forgings, which are around 1,250 °C in temperature and up to 120 kg in weight. The initial programming was provided by Lasco and is based on reference components. The foreman and shop personnel adapt the pro-gramming for items that are to be forged by hammer for the first time. In this way, experi-ence is gained that is then fed into the workflow.

In line H16, forgings pass through the following stations: Robot #1 transfers the heated block of material from the in-duction furnace for it to undergo the pre-forming operation (up-

setting or hot working). The ma-terial is then placed precisely in the hammer die. After forging, robot #2 picks up the part and takes it to the deflashing press, where it undergoes trimming and/or piercing. Robot #2 then places the part and the flash into suitable boxes. The robot thus takes up a reformed part after each work step. So that a maxi-mum of working precision is achieved despite the variety of products, we require many clamps, jaws, grippers and pin-cer arms for each robot. A “jaw rack” is situated in proximity to the hammer for these tools. It was developed as part of a KAI-ZEN project. Each tool now has its own assigned place and is quickly available for change-overs in production. The rack hence guarantees a high level of efficiency and reproduction accuracy.

KAIZEN The term “Kaizen” comes from the Japanese and means “change (KAI) for the better (ZEN)“.

photo: Karin Kriebel

approved. Representatives from the French State Railways (SNCF) have visited and audited Schmiedag in Hagen on several occasions. Re-cently SNCF issued the company their approval to supply forged com-ponents. The entire process took more than twelve months, the reason being the customer’s stringent requirements with regard to non-de-structive testing and the documentation of all the test steps undergone by the components. During this period the additional requirements of the SNCF were also incorporated into Schmiedag’s existing quality management system. The customer also satisfied itself directly on site in Hagen just how effectively the arrangements are implemented. Besides approval by the SNCF, incidentally,Schmiedag successfully completed its re-certification for German rail carrier Deutsche Bahn at the start of the year. It is also in the process of completing such an approval process for Trenitalia (successor company of the Italian state railways). Through these approvals and certifications, Schmiedag is systematically extend-ing its qualifications as a specialist in railway technology products on the European market. The photo shows one of the products to which the diverse approvals relate: wheel-mounted brake disks.

Andreas Studinski

Worthwhile. Wildauer Schmiedewerke has a new magnaflux (MF) crack detection system. The Wildau-based company is now able, as a result, to inspect connecting rods weighing as much as 1,000 kg. The installed coil is also capable of inspecting round components measur-ing up to 300 x 700 mm with minimum effort. The new MF system ad-ditionally offers greater reliability in the event of disruptions caused by power or compressed air outages. Designed by company Karl Deutsch, it ensures that the forgings remain safely in their fixture. With “old” MF systems it happens at least once a month that a component undergo-ing inspection falls into the testing-medium collecting tray and suffers considerable deformation in the process. These deformations greatly impair the off-flow of the testing medium and make cleaning more difficult. The new crack detection system not only replaces an older sys-tem (UNI 260) but also lightens the work load of a larger, still installed system (UNI 500). The bottom line is that the investment is proving worthwhile in several ways: it eliminates bottlenecks in the finishing shop, increases flexibility, and shortens the throughput times for forged components. The photo shows “fluxer” Karsten Krüger checking the field intensity at the new crack detection system.

Harald Dröge and Frank Ledderbohm

technical data

Width: 1,400 mmLength: 4,000 mmHeight: 1,800 mmCoil interior: 500 x 800 mm

photo: Christian dinter

photo: Karin Kriebel

The new “jaw rack“


audit confirms: a sustainable energy policy increases energy efficiencyEtE · An energy management system was introduced in 2010 – certified by Det Norske Veritas (DNV) in accordance with DIN EN 16001. The positive result of the audit was posted on the DNV website.

Energietechnik Essen GmbH has been a company of the

Georgsmarienhütte Group since 2003, but it can look back on a company tradition stretching over several decades. The com-pany manufactures cap rings for generators in processes which are particularly energy-intensive. The rings manufactured from non-magnetic special steel are used to fix the copper windings which protrude at rotor ends against centrifugal forces. Ener-gietechnik Essen also produces nitrogen-alloyed steels, which are used, for example, in ball screws for adjusting elevators in aeroplanes. Quality assur-ance is absolutely paramount in the case of these specialised and safety-relevant high-tech products and for this reason the company has been certified by DNV according to ISO 9001 since 1993.

In the course of the years, certifications according to OH-SAS 18001 and ISO 14001 have been added and summarised in an integrated management sys-tem. Since 2010 the company has also been certified according to DIN EN 16001 and has been improving the system continu-ously. But it is not always easy to introduce and implement meas-ures. In particular, the structural fabric of the production build-ings represents a major challenge because, for instance, of a lack of heat insulation in buildings con-structed in the first half of the 20th century.

Employees must be integrated

Nevertheless, even a company with these difficulties can ful-fil its claim to be a sustainable company – as described in the

mission statement of Energie-technik Essen. The company would like to “meet the chal-lenges of a rapidly growing energy machinery market by developing further from an adaptable organisation to a sus-tainable one. This objective will be implemented by managers and employees together, at both strategic and operative levels.“

To come a step closer to being a sustainable company, energy management must be organised systematically. At Energietechnik Essen GmbH this is achieved by a committee composed of different company members, the so-called “Energy Circle”. In addition to Hermann Skotz, the Officer for Quality, Environ-mental and Energy Manage-ment, members include external consultants, company engineers and the company management. The great support provided by the management – expressed, for example, by their participa-tion in the Energy Circle – makes it much easier to enforce the required energy saving meas-ures. However, the energy goals which have been set can only be

achieved throughout the com-pany if the whole workforce is convinced about them.

“The employees should always be integrated into the resolution to save energy because, in addi-tion to static measures, such as the insulation of heating pipes, they must also discover further potential for saving energy in their daily working schedules and implement appropriate measures”, says Hermann Skotz. For if, for example, the residual heat from heat treatment fur-naces can be used for heating other production parts, instead of heating these separately, there is quite a lot of potential here for reducing costs. But in order for this procedure also to be used in practice, the workforce must be convinced of the posi-tive aspects. Here it is helpful to involve them in conceiving the measures in order for them to be able to assess whether, in addi-tion to the theoretical potential, such measures can actually be implemented in practice.

Different media are used to inform the employees at Ener-gietechnik Essen GmbH. Posters

have been hung up throughout the company, for example, draw-ing attention to the potential for saving energy. Furthermore, ex-tensive information can be found on the intranet, and notices are clearly displayed in show cases for employees who do not have access to personal computers. Young employees are specifically addressed by means of interac-tive information on monitors. Customers are also informed about the measures which have been introduced in the context of customer audits. Here the company’s experience has been that the energy-saving measures often meet with astonishment. Specific demands for an energy management system are not yet common practice amongst cus-tomers.

Sustainable company policy

The motives for the company to introduce an energy manage-ment system and have it certified by DNV were above all to depict the sustainable company policy as credible to the outside world and respond to the public dis-cussion relating to the topic of “saving energy“. It is particularly important for the management to avoid waste because it is not only expensive but also damag-ing to the environment. Since then, different measures have been introduced with the aim of achieving a sustainable reduction in energy consumption. In an initial analysis, the cause of the greatest electricity consumption within the company was quickly identified – the electro-slag re-melt facilities. There, however, a major investment is required in order to make any significant impact.

Interview with Hermann SkotzEnergietechnik Essen has had a certified quality management system since 1993. In 2006 the integrated management system (IMS) was cer-tified for the first time by certification company DNV (Det Norske Veri-tas) (Quality, Environmental and Safety at Work Management Systems are interlinked at IMS). This IMS was supplemented in 2010 by the En-ergy Management System (EnMS) and the company had it audited by DNV according to DIN EN 16001. In December 2011 the periodical audit of the Energy Management System was carried out. In this audit it became clear that ETE provides a good example of how small meas-ures can have a great effect and energy consumption can be reduced. For this reason DNV interviewed EnMS Officer Hermann Skotz with the aim of presenting ETE as a DNV-certified company on its website. glückauf has printed the original of the article here. More information about Norske Veritas can be found at www.dnv.de.


The Energy Circle therefore focused on other areas and be-gan, for example, with the insu-lation of approx. one kilometre of heating pipes in the produc-tion buildings. This measure could be implemented relatively cheaply and, according to the company’s calculations, it will pay off within just a few years. The same applies with regard to installing photoelectric lighting controllers and time switches in buildings where there is natural daylight. Thus during the day, only some of the lighting is switched on and the remainder is switched on additionally at dusk. Other measures included optimi-sation of the treatment tempera-ture of products or saving gas in burners.

In addition to these small measures, complete production processes were examined and re-organised. Previously, for exam-

ple, hot steel ingots were subject-ed to controlled cooling before undergoing downstream process-ing at another company, where they would then be re-heated by a service provider. Today, special transporters are used to transport the ingots in hot condition and thus to save energy.

Only time will tell what re-sults these rather small measures can actually achieve. Members of the Energy Circle, however, are certain that “there is still considerable room for Improve-ment”.

In comparison with other management systems the energy management system has the advantage that its effectiveness becomes visible very quickly. By contrast, an Environmental Man-agement System according to ISO 14001 – for example – is based rather on legal certainty. Invest-ments in keeping the air pure are

often too high and the results cannot be directly measured from a financial point of view, whereas an energy management system has a direct influence on the monthly costs. Parts of both standards are very similar, how-ever, and companies which are certified according to ISO 14001 can therefore introduce an en-ergy management system accord-ing to DIN EN 16001 or DIN EN ISO 50001 more easily and have it certified.

Improvements can be made regularly by certifying and con-tinuously checking the system. “Up to now, every DNV audit has led to measures which have a high added value for our com-pany”, states Hermann Skotz. The auditor often detects process weaknesses which the company itself fails to identify. However, the Officer for Quality, Environ-mental and Energy Management

also views certain aspects of the audits more critically and sums up: “In addition to the core stock of measures with a high added value which must be implement-ed after an audit, there are always specifications which are less rel-evant for the company.“

A lot has changed in the field of energy management at Ener-gietechnik Essen GmbH as a re-sult of the certification. Success has become measureable through the introduction and certification of the energy man-agement system and Hermann Skotz is convinced of the future success: “In future, a few things can also be achieved through the fact that the employees are be-coming increasingly open to change, that they bring in their own ideas and that they simply feel that they also have a respon-sibility.”

Cooperation at the highest levelBVV · Experts from eleven manufacturers in nine countries got together at the ERWA Spring Meeting in May for technical discussions.

this time, Bochumer Verein Verkehrstech-nik (BVV) hosted the ERWA Spring Meet-

ing, which takes place once a year. The Meet-

ing ranks as the consultation forum for the Technical and Development Committees of the “European Railway Wheels Association“.

The Association was founded in 2004 under the umbrella of the UNIFE (Euro-pean Rail Industry). Its members are the eleven renowned European manufacturers of railway wheels and wheelsets from nine nations, namely Bonatrans, CAF (Construc-ciones y Auxiliar de Ferrocarriles, S.A.), Gutehoffnungshütte Radsatz, Lucchini Italy, Lucchini Sweden, Lucchini UK, Lucchini Poland, Valdunes SAS and Valdunes Belux, as well as Bochumer Verein Verkehrstech-nik and Radsatzfabrik Ilsenburg. All these different companies with their experience embody the core expertise of this branch of industry – ranging from the corresponding research and development of suitable steels to the finished and certified product.

The aim of the committee work is to support the international rail vehicle manu-facturers in the development of the most efficient wheelset systems possible for their various vehicles.

Besides information and discussions at the meeting, culture also featured on the agenda. Completely in keeping with the tradition between coal and steel, the programme in-cluded a visit to two extraordinary sightsee-ing venues in Essen: the UNESCO World Heritage site of “Zeche Zollverein“, and Villa Hügel.

em Impressive setting: Participants of the ERWA Spring Meeting on a visit to Zeche Zollverein in Essen.

photo: andreas dal Canton


Moscow Metro wants greater energy efficiencyraFIl · Ilsenburg-based company to supply first broad-gauge wheelsets for new Moscow Metro cars. Manufacturing quality convinces rail vehicle builder and operator.

Who is not familiar with the opulent edifices of the

Moscow Metro – at least from TV reports or photos? Its first line, connecting 13 stations between Sokolniki and Park Kultury, went into service as early as 1935 and was nevertheless 11.5 km in length.

Today the Metro has grown to become a route network extend-ing over 305 km and including 185 stations. Not all, of course, are able to exude the great splen-dour of small palaces in the style of Stalinist classicism, such as Komsomolskaja or Majakowskaja Station.

But it does boast other super-latives. At some locations, Mos-cow’s underground railway runs 84 m below the earth’s surface, making it the deepest metro sys-tem in the world. And passengers reach the subterranean platforms via gigantic escalators 126 m in length and comprising as many as 740 steps.

Some nine million passengers daily are carried on the route network in different, mainly Russian-built vehicles: all in all 4,500 cars. Depending on their year of manufacture and techni-cal standard, the vehicles travel at speeds of up to 100 km/h.

They were, and still are, built at the engineering works of “Metrowagonmasch“ in Mytisch-tschi, near the Russian capital (the only exception being 120 cars that were brought from occu-pied Berlin in 1945 as reparation payments and adapted to the Russian broad-gauge network).

After the war, numerous indigenous vehicles were devel-oped and produced in Mytisch-tschi. The most modern trains currently in service belong to the 81-760/761 series. They have been in production since 2012 and use less power than their predecessors. So much regarding

the history and current state of the Moscow Metro.

Further vehicles of the 81-760/761 series are to be built in future. For their production, RA-FIL was awarded a contract only last year to supply 128 driven wheelsets, including gear units from ZF Friedrichshafen.

This contract came at an ideal point in time, incidentally, the Ilsenburg company having just completed a retrofit programme involving 3,000 wheelsets for Berlin’s rapid transit “S-Bahn” system.

Although assembly tracks in the Russian gauge of 1,168 mm were needed for the contract, this proved to be the least of the problems, as such tracks were still available in Ilsenburg from the time of working together with Deutsche Waggonbau AG. Up to the early 1990s, RAFIL had pro-duced huge numbers of wheel-sets for passenger coaches and special-purpose refrigeration vans designed for Russia’s broad-gauge network.

The first-piece inspection for the new driven wheelsets took place in Ilsenburg in April suc-cessfully, RAFIL’s manufacturing quality convincing the repre-sentatives of both “Metrowagon-masch“ (vehicle builder) and the Moscow Metro (train operator). RAFIL thereby qualified as an approved wheelset manufacturer for the Moscow Metro.

What remains to be hoped is that this good impression can also help to win further con-tracts. As is generally known, Moscow has a major goal in mind: the 2018 football world championship. By then the in-tention is to invest 4 billion euros in the Metro system in order to expand the route network by 82.5 km, and, in particular, to procure new vehicles.

em

photo: em

Dimensional inspection on a driven Metro wheelset


Prototype undergoing trialsraFIl · Original Ilsenburg Lightweight Wheels developed for the PRASA

radsatzfabrik Ilsenburg (RA-FIL) is to supply the Passen-

ger Rail Agency of South Africa (PRASA) with Original Ilsenburg Lightweight Wheels. According to Andreas Bader, the key man-ager responsible for the region, “We established initial contacts as long ago as the 16th Inter-national Wheelset Congress in Cape Town in 2010.” Which goes to show that being present at trade fairs does pay off.

Background: With the excep-tion of thoroughly state-of-the-art business trains fitted with air conditioning and other features, the vehicle fleet operated by the Republic of South Africa is out-dated – and not really equipped to meet the requirements of the modern age. Nevertheless, much of the rolling stock can still be used in the future – provided it is suitably retrofitted and upgraded (e. g. with air-conditioning, com-munication and safety systems).

But modernise which parts, and how? Design engineers from Ilsenburg under the direction of Matthias Schwartze made several visits to take a closer look at the rolling stock. They promptly

submitted a proposal on how to retrofit the running gear for a large part of the short-distance trains. This also took account of PRASA’s wish to save weight as a means of achieving higher en-ergy efficiency.

The short-distance trains still operate with tyred wheels as part of their driven and non-driven wheelsets, in accordance with the AAR (American Associa-tion of Railroad) Standard. They are, as a result, of heavyweight

design. RAFIL’s proposal to the customer is therefore to fit the 5M2A trains with a new wheelset generation based on the tried and proven Ilsenburg lightweight wheel. The development of the prototype has taken account of the many lessons learned from the operation of metro systems in Berlin, Helsinki and also Mos-cow.

The proposal put to the PRASA was a convincing one. According to Matthias Schwartze,

“Given the changed design loads, the customer also agreed to now apply European Standards to the design of the wheelsets, in variance from the previous AAR requirements.”

What will then “move” people at the Cape in future will become evident after the three-month phase of testing undergone by the first wheelsets. At the present time the production work being undertaken in Ilsenburg compris-es 12 non-driven and 24 driven wheelsets. One prototype of both will, because time is of the es-sence, be sent by air freight to Africa, where the testing will take place. If everything turns out to the customer’s satisfaction, the first 5M2A type vehicles will, probably, be retrofitted soon in the well-equipped workshops in Koedoespoort. RAFIL will then send individual components, lightweight wheels and wheelset axles by sea to South Africa for assembly locally.

According to information from the relevant ministry, South Africa intends, within the next 20 years, to invest as much as 30 billion euros in the mod-ernisation of the country’s rail infrastructure. The programme will include not only rail tracks, stations and halts, but also the procurement of new Electrical Multiple Units (EMU) – and the retrofitting of many of the more than 4,000 rail vehicles in the Republic of South Africa.

em

photo: andreas Bader

Old and new: modern and traditional side by side.

Completely within budget BtBEd · Easter repairs encompassed “axle and ring” production chain including rotary hearth furnace

W ithin the space of three weeks, Bahntechnik Brand-

Erbisdorf (BTBED) carried out a major overhaul of three facilities in parallel: its rotary hearth fur-nace, the Linsinger-built sawing line, and the SXP 25 axle forging machine. Three weeks had also been estimated for the entire “ring” production line, including heat treatment stage. Peripheral and downstream facilities that were inaccessible during ongoing production (due to continuous operation) were additionally

serviced and repaired. These in-cluded the charging machine for batch furnaces 11 to 25, and the quench tank.

The main focus of this year’s repair and maintenance work was, without doubt, the rotary hearth furnace, which was in a very rundown state. Emergency repairs had only just made it possible to keep it operating until the start of the scheduled overhaul.

“Supervisory responsibility” lay in the capable hands of BT-

BED’s maintenance department, which had the task of coordinat-ing all the external contractors technically and organisationally on this major job site. A total of 203 individual activities car-ried out by five teams had to be managed. No easy task, given that one “old hand” had left on reaching retirement age, and a field supervisor had suddenly fallen ill. It therefore became necessary to re-allocate the main-tenance and repair activities con-cerned – resulting in additional work loads for the personnel.

It had taken some five months beforehand to prepare the work and procure spare parts. What had to be repaired and serviced had already been identified in advance – by evaluating the re-pair work undertaken in 2011 as well as the findings submitted by the plant manufacturers’ service technicians. Added to this there

were malfunctions and plant and equipment faults that had come to light in the meantime.

The total maintenance and re-pair programme was budgeted at around 500,000 euros, which also includes still outstanding spare parts that were not delivered on time and cannot therefore be in-stalled until later. This concerns primarily the new pistons for the Lasco pre-forming press.

It proved possible to keep within schedule. A time exten-sion became necessary only in the ring rolling mill, this being due to, among other things, the unforeseeable state of wear of the rolling table guides. Inspection findings regarding individual groups of installations are al-ready available, enabling BTBED to start planning, budgeting and scheduling the maintenance and repair work for 2013.

Bernd Vogel


Idea costs time, but saves moneyBVV · Special “energy saving” drive generates a host of proposals - and a lucky winner.

What prompted this was a large-scale

poster campaign by GMH Holding on the topic of “energy saving”. It gave Bochumer Verein Verkehrstechnik (BVV) the idea of launching a special drive within the scope of its Employee Suggestion Scheme. The company used its special drive with a two-fold aim in mind: firstly, to save energy and, secondly, to stimulate its Employee Sugges-tion Scheme.

And successfully, too. Between April and November last year, 22 improvement sugges-tions on the topic of “energy saving” were entered. Of these 22 suggestions, six were rated positively. They will, as a result, be adopted because it will be worthwhile for the company to do so – which in turn also ben-efits the entrants financially.

A prize draw has mean-while been held at the first employee meeting to re-ward these six suggestions. Good luck fairy Kathleen Vowe (works councillor) drew the lucky winner of the main prize: Sven Hed-wig, a painter in the Ma-chining Department. Dan-

iel Weihmann, Chairman of the Employee Suggestion Scheme, presented him with the main prize, an i Pad II.

The suggestion entered by Sven Hedwig was an energy-saving and more cost-effective way of cleaning dummy components. Such dummies are needed to be able to apply coats of paint to wheels that, because of their size and design, are unsuitable for painting in-dividually in the wheelset paint shop. To do this, they are mounted on so-called “dummy axles”.

After painting, these dummies are totally smeared with paint, and would be cleaned in a work-intensive process in a dry ice blasting unit. This unit would be operated for several hours using a 65 kW compressor, resulting in an enormous power consumption in relation to the comparatively small components.

The idea submitted by Sven Hedwig has led to a remedy. He has suggested 24-hour immersion of the dummy components in a medium that removes the paint not only in an environmentally friendly way but also cost-effectively. The outcome: the dummies can be cleaned without any power being needed at all.

The dry ice blasting unit is now only used to strip paint quickly and efficiently from wheels, axles and complete wheelsets that are due for repair.

Daniel Weihmann

photos: daniel Weihmann

Sven Hedwig (painter in the Machining Department) at work

Main prize winner Sven Hedwig


When a job is difficult, Harz Guss Zorge is the one to contactHGZ · Thermal analysis as a means of process control and monitoring

I NtErV IEW

OCC – most associate this ab-breviation with a firm called Orange County Choppers from the TV series “American Chop-per”. However, in the foundry industry these three letters stand for Mönchengladbach-based company Octagon Com-puter Concepts which, since mid-2010, has been working as a partner with Harz Guss Zorge (HGZ) on a project to implement thermal analysis as a means of controlling and monitoring the processes for the production of vermicular and nodular cast iron. HGZ employee Björn Dhonau gives a few details in this regard.

glückauf: Mr. Dhonau, please throw a little light on such terms as vermicular, grey and nodular cast iron, and so on, for our readers. What do they mean exactly?Björn dhonau: Standards classify grey solidified cast iron accord-ing to the shape of its graphite precipitations, namely lamellar (EN-GJL, grey iron), vermicular (EN-GJV) and spheroidal (EN-GJS, nodular cast iron).

Put in plain terms, then, the graph-ite is present in the component ma-terial either in leaf (lamellae), worm (vermicular) or spheroid (globule) form. How do these differences come about?dhonau: The final shape of the graphite is determined by the imparted magnesium content and inoculation treatment. To produce GJV or GJS, the molten metal has to be both treated with magnesi-um and inoculated. Grey cast iron is not treated with magnesium, but just inoculated. And that’s how the differences come about.

High-strength GJV materials are not at all easy to produce Why is that?dhonau: It’s because their pro-duction poses very specific chal-

lenges in regard to the process parameters. Which is why by no means everyone operating on the global markets has mastered this process.

And Harz Guss Zorge has, hasn’t it?dhonau: It has now. We saw it as an outstanding opportunity to raise our profile as an innovative, specialised supplier – a strategy we have already been pursuing for years. And successfully so. In fact, HGZ is a partner sought-after by customers when it comes to resolving difficult material-related problems.

Difficult in what way?dhonau: Let’s take the require-ments that have become more exacting in the past few years concerning diesel engines. They have forced our customers to replace traditional materials such as GJL with new ones. It is with this in mind that various cus-tomers approached HGZ in 2009,

requesting the supply of com-ponents made of high-strength GJV. To meet this demand, we conducted trials in the first half of 2010 involving different means of treatment for the pro-duction of GJV.

Successfully?dhonau: Yes – but they left a few things to be desired regarding process robustness and automa-tion possibilities. We therefore got OCC onboard as a coopera-tion partner. The company has made a name for itself installing GJV production systems in the industry. Several successful mar-ket competitors as well as cus-tomers have been putting their faith in OCC production systems for years.

Have your expectations been ful-filled?dhonau: More than that, because we are able to use the process not only to produce GJV, but also to optimise GJS production. Which

is why the foundry manage-ment has decided to use the now installed analysis and control technology for nodular cast iron production as well.

Which has drastically increased the scope of the project.dhonau: Of course. Because the aim was to realise the existing GJS production process by means of the new system – without signifi-cantly altering the operating pro-cedures or reducing productivity.

Has that been difficult?dhonau: Yes. Because the “tem-po” in series production at HGZ has surprised even the experi-enced OCC specialists. We have as many as 28 treatments per hour, in other words an average time interval between treatments of somewhat over two minutes. This rate at which the processes take place at HGZ presented the technicians with a several major challenges.

What is the situation at the moment?dhonau: The system has been in use in series production since Easter of this year and will reach its full potential in the course of the year – once the usual teeth-ing difficulties and specific issues that crop up only in actual op-eration have been put right.


For the expert

the oCC system is based on thermal analysis as a means of controlling and moni-toring the treatment process. Thermal analysis is a technique whereby the temperature of solidifying molten metal is meas-ured in a sample crucible and plotted over time. The cooling curves thus generated enable metallurgists to reach various conclusions regarding the state of the melt. Thermal analysis has been used for years in aluminium and iron foundries. The OCC system automatically determines significant values from the cool-ing curves and, using them as a basis, calculates the wire lengths for the magnesium and inocula-tion treatments, such that the treatment parameters are reliably adapted to the current metallur-gical state of the base iron, and documented.

Molten iron undergoing OCC-controlled magnesium treatment

photo : mh


dialogue on equal terms raises awarenessWH · It is always a good idea to investigate new methods – also as far as communication is concerned: two colleagues communicate aspects of industrial safety in a new way – and receive very positive feedback from their colleagues.

Industrial safety is one of the most important guiding prin-

ciples in the manufacturing of products and the prime objective of superiors and employees alike. This applies particularly in the foundry industry. Because in this industry employees have to deal with dangerous machinery and substances – molten material, metals, and dust, just to mention a few examples – on a daily basis. In such a context “safety first!” takes on a special significance.

Two safety officers from Walter Hundhausen have taken

this issue particularly seriously. It all started with their two-stage training to qualify as Safety Of-ficers I and II, conducted by the “Berufsgenossenschaft Holz und Metall” (employers’ liability insurance associations for the wood and metal industries). Af-ter their training sessions they did not want simply to return to their workplaces and continue as before.

Murat Gür (Finishing Depart-ment) and Martin Heistermann (QM Department) had the idea of sharing their knowledge with

their colleagues. This is why they spent many hours of their free time preparing an “industrial safety presentation” together. This presentation contained ele-ments from the safety training sessions which they attended as well as industrial safety topics which are particularly important at Walter Hundhausen.

The result was an impres-sive and very comprehensible presentation. It has already been seen and very well received by a substantial number of colleagues. They particularly liked the fact

that it was so easy to understand and was also of direct practical application. Acceptance of the content conveyed has also in-creased significantly – according to comments made by colleagues who have already attended the events.

The presentation focused less on the consequences that ensue for the employer in connection with accidents at work. Instead it concentrated on the conse-quences for the employees con-cerned. Murat Gür and Martin Heistermann made the situation quite clear: any serious accident at work – for example, loss of an eye, an occupational disease, impairment to hearing – means a significant reduction in quality of life. Such arguments made it possible for them to increase em-ployees’ awareness of how neces-sary it is to take steps to avoid such dangers.

Other important issues were cleanliness and orderliness at the workplace (according to the “5S” method), how to deal with forklift trucks and electric lift-ing trucks (so-called industrial trucks) as well as the wearing of personal protective equipment, and what it should include. Many interesting discussions evolved in connection with the subject of “industrial safety” and the risks which are to be found lurking at work. Further training was also provided about how to behave in case accidents do oc-cur.

The presentation, however, also made it clear to the em-ployees that safety does not stop when you leave the works premises. It is to be taken equally seriously in leisure time and in a private context.

The two “trainers” answered participants’ questions extremely knowledgably and with great empathy. Maik Lücke, Head of the Finishing Department also found the training sessions to be very positive. This is why he sup-ported the initiative taken by the two employees.

Finally the experts and em-ployees were all in agreement: it was a great idea this time to deal with the subject of safety on a “colleague to colleague” basis – and not always “from the top downwards”.

nh

Shortly before the start (from left to right): Martin Heistermann (Quality Management), Murat Gür (Finishing Department) and Hans-Peter Limberg (Safety Officer) doing a final check before giving a talk to colleagues on the subject of industrial safety.



Successful start: Now dHG also casts steeldHG · New field of business was prepared well in advance.

a fter two years of preparation, Dieck-erhoff Guss has entered into the steel

casting business. Development contracts for renowned turbocharger manufacturers have also been secured in parallel over the past few months. Prototype fabrication is cur-rently in progress. The first components have already undergone acceptance inspection and are being tested by the end user. Once they have passed the trial phase, their vol-ume production could begin.

But why cast steel? One thing is for cer-tain: the cost of fuel will continue to rise. Au-tomobile makers are responding to this with the development of more efficient engines - meaning that exhaust temperatures will also, inevitably, rise. In case of petrol engines,

they get as high as 1,050 °C. The only class of materials able to withstand such thermal loads are heat-resistant austenitic steels, namely 1.48xx.

And how does the casting take place? The cast steel components are produced on Dieckerhoff’s HWS moulding line. A new binder system optimally suited to cast steel has been adopted for the coremaking pro-cess. The molten steel comes from a separate crucible furnace that has a special refractory lining.

Interim assessment: Dieckerhoff has made a successful entry into the steel casting busi-ness. Market demand is set to increase, and the response among customers is extremely good. Despite all the euphoria, though, there must be caution not to expand all too rapidly in this segment.

Dirk Oebel

league of quality all of its ownSGG · Producing for a global player: Offshore castings to NORSOK standard.

SBM Offshore (Netherlands) operates in-ternationally in the offshore oil and gas

industry. Stahlguss Gröditz (SGG) recently had the opportunity to produce castings for SBM’s representative office based in Monaco (the enquiry having been received from a Spanish component supplier).

It was a challenging task, as the castings were to be produced in a material listed in offshore standard NORSOK M-122, namely NORSOK M-122 grade 420 /ASTM A148 grade 90-60 (modified). Technologically, its production regime calls for high accuracy in its melting, heat treatment and testing.

The castings are needed to anchor a dy-namically positioned oil drilling ship. And because the required delivery period was so

short, the Spanish customer split the con-tract between three foundries: ebroacero (Zaragoza), GUIVISA (Basauri), and Stahlguss Gröditz. By doing so, the Spanish company wanted to make sure that the requisite cast-ings are available on time for assembly.

The joint technical kick-off meeting took place at SBM’s office in Monaco as early as mid-October. Also present were the contract-ed foundries, the representatives of manu-facturer asturfeito (Carreno), and engineers from SBM. The discussed topics included the type of material, the mechanical-technolog-ical properties expected during the material testing, and the machined condition of the individual components within the required deadlines. The foundries were able to clarify outstanding questions regarding design and type of material, so as to pre-pare optimally for production.

After the necessary pattern equipment had been fabricat-ed, Stahlguss Gröditz began in October 2011 with the produc-tion of the castings. The aim was to deliver twelve batches of three different castings by February 2012. In the course of the castings’ production, a series of material quality tests were conducted, which were

monitored and certified by inspection agency ABS (American Bureau of Shipping).

The outcome: the set requirements were reliably met. The castings also had to demon-strate in further tests that they satisfied cur-rent international standards. Required were an accompanying welding procedure quali-fication test, CTOD tests, and notch impact and tensile testing for wall thickness ratios ranging from 50 to 600 mm. This resulted in valuable information concerning the general material behaviour in these fields for future applications and approaches.

This accumulation of knowledge was not the only positive experience to come out of this project, however. The parts were also supplied successfully, on schedule, to the cus-tomer, who expressed his appreciation to the entire SGG team with photos showing the units after their final completion in Spain.

ul Assembly of the chain guide

Outstanding questions regarding the design and type of material. One example of this is the casting proposal for a selected part depicted as a 3D representation, using the magmasoft casting simulation pro-gramme.

Company employees Shakir Öksuzoglu (left) and Sevret Karamugara pouring molten steel, which comes from a separate crucible furnace.

A core made with a special binder system specifically for the steel castings



source: SGG


Crane manufacturer custom- builds system for automatic coil annealing facility KBK · The first construction phase saw the delivery of the crane system for the new batch annealing shop. The second phase will see the installation of an automatic coil store and cold mill.

I NtErV IEW

In May 2011, Bilstein Service GmbH awarded a contract to Kranbau Köthen to supply a crane system for its new batch annealing shop in Hagen- Hohenlimburg. In the new shop the crane will handle (i. e. charge and dispose of) coils in automatic mode. Heiner Witke (project manag-er) gave details in this regard in an interview with glückauf:

glückauf: How should we picture the crane, Mr. Witke?Heiner Witke: The crane features two hoist units mounted on a crab frame. They have a lift-ing capacity of 50 tonnes and 28 tonnes respectively, operat-ing over a span of around 32.8 metres. The classification of the drive system is group 5m and thus of maximum possible de-sign. And to optimise availabil-ity, the hoist units are fitted with planetary gears.

What advantages does that offer?Witke: Even if one drive unit fails, production can continue, because the remaining drive unit is capable of lifting the entire load, albeit at only half the lift-ing speed.

Were there any special safety re-quirements in this regard?

Witke: Certainly. Within the operating envelope of the crane there are pressurised hydrogen lines used for the an-nealing facility. We therefore have the same safety systems in place as for transporting molten materials. And because of the shop’s envi-ronmental conditions, the ambi-ent temperature while the crane is operating is around 60 °Celsius. The entire crane control system is therefore installed within the insulated and air-conditioned crane bridge. There is also a dust extraction system in proxim-

ity to the crane rails and, of course, fire ex-tinguish-

ing appli-ances for

the switch-gear.

Why is a dust extraction system necessary?Witke: So that any material abraded from the crane wheels and rails can be removed imme-diately and not affect the anneal-ing process.

The crane, as mentioned, will oper-ate in automatic mode. What will this mean in terms of on-the-job safety?

Witke: We have, for example, installed a fence to screen off the envelope for automatic operation from unauthorised personnel ac-cess. The crane control system is, additionally, linked via a data in-terface to the customer’s data sys-tem and to the annealing shop.

How did the transportation and in-stallation turn out?Witke: It wasn’t a very easy job. The annealing pit in the new building lies four metres below floor level, making it necessary

to manoeuvre the crane compo-nents around within the shop. This was the only way we could realise the lifting and assembly work from the outside via the roof opening using a mobile crane.

Its installation concludes the first construction phase. What is the next step?Witke: In the second construc-tion phase, an automatic coil store and cold mill are to be installed. The automatic control system of the present annealing shop crane has already been pre-pared for the second construc-tion phase. And we are also look-ing to supply the crane equip-ment for the second phase.


Top: Ready for transportation. Left: Distance measurement.

And up it goes … … and fits – and the first bridge element … … is in place on the rails.

Heiner Witke

photos: Heiner WitkePhoto by courtesy of the GMH Group


rainer Becher and his radio messagesGMHütte · Many more of these are likely to be heard in future, especially by amateur radio enthusiasts tuned in to the relevant frequency: “CQ CQ, here is DL0GMH, the club station of Georgsmarienhütte GmbH.”

I NtErV IEW

Many former as well as cur-rent employees of GMHütte share a hobby: amateur radio. And they are in good company with this passion. Worldwide the number of amateur radio enthusiasts is estimated to be around two million. In an in-terview with glückauf, Rainer Becher (DO1BR), chargehand in the roll and fittings shop in the rolling mill, explains what is so fascinating about radio transmission:

glückauf: Mr. Becher, what exactly do you mean when you talk about amateur radio? rainer Becher: Amateur radio is a hobby for technical enthusiasts who like to communicate with other people via radio transmis-sion.

What kind of technology and tech-niques do radio amateurs use?Becher: We radio amateurs have a wide choice of possibili-ties available. First of all there is simple voice transmission and telegraphy, in other words Morse code. Furthermore there are the teleprinter, today usually done by PC, the PSK31 procedure and also package radio, the predeces-sor of the internet.

And what kind of things do you ex-change information about? Becher: Most of us talk about our hobby, amateur radio. There are, however, lots of interest groups as well as individual radio amateurs who always meet at certain times and on the same frequencies. In addition to amateur radio, they also talk about other subjects. For example there are the naval radio operators, the railway group and many other forums.

How do you find your conversation partner “somewhere out there in the world”? Becher: In Germany alone there are about 82,000 licensed radio amateurs who are active on all bands, including well-known personalities such as the politi-cian Friedrich Merz or the astro-naut Thomas Reiter. And inter-nationally there are a number of active VIPs such as the widow of Elvis Presley and even the King of Spain.

Can anyone transmit via radio? Becher: You have to take an ex-amination at the German Federal Network Agency (Bundesnetz-agentur) which covers three areas:

operating technology, legal issues and electrical engineering. In or-der to pass, you have to do a bit of swotting, but for technology en-thusiasts it should be no problem. Once you have passed the exami-nation you can register your own call sign, and then you can enter the world of amateur radio.

What about hardware? Becher: You have the right to build your own radio transmitter. We are allowed to do that, unlike CB radio enthusiasts. Or you just buy your radio equipment and set up your own antenna.

Setting up an antenna cannot be so easy. How does that work?

Becher: There are local groups of the “Deutscher Amateur Radio Club e. V.” all over Germany. They are always happy to help setting up an antenna or pur-chasing the equipment.

One of these groups is also located in Georgsmarienhütte. Is there any special news from there?Becher: We, the radio amateurs of local group I 37 of “Deutscher Amateur Radio Club e. V.” have applied for club sign DLOGMH for our GMHütte. We would like to keep in contact with our col-leagues in other companies of the GMH Group.

How can interested persons partici-pate in these activities?Becher: Anyone who would like to take part is welcome to con-tact me. I am active in the D-Star field (Ref 010) or you can contact me via emai:l [email protected].

Thank you for talking to us

beyondtheplant

A hi-tech hobby: Rainer Becher with his radio equipment and the club signal of the GMHütte.

photo: thomas Becher


Recently I tried out an adapted version of a recipe created by British star chef Jamie Oliver: his wife Jools’ favourite pasta dish. My wife loves this pas-ta dish as well. Not only because it tastes fantas-tic but also because it is so easy to make. But she liked my Risotto variation even more because rice absorbs the flavours better. So when using rice you should reduce the spice quantities as otherwise the subtle and elegant flavour would be overpowered. The quality of the cinnamon is crucial. Take a cinnamon powder which smells strongly of cinna-mon. As a matter of fact you can also enhance the taste if you ensure all other ingredients you select are of very high quality too. Particularly as far as the tuna fish is concerned. And, incidentally, buying tuna from sustainable fisheries will also be good for your conscience.

Preparation:• Dice the onion.• Pick the basil leaves off the stalk and chop the

stalks into small pieces.• Heat the stock in a pot.• Grate the parmesan.• Drain the olive oil from the tuna into a second

pot. Add olive oil if required to ensure the bot-tom of the pot is well covered.

• Lightly fry the onions together with the basil stalks and the chili flakes in this oil. Add a little salt.

• Add the rice and the cinnamon powder and roast it briefly in the oil. There should be enough oil in the pot for the rice to absorb some of it.

• When the rice starts to stick on the bottom and there is no more oil left, add the white wine. Reduce the heat and stir constantly until it has boiled down.

• As soon as the liquid has been completely absorbed by the rice, add the stock gradually with a ladle and allow to boil again.

• Add a piece of tuna with each ladle of stock.

IMPORTANT: A good risotto needs to be stirred. Oth-erwise the starch will sink to the bottom and the risotto will burn. The heat should be as constant as pos-sible, which is why the tuna should be added piece by piece.• When all the tuna has been added to the

risotto, add the drained chopped tomatoes.• At the end of the cooking time (after approx.

20 to 25 minutes) check whether the rice is properly cooked. It should be firm on the outside but soft on the inside.

• Now remove the pot from the oven and grad-ually stir in a sizeable piece of butter (directly out of the fridge) and about 2 handfuls of grated parmesan (to taste).

Arrange basil leaves and sprinkle parmesan over the dish before serving.

Bon appetit! and best wishes from your

glückauf Master Chef

Rather rice than pasta – basta!Creative cooking the simple way: Just vary the recipes of a master chef.

Masthead

Publisher:Ge orgs ma ri en hüt te Hol ding GmbHNeue Hüt ten stra ße 149124 Ge orgs ma ri en hüt tewww.gmh-hol ding.de/uk/

responsible in accordance with press law:Iris-Kath rin Wil ckens

translations: Carol Hogg, Michael Snowley

design: elemente designagentur, Münster

The

glüc

k auf m

aster chef recommends:

Ingredients:

• 250 g risotto rice• 1 small onion or shallot• 5 stalks of basil• 1 heaped teaspoon

cinnamon powder• chili flakes• olive oil• 0.1 l white wine• 200 g tuna in olive oil• 400 g pealed tomatoes (tin)• approx. 0.75 l stock• 50 g parmesan• butter• salt

photo: thomas Hesselmann

take a look here!In which city and in front of which building is Vera Loose (GMHütte) reading glückauf 1/2012? Tip: In order to enter the city of her birth a popular singer does not always require a bright red rubber dinghy. And in the building, noble prizes are award in the interest of peace. Send your reply to [email protected] or (by postcard) to Matthias Krych, RRO GmbH, Rheinstraße 90, 49090 Osnabrück. Closing date for entries is 30th August 2012. If more than one correct entry is received, the winner will be drawn

from all correct entries submitted. The winner will re-ceive a polo shirt from the GMH Fan Shop. (No legal recourse permitted.) And where is your photo? Would you also like to submit a picture puzzle? Just take a photo featuring glückauf in the foreground. In the background there should be enough specific details to be able to recog-nise in which place or in which town the photo was taken. Mail your photo to [email protected].

did you know?In our last picture puzzle, Petra Meier (ESB) was standing in front of the station in Lüttich (Liège-Guil-lemins). The winner, Philippe Scheepers (Engineering Steel Belgium) was drawn from all correct entries sub-mitted (thank you for taking part!) Congratula-tions!

The winner will be informed by the glückauf editorial team. photo: Frank Swierzinski

photo: privat

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