thyssenkrupp system engineering system engineering thyssenkrupp-11-how the fascination with car...

A company ofThyssenKruppTechnologies

ThyssenKrupp System Engineering

Thys

senK

rupp

- 1 -

ThyssenKrupp System EngineeringDrauz Nothelfer I Krause I EGM



Thys

senK

rupp

- 2 -

Elevator

ThyssenKruppSales: € 51.7 bn • Employees: 191,350

Stainless ServicesTechnologies

Steel

Steel

Sales 2006/07; Employees: 30. Sep. 2007; rounded

Sales:€ 13.2 bnEmployees:39,600





ServicesCapital Goods

ThyssenKrupp: Focused Industrial Group With Three Pillars



Thys

senK

rupp

- 3 -

Sales 2006/07; Employees: 30. Sep. 2007; rounded

Transrapid

PlantTechnology

MarineSystems

Sales: € 2.0 bnEmployees: 8.800


Mechanical Components


AutomotiveSolutions


ThyssenKrupp TechnologiesSales: € 11.5 bn Employees: 54.762

ThyssenKrupp Technologies - Overview



Thys

senK

rupp

- 4 -

Automotive Solutions: Innovative Systems

Presta SteeringSteering columns, gears

and systems (EPAS, HPS)

Drauz NothelferSystem partner

body solutions, dies,body-in-white, assembly,

production

KrauseAssembly/test systems

for engines, trans-missions, axles

Bilstein SuspensionAir suspension systems,

dampers, springs, stabilizers




Thys

senK

rupp

- 5 -

ThyssenKrupp System Engineering - Organization

Drauz NothelferForming Dies

Josef Görgen

Krause / EGMTesting Solutions

Peter Kohlwig

KrauseAssemblySystemsDr. Joachim Haats

Drauz NothelferBody-in-White

Josef Görgen

Drauz NothelferPart Production

Bernd Becker

• Engine testing

• Transmission

testing

• Axle testing

• Measuring

machines

• Engine assembly

• Transmission

assembly

• Axle assembly

• Body-in-White

• Final assembly

• Tools & Dies

• Prototypes

• Body assembly

• Hydroforming

• Special vehicles

3 Brands, 4 Continents, 11 Countries, 4000 People, 800 million € Sales


Bernd Becker (CEO) Dr. Joachim Haats (CSO) Dr. Johannes Dippel (CFO)



Thys

senK

rupp

- 6 -

Div

isio

n Te

stin

g So

lutio

ns

Engine / Transmission / AxleTurnkey solutions for test systems

End of Line Test bench

Function & NVH test bench• Engine• Transmission• Axle

Complete test areas

• Dimensional measuring

• Part control• Leak test• ect.

Measuring technologyHardware

Measuring technologySoftware

Component testing and integrated quality assurance (IQA)

Test areas

Measuring computers• Decentral measuring

electronic DME• Programmable

measurnig electronic

PMESensors

• Laser

UPS 32

Extensive test applications

UMSDimensional measurement andIQA

• Simultaneous Engineering

• Training• Production support• Retools• Maintenances• Spare parts• etc.

Service

Satisfied Customers are our MotivationTesting Solutions – Product Range



Thys

senK

rupp

- 7 -

Div

isio

n Te

stin

g So

lutio

nsSatisfied Customers are our MotivationTesting Solutions – Selected References

Test bench for dual clutch transmission

Test bench for Diesel engines

Test bench for differential

• Function test (mechanical, electrical) at nominal speed and torque• Noise vibration harshness (NVH)• Park pawl test• Determination of clutch characteristics• Diagnosis of TCU and CAN bus simulation

• Combined NVH and balancing with up to 40 % reduction of investment costs• Initial breakaway torque, drag torque, ratio test, differential test • Noise vibration harshness (NVH)• Balancing of pinion flange

• Engine function test (mechanical, electrical) in unfired, torqued mode• Engine mechanic test (crank – cam shaft)• Common Rail Test with max. system pressure • NVH test• Test of engine sensors and actuators



Thys

senK

rupp

- 8 -

Automatic Stations

Transport Systems

• Friction rollerconveyor- horizontal- vertical- up to max. 2000 kg

• Flex link conveyor(KSR)

• Components (modular)

• Assembly operation• Tightening and

press-in operation• Sealant application• Measurement and

adjustment

Manual Stations

• Simultaneous Engineering

• Instruction/Training• Production attendance• Modifications• Maintenance• Spare parts

Service

Engine / Transmission / Axle AssemblyTurnkey Powertrain Assembly Systems

Service

Why the total is the sum of many partsAssembly Systems – Business Activities

Div

isio

n A

ssem

bly

Syst

ems

Pallet Systems (Pallet, Adapter)

Assembly Systems

• IMS+• Multi-adapter

system- Flexible use- Modular design

• Highly flexible• Ergonomically

designed• Modularly

extendable

Complete assembly systems for engines, transmissions and axles including measuring technology and testing solutions from one source



Thys

senK

rupp

- 9 -

Div

isio

n A

ssem

bly

Syst

ems

• Flexible ergonomically designed manual work stations

• Adapter/pallet concept for further engine types prepared

• Output up to 300.000 engines/year• Ideal for “low cost” locations

• Automatic assembly line for engine, cylinder head and final dress

• Automatic valve-lash adjustment• Automatic engine function test and

leak test

• Standardized stations• Different cylinder head versions

on one assembly line• Space allowance for integration

of additional product variations• I3-I6 cylinder

• Overall responsibility for complex controlled processes

• Early fault detection• Optimal work station layout• Fuel-saving future technology

• Flexibility: In-line 4-cylinder up to V12 engine

• Modular concept• Output: 10.000 up to

500.000 engines/year

Why the total is the sum of many partsAssembly Systems – Selected References

• Highly automated assembly and test facilities for 5 worldwide production locations

• Same quality at all locations• Global project management by

utilization of 5 TK Krause locations

Navistar / 12.4 L I6 Truck EngineFord Commonality / Global System Supplier for 10 Assembly Lines

Renault / Semi-automatic Engine Assembly SystemVolvo Car / Fully automatic Cylinder Head Assembly

Volkswagen Double Clutch Transmission GM Automatic Transmission



Thys

senK

rupp

- 10 -

How the fascination with car design and structureis embracedBody-in-White – Business Activities

Div

isio

n B

ody-

in-W

hite

Turnkey, customized body-in-white plants

Virtual process safeguarding at an early stage

• Framing stations up to 8 models

• Robot framing

• Brazing, cutting, welding

• Remote welding

• Tabletop hemming• Roller hemming• Hem dies

• Upgrade/Relocation• Plant optimization• Spare part service• Training

Car Body Manufacturing

General contractor for complete final assemblies

• Manual and automated systems

• Roller technology

- Marriage assembly systems- Chassis equipment- wheel assembly

Semi- and fully automated glass gluing and flange seal assembly

e.g. for bumpers, cockpit, frontend and center console

Final assembly technology

Planning – Virtual Safeguarding – Project Management - Commissioning - ServiceTurnkey Sealer applications Marriage systems Window assembly systemsModule assembly syst.

Turnkey Digital factory Framing Hemming technologyServiceLaser application



Thys

senK

rupp

- 11 -

How the fascination with car design and structureis embracedBody in White – Selected References

Div

isio

n B

ody

in W

hite

• Body equipment closures• Planning in Germany, local pro-

cessing• > 40% local rate

• 3 sites: Ingolstadt, Neckarsulm,Changchun

• Use of the Drauz Nothelfer plate technology for the application of door sealings

• 5 models, cycle time 55 sec.• Engineering in Germany• co-operation with local suppliers• Local design and commissioning

• Industrialization of remote laser welding

• Supplier for remote laser cell doors

equipment in Sindelfingen andSouth Africa

• Realisation of side panel equip-ment in Wolfsburg, Brüssel and Mosel

• Processing via all German Drauz Nothelfer sites

• System partner doors (tools and side panel) and side panel forZaragoza plant

• Quality responsibility for door module

Shanghai VW Santana 4000

Audi A4 / Door sealer application

Renault Logan Brasilien / Marriage

Mercedes C-Klasse / Remote laser welding

VW Golf V / Side panel

Opel Meriva /Doors and side panel



Thys

senK

rupp

- 12 -

Tools for serial production

System responsibility for assemblies up to complete bodies hand in hand with the division body-in-white

Tools - Components – Fixtures - Assemblies Tools for outer body parts and structure – all materials

Simultaneous Engi-neering, method planning, design

individual operations/ value-added levels up to full outsourcing worldwide

Quality attainment of own and supplied tools

From individual components to o.k. assembly, respecively o.k. car body

e..g. digitalization,laser hardening/cladding, lean tooling standards

Preventive mainte-nance/maintenance, spare part management

Div

isio

n Fo

rmin

g D

ies

Engineering Purchasing Tryout Matching Innovations Service

How to form QualityForming Dies – Business Activities

Prototypes



Thys

senK

rupp

- 13 -

• 14 die sets e.g. longitudinal carrieraxle support

• High strength dual phase materials e.g. DP 600, up to 2mm thickness• High quality requirements

Div

isio

n Fo

rmin

g D

ies

• System responsibility door assy.•Inhouse manufacture outer skin and inner panel

• Sourcing in Eastern Europe and Asia

• Material aluminium / steel• Responsibility for doors, bonnets

and tailgates/hatchbacks as assy.• Development tooling• Sourcing China

• Planning and consultation regar-ding components

• Prototypes with production intent• Worldwide supplier management• Tryout in press shop• Integration of all TKDN sites in

Europe and North America

• Manufacture and tryout of side panel

tooling for Genk

Audi Q5 / High strength steel expertise

Jaguar XF / Closures as system supplier

BMW X5 / General contractor for about 700 tools

Ford Galaxy / Side panelOpel Corsa / System partner doors

How to form QualityForming Dies – Selected References

• Consultation regarding component engineering

• First sample parts• Prototype tooling• Small-series tooling• Welding equipment• Laser cutting equipment

Fendt



Thys

senK

rupp

- 14 -

Many of our Competencies join in ProductionPart Production – Business Activities

Div

isio

n Pa

rt P

rodu

ctio

n

• Manufacture of low-weight and high-strength hydroforming parts for ultimate stress

• Manufacture of IHF tooling in own tool shop

Karosseriefertigung

• From individual assemblies up to complete body insteel or aluminium

• Planning, design and commissioning of equipment and tooling by body-in-white and forming dies division

• Support in Simultaneous Engineering

Hydroforming (IHU)



Thys

senK

rupp

- 15 -

Many of our Competencies join in ProductionPart Production – Selected References

• Material aluminium• Serial components and equipment• Manufacture of about 160

assemblies per day

Porsche 911 / water tube IHF

Audi Space Frame ® / different IHF parts A8, TT, R8

• Material aluminium• Serial components and equipment • Patented sealing process for multi-

chamber extrusions • Total forming process inhouse

Lamborghini Gallardo Coupe and Spider / Complete body

• Aluminium bodyframe construction• Small series manufacture, about

10 bodies per day• Outer skin expertise• Simultaneous Engineering

Porsche 911 und Boxster / Back panel lower for spare wheel

• Material steel• Manufacture of 150-200

assemblies per day

Mercedes S-Klasse / Main floor

• Material steel• Highly automated manufacture

with 400-500 assemblies per day• Successful trials with Bondal

plates

Div

isio

n Pa

rt P

rodu

ctio

n

• Material high-grade steel• Different cages from one modular

tool• Multi-part production• Close limit inside component

Behr / Cage for heat exchanger in IHF



Thys

senK

rupp

- 16 -

Products and Services along the Automotive Value ChainDrauz Nothelfer I Krause I EGM

Drauz Nothelfer

Krause and EGM



Thys

senK

rupp

- 17 -

ThyssenKrupp System Engineering - Philosophy

• short decision-making channels• minimum number of interfaces• short reaction time• high degree of customer orientation

• cost reduction• quality increase• high system uptime• short delivery time• reduced maintenance and spare parts expenditure• high degree of reuse for

modifications/extensions

• Americas: USA, Mexico, Brazil• Eastern Europe: Poland• Asia: China• cooperation with local partners

Project-oriented organization structure with

Standardized, modular solutions to the advantage of our customers

Utilization and expansion of world-wide low-cost production locations



Thys

senK

rupp

- 18 -

ThyssenKrupp System Engineering - Customer ReferencesAmerica Europe Asia/Australia



Thys

senK

rupp

- 19 -

Global Company - Local Presence

Subsidiaries

Service branches

Commercial agencies

A company of ThyssenKrupp

TechnologiesThyssenKrupp System Engineering

Thys

senK

rupp

- 20 -

• Ford - Q1 Award• Best Factory Award• County of Saxonia Price for Quality• BMW – “7-series Partner” • GM - Supplier of the Year: Body Shop Equipment & Service• VW - Global Supplier Award• S-VW - Golden Prize for Best Commercial Performance (China) • Ford / Jaguar - Reliability & Maintainability compliment

• ISO 9001 Quality Management• IQNet ISO 9001:2000 International Certification Network for Quality Management System• VDA 6.4 Quality Management

(production equipment)• ISO TS 16949 Quality System Management for

the automotive industry• QS 9000 TES Quality Management System• ISO 14001 Environmental Management

Recent Awards Certificates

Award and Certificates

thyssenkrupp system engineering system engineering thyssenkrupp-11-how the fascination with car...

Documents