thyssenkrupp system engineering corporate (without divsion) thyssenkrupp system engineering drauz...

ThyssenKrupp System EngineeringCorporate (without Divsion)

ThyssenKrupp System EngineeringDrauz Nothelfer I Krause I EGM

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ThyssenKruppSales 53.4 billion € • EBT 3.128 million € • 199.000 employees

Umsatz 2007/08; Mitarbeiter: 30. Sept. 2008; gerundet

SteelAmericas

SteelEurope

TK Steel Europe• Steel Europe • Processing

ServicesElevator

Nirosta

AST

NewStar

Mexinox

Stainless International

SKS

VDM

Stainless International

Materials Services

Elevator Technology

Plant Technology

Components Technology

Marine Systems

CSA

CompassMetals Services Special ServicesIndustrial Services

UhdePolysiusFördertechnik

System EngineeringTransrapid

Rothe ErdeBerco

CamshaftsSteeringForging GroupBilstein-GruppeWaupaca

HDWBVNBVSS

CENESEAMEAMSAP

ES/PBBAccessibility

Division Materials

Division Technologies

ThyssenKrupp: Focused Industrial Group With Two Pillars

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ThyssenKrupp System Engineering - Organization

Drauz Nothelfer

Forming Dies

Josef Görgen

Krause / EGM

Testing Solutions

Peter Kohlwig

Krause

AssemblySystemsJean-Luc Guyon

Drauz Nothelfer

Body-in-White

Josef Görgen

Drauz Nothelfer

Part Production

Bernd Becker

•Engine testing

•Transmission

testing

•Axle testing

•Measuring

machines

•Engine assembly

•Transmission

assembly

•Axle assembly

•Body-in-White

•Final assembly

•Tools & Dies

•Prototypes

•Body assembly

•Hydroforming

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

ThyssenKrupp System Engineering

Bernd Becker (CEO) Uta Anders (CFO) Martin Hilbig (CHRO) Bernd Becker (CEO) Uta Anders (CFO)

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Motor / Transmission / AxlesTurnkey solutions for test systems

End of Line Test bench

Function & NVH test bench• Engine• Transmission• Axle

Complete test areas

• Dimensional measuring• Part control• Leak test• ect.

Measuring technologyHardware

Measuring technologySoftware

Component testing and integrated quality assurance (IQA)

Test areas

Measuring computers• Decentral measuring electronic DME• Programmable measurnig electronic PME Sensors• Laser

UPS 32

Extensive test applications

UMSDimensional measurement andIQA

• Simultaneous Engineering• Training• Production support• Retools• Maintenance• Spare parts• etc.

Service

Satisfied Customers Are Our MotivationTesting Solutions – Product Range

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Test bench for dual clutch transmission

Test bench for Diesel engines

Test bench for differential

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

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

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

Satisfied Customers Are Our MotivationTesting Solutions – Selected References

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Automatic Stations

Transport Systems

• Friction roller conveyor - horizontal - vertical - up to max. 2000 kg• Flex link conveyor (KSR)• Components (modular)

• Assembly operation• Tightening and press-in operation• Sealant application• Measurement and adjustment

Manual Stations

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

Service

Engine / Transmission / Axle Assembly Turnkey Powertrain Assembly Systems

Service

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Pallet Systems (Pallet, Adapter)

Assembly Systems

• IMS+• Multi-adapter system - flexible use - modular design

• Highly flexible• Ergonomically designed• Modularly extendable

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

Why the Total Is More Than the Sum of Many PartsAssembly Systems – Business Activities

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•Flexible ergonomically designed manual work stations

•Adapter/pallet concept for further engine types prepared

•Output up to 300.000 engines/year

•Ideal for “low cost” locations

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

•Automatic valve-lash adjustment

•Automatic engine function test and leak test

•Standardized stations•Different cylinder head

versions on one assembly line

•Space allowance for integration of additional product variations

•I3-I6 cylinder

•Overall responsibility for complex controlled processes

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

technology

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

•Modular concept•Output: 10.000 up to

500.000 engines/year

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

•Same quality at all locations•Global project management by

utilization of 5 TK Krause locations

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

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

Volkswagen Double Clutch Transmission GM Automatic Transmission

Why the Total Is More Than the Sum of Many PartsAssembly Systems – Selected References

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Turnkey, customized body-in-white plants

Virtual process safeguarding at an early stage

•Framing stations up to 8 models• Robot framing

• Brazing, cutting, welding• Remote welding

• Tabletop hemming• Roller hemming• Hem dies

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

Car Body Manufacturing

General contractor for complete final assemblies

• Manual and automated systems•Roller technology

• Marriage assembly systems• Chassis equipment• Wheel assembly

Semi- and fully automated glass gluing and flange seal assembly

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

Final assembly technology

Planning – Virtual Safeguarding – Project Management - Commissioning - Service

Turnkey Sealer applications Marriage systems Window assembly systemsModule assembly syst.

Turnkey Digital factory Framing Hemming technologyServiceLaser application

How the Fascination With Car Design And Structure Is EmbracedBody-in-White – Business Activities

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• Body equipment closures• Planning in Germany, local processing• > 40% local rate

• 3 sites: Ingolstadt, Neckarsulm, Changchun• Use of the Drauz Nothelfer plate technology for the application of door sealings

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

• Industrialization of remote laser welding • Supplier for remote laser cell doors equipment in Sindelfingen and South Africa

• Realisation of side panel equipment in Wolfsburg, Brüssel and Mosel• Processing via all German Drauz Nothelfer sites

• System partner doors (tools and bodyshop) and side panel for Zaragoza plant• Quality responsibility for door module

Shanghai VW Santana 4000

Audi A4 / Door sealer application

Renault Logan Brasilien / Marriage

Mercedes C-Klasse / Remote laser welding

VW Golf V / Side panel

Opel Meriva /Doors and side panel

How the Fascination With Car Design And Structure Is EmbracedBody in White – Selected References

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Tools for serial production

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

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

Simultaneous Engi-neering, method planning, design

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

Quality attainment of own and supplied tools

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

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

Preventive mainte-nance/maintenance, spare part management

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Engineering Purchasing Tryout Matching Innovations Service

Prototypes

How To Form QualityForming Dies – Business Activities

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• 14 die sets e.g. longitudinal carrier

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

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• System responsibility door assy.• Inhouse manufacture outer skin and inner panel• Sourcing in Eastern Europe and Asia

• Material aluminium / steel• Responsibility for doors, bonnets and tailgates/hatchbacks as assy.• Development tooling• Sourcing China

• Planning and consultation regarding components• Prototypes with production intent• Worldwide supplier management• Tryout in press shop• Integration of all TKDN sites in Europe and North America

• Manufacture and tryout of side panel tooling for Genk

Audi Q5 / High strength steel expertise

Jaguar XF / Closures as system supplier

BMW X5 / General contractor for about 700 tools

Ford Galaxy / Side panelOpel Corsa / System partner doors

• Consultation regarding component engineering• First sample parts• Prototype tooling• Small-series tooling• Welding equipment• Laser cutting equipment

Fendt

How To Form QualityForming Dies – Selected References

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

• Manufacture of IHF tooling in own tool shop

Part Production

• From individual assemblies up to complete body in steel or aluminium

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

• Support in Simultaneous Engineering

Hydroforming (IHU)

Many of our competencies join in productionPart Production – Business Activities

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• Material aluminium• Serial components and equipment• Manufacture of about 160 assemblies per day

Porsche 911 / water tube IHF

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

• Material aluminium•Serial components and equipment • Patented sealing process for multi- chamber extrusions • Total forming process inhouse

Lamborghini Gallardo Coupe and Spider / Complete body

•Aluminium bodyframe construction

•Small series manufacture, about 10 bodies per day

•Outer skin expertise•Simultaneous Engineering

Porsche 911 und Boxster / Back panel lower for spare wheel

•Material steel•Manufacture of 150-200

assemblies per day

Mercedes S-Klasse / Main floor

•Material steel•Highly automated

manufacture with 400-500 assemblies per day

•Successful trials with Bondal plates

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• Material high-grade steel• Different cages from one modular tool• Multi-part production• Close limit inside component

Behr / Cage for heat exchanger in IHF

Many of our competencies join in productionPart Production – Selected References

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Drauz Nothelfer

Krause and EGM

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

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Automation and Assembly Competence for AerospaceNew Business Unit Aerospace

• Process Planning and Simultaneous Engineering

• Management of complex turn-key assembly system projects as general supplier

• Design and commissioning of customer-oriented optimized modular assembly equipment

• Implementation and combination of proven production and assembly technologies

• Development and use of advanced joining and testing technologies

Airbus A350XWB ProgramSimultaneous Engineering for

automatedproduction equipment of• Outer Wing Box• Center Wing Box• Vertical Tail Plane • Horizontal Tail Plane

From Concept to Realization Selected References

Boeing 787Finishing of CFRP tools for front

spar andfront spar bond assembly

Airbus A400MDesign, manufacturing and

delivery of the inner and outer flap rack

Airbus - Next Generation Flaps

Development and Build of audit cells for

automated testing of integrated CFRP flaps

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Subsidiaries

Service branches

Commercial agencies

Global Company - Local Presence

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ThyssenKrupp System Engineering - Philosophy

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

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

modifications/extensions

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

Project-oriented organization structure with

Standardized, modular solutions to the advantage of our customers

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

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ThyssenKrupp System Engineering - Customer ReferencesAmerica Europe Asia/Australia

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

• DIN EN ISO 9001:2000 Quality Management System• IQNet ISO 9001:2000 International Certification Network for Quality Management System• VDA 6.4 Quality Management System for production equipment• TS 16949 Quality System Management for the parts supply into the automotive industry• DIN EN ISO 14001 Environmental Management

Recent Awards Certificates

Awards and Certificates

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TKSE is well established in North AmericaNAFTA Region Overview - 40 yrs experience, 5 Sites, 100 Mio. $ Sales, 370 Employees

Chrysler SebringDecklid Assembly Cell with Lazer Brazing

Forming DiesTesting Solutions

Assembly Systems Body in White

Freightliner P3Turnkey Bodyshop for Aluminium Cab, Saltillo, Mexico

BMW X5Engineering, Sourcing, Matching and Launch management

Ford D3XEngine Assembly on a convertible & globally common system architecture

GM 6RTransmission Sub-assembly, Assembly & Test for Europe, Mexico and the U.S.

GETRAG RDM 646Combined Balance & NVH End-Of-Line Test Stand for Rear Axles

Selected References

Detroit, MI - Auburn Hills

12,600 sqm 213 employees

- Janesville, WI: 232 sqm - 14 employees

- Huntsville, AL: 836 sqm - 13 employees

- Greer, SC: 520 sqm - 5 employeesQuerétaro, Mexico

3,600 sqm89 employees

Sales & Service Sites

Site Map

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Fast Growth in Asia Far East Region Overview

Forming DiesTesting Solutions

Assembly Systems Body in White

Site Map

Selected References

ThyssenKrupp System Engineering (Shanghai) Co., Ltd

Gaodong Facility (Northeast of Shanghai)

- 1400 sqm in total- 25 direct employees- 20 contractors

Sales and Service Sites in India, Korea and Japan

Commercial Agencies

S-VW FabiaFraming and Closure weld lines (China)

Tata ACE MinitruckEngineering and Turn-Key Bodyshop (India)

Opel Meriva NewSourcing of door dies(Korea)

Tata Small CarEngine Function Test (India)

VW TSTransmission Assembly Line (China)

KOEL Transport system, pallets and verification stations (India)

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Site Map Selected References

ThyssenKrupp Production

Systems Ltda.,Sao Paulo, Brazil- founded in 1973- 40 Mio. € Sales- 125 employees- 15.000 sqm shop floor

- 35.000 sqm in totalFilial Site in Buenos

Aires, Argentina

Testing Solutions

Body in White

Mercedes Class C coupé and Class ATurn-Key Bodyshop, Juiz-de-Fora, Brazil

FIAT Fire MotorEngine function test, Belohorizonte, Brazil

VW new Gol familyTurn-Key Bodyshop, Taubaté and Anchieta, Brazil

Ford TruckChassis line, São Bernardo, Brazil

Assembly Systems

VW power train EA-111Powertrain line, São Carlos, Brazil

Top League of South American Production Equipment SupplierSouth-America Overview

thyssenkrupp system engineering corporate (without divsion) thyssenkrupp system engineering drauz...

Documents

ratio test

thyssenkrupp sales

control leak test

diesel engines test

system pressure nvh

egm slide

white final assembly

focused industrial group