ThyssenKrupp System Engineering
Drauz Nothelfer I Krause I EGM
ThyssenKrupp System Engineering
Corporate (without Divsion)
ThyssenKrupp: Focused Industrial Group With Two Pillars
ThyssenKrupp
Sales 53.4 billion € • EBT 3.128 million € • 199.000 employees
Steel
Americas
TK Steel EuropeCSA
• Steel Europe Compass
• Processing
Stainless
Materials
International Services
Nirosta
AST
NewStar
Mexinox
Stainless
International
SKS
VDM
Metals
Services
Special
Services
Industrial
Services
Elevator
ServicesMarine
Elevator
Plant
Components
Technology Technology Technology Systems
CENE
SEAME
AMS
AP
ES/PBB
Accessibility
Division Materials
Division Technologies
Umsatz 2007/08; Mitarbeiter: 30. Sept. 2008; gerundet
ThyssenKrupp System Engineering
Corporate (without Divsion)
Uhde
HDW
Rothe Erde
Polysius
BVN
Berco
Fördertechnik
BVSS
Camshafts
System
Steering
Engineering Forging Group
Transrapid
BilsteinGruppe
Waupaca
-2-
ThyssenKrupp
Steel
Europe
ThyssenKrupp System Engineering - Organization
ThyssenKrupp System Engineering
Bernd Becker (CEO)
Uta Anders (CFO)
Martin Hilbig (CHRO)
Krause / EGM
Krause
Drauz Nothelfer
Drauz Nothelfer
Drauz Nothelfer
Testing Solutions
Assembly
Systems
Body-in-White
Forming Dies
Part Production
Peter Kohlwig
Jean-Luc Guyon
Josef Görgen
Josef Görgen
Bernd Becker
• Engine testing
• Engine assembly
• Body-in-White
• Tools & Dies
• Body assembly
• Transmission
• Transmission
• Final assembly
• Prototypes
• Hydroforming
• Axle testing
assembly
• Axle assembly
• Measuring
machines
3 Brands,
4 Continents, 11 Countries, 4000 People, 800 million € Sales
ThyssenKrupp System Engineering
Corporate (without Divsion)
-3-
ThyssenKrupp
testing
Satisfied Customers Are Our Motivation
Testing Solutions – Product Range
Motor / Transmission / Axles
End of Line Test
bench
Function & NVH test
bench
• Engine
• Transmission
• Axle
Test areas
Complete test
areas
• Dimensional
measuring
• Part control
• Leak test
• ect.
Measuring technologyMeasuring
Measuring
computers
Hardware
technology
• Decentral measuring Software
electronic DME
• Programmable
measurnig
electronic
PME
Sensors
• Laser
UPS 32
Extensive test
applications
UMS
Dimensional
measurement and
IQA
ThyssenKrupp System Engineering
Corporate (without Divsion)
Component testing and integrated
quality assurance (IQA)
-4-
Service
• Simultaneous
Engineering
• Training
• Production support
• Retools
• Maintenance
• Spare parts
• etc.
ThyssenKrupp
Division Testing Solutions
Turnkey solutions for test systems
Satisfied Customers Are Our Motivation
Testing Solutions – Selected References
• 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
Test bench for differential
• 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
Test bench for Diesel engines
• 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
ThyssenKrupp System Engineering
Corporate (without Divsion)
-5-
ThyssenKrupp
Division Testing Solutions
Test bench for dual clutch transmission
Why the Total Is More Than the Sum of Many Parts
Assembly Systems – Business Activities
Engine / Transmission / Axle Assembly
Assembly Systems
Automatic
Stations
• Assembly
operation
• Tightening and
press-in operation
• Sealant application
• Measurement and
adjustment
Transport
Systems
Manual Stations
Pallet Systems (Pallet, Adapter)
• Friction roller
conveyor
- horizontal
- vertical
- up to max. 2000 kg
• Flex link conveyor
(KSR)
• Components
(modular)
• IMS+
• Multi-adapter
system
- flexible use
- modular design
ThyssenKrupp System Engineering
Corporate (without Divsion)
• Highly flexible
• Ergonomically
designed
• Modularly
extendable
Complete assembly
systems for engines,
transmissions and
axles including
measuring technology
and testing solutions
from one source
-6-
Service
• Simultaneous
Engineering
• Instruction/Training
• Production
attendance
• Modifications
• Maintenance
• Spare parts
ThyssenKrupp
Division Assembly Systems
Turnkey Powertrain Assembly Systems
Why the Total Is More Than the Sum of Many Parts
Assembly Systems – Selected References
Renault / Semi-automatic Engine Assembly System
• Standardized stations
• Different cylinder head versions
on one assembly line
• Space allowance for integration
of additional product variations
• I3-I6 cylinder
• 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
Ford Commonality / Global System Supplier for 10 Assembly
Lines
• Flexibility: In-line 4-cylinder up to
V12 engine
• Modular concept
• Output: 10.000 up to
500.000 engines/year
Navistar / 12.4 L I6 Truck Engine
Volkswagen Double Clutch Transmission
GM Automatic Transmission
• Overall responsibility for
complex controlled processes
• Early fault detection
• Optimal work station layout
• Fuel-saving future technology
• 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
ThyssenKrupp System Engineering
Corporate (without Divsion)
• Automatic assembly line for
engine, cylinder head and final
dress
• Automatic valve-lash adjustment
• Automatic engine function test and
leak test
-7-
ThyssenKrupp
Division Assembly Systems
Volvo Car / Fully automatic Cylinder Head Assembly
How the Fascination With Car Design And Structure Is
Embraced
Car Body Manufacturing
Body-in-White
– Business Activities
Digital factory
Turnkey,
Virtual process
customized body-in- safeguarding at an
white plants
early stage
Framing
Laser application
Hemming technologyService
• Framing stations
up to 8 models
• Robot framing
• Brazing, cutting,
welding
• Remote welding
• Tabletop hemming • Upgrade/Relocation
• Plant optimization
• Roller hemming
• Spare part service
• Hem dies
• Training
Planning – Virtual Safeguarding – Project Management - Commissioning - Service
Turnkey
Sealer applications
Marriage systems
Window assembly systemsModule assembly syst.
General contractor
for complete final
assemblies
• Manual and automated
systems
• Roller technology
• Marriage assembly
systems
• Chassis equipment
• Wheel assembly
Semi- and fully automated e.g. for bumpers,
glass gluing and flange
cockpit, frontend and
seal assembly
center console
Final assembly
technology
ThyssenKrupp System Engineering
Corporate (without Divsion)
-8-
ThyssenKrupp
Division Body-in-White
Turnkey
How the Fascination With Car Design And Structure Is
Embraced
• Industrialization of remote laser
welding
• Supplier for remote laser cell
doors
equipment in Sindelfingen and
South Africa
Shanghai VW Santana 4000
• Body equipment closures
• Planning in Germany, local processing
• > 40% local rate
Opel Meriva /Doors and side panel
Renault Logan Brasilien / Marriage
• System partner doors (tools and
bodyshop) and side panel for
Zaragoza plant
• Quality responsibility for door
module
• 5 models, cycle time 55 sec.
• Engineering in Germany
• Co-operation with local suppliers
• Local design and commissioning
VW Golf V / Side panel
Audi A4 / Door sealer application
• Realisation of side panel equipment in Wolfsburg, Brüssel and
Mosel
• Processing via all German Drauz
Nothelfer sites
ThyssenKrupp System Engineering
Corporate (without Divsion)
-9-
• 3 sites: Ingolstadt, Neckarsulm,
Changchun
• Use of the Drauz Nothelfer plate
technology for the application of
door sealings
ThyssenKrupp
Division Body in White
C-Klasse / Remote laser welding
BodyMercedes
in White
– Selected References
How To Form Quality
Forming Dies – Business Activities
Tools for serial production
Tools - Components – Fixtures - Assemblies
Engineering
Purchasing
Tools for outer body parts and structure – all materials
Tryout
Simultaneous Engi- Individual operations/ Quality attainment
neering, method
value-added levels up of own and supplied
planning, design
to full outsourcing
tools
worldwide
Matching
From individual
components to o.k.
assembly,
respecively o.k. car
body
Innovations
e..g. digitalization,
laser hardening/
cladding, lean
tooling standards
Service
Preventive maintenance/maintenanc
e, spare part
management
System responsibility for assemblies up to complete bodies hand in hand with the division body-in-white
ThyssenKrupp System Engineering
Corporate (without Divsion)
- 10 -
ThyssenKrupp
Division Forming Dies
Prototypes
How To Form Quality
Forming Dies – Selected References
Opel Corsa / System partner doors
Ford Galaxy / Side panel
• Manufacture and tryout of side
panel
tooling for Genk
BMW X5 / General contractor for about 700 tools
Audi Q5 / High strength steel expertise
• 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
Fendt
Jaguar XF / Closures as system supplier
• Material aluminium / steel
• Responsibility for doors, bonnets
and tailgates/hatchbacks as
assy.
• Development tooling
• Sourcing China
ThyssenKrupp System Engineering
Corporate (without Divsion)
• 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
- 11 -
• Consultation regarding
component
engineering
• First sample parts
• Prototype tooling
• Small-series tooling
• Welding equipment
• Laser cutting equipment
ThyssenKrupp
Division Forming Dies
• System responsibility door assy.
• Inhouse manufacture outer skin
and inner panel
• Sourcing in Eastern Europe and
Asia
Many of our competencies join in production
Part Production – Business Activities
• 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
ThyssenKrupp System Engineering
Corporate (without Divsion)
- 12 -
ThyssenKrupp
Division Part Production
Hydroforming (IHU)
Many of our competencies join in production
Part Production – Selected References
Behr / Cage for heat exchanger in IHF
• Aluminium bodyframe construction
• Small series manufacture, about
10 bodies per day
• Outer skin expertise
• Simultaneous Engineering
Mercedes S-Klasse / Main floor
Audi Space Frame ® / different IHF parts A8, TT, R8
• Material steel
• Highly automated manufacture
with 400-500 assemblies per day
• Successful trials with Bondal
plates
Porsche 911 und Boxster / Back panel lower for spare wheel
• Material steel
• Manufacture of 150-200
assemblies per day
• Material aluminium
• Serial components and equipment
• Patented sealing process for multichamber extrusions
• Total forming process inhouse
Porsche 911 / water tube IHF
• Material aluminium
• Serial components and
equipment
• Manufacture of about 160
assemblies per day
ThyssenKrupp System Engineering
Corporate (without Divsion)
• Material high-grade steel
• Different cages from one modular
tool
• Multi-part production
• Close limit inside component
- 13 -
ThyssenKrupp
Division Part Production
Lamborghini Gallardo Coupe and Spider / Complete body
Products and Services along the Automotive Value Chain
Drauz Nothelfer
Krause and EGM
ThyssenKrupp System Engineering
Corporate (without Divsion)
- 14 -
ThyssenKrupp
Drauz Nothelfer I Krause I EGM
Automation and Assembly Competence for Aerospace
New Business Unit Aerospace
From Concept to Realization
Selected References
Airbus A350XWB Program
Simultaneous Engineering for automated
production equipment of
• Outer Wing Box
• Center Wing Box
• Vertical Tail Plane
• Horizontal Tail Plane
• Process Planning and Simultaneous
Engineering
Boeing 787
Finishing of CFRP tools for front spar
and
front spar bond assembly
• Management of complex turn-key assembly
system projects as general supplier
Airbus A400M
• Design and commissioning of customeroriented optimized modular assembly
equipment
Design, manufacturing and delivery of
the
inner and outer flap rack
• Implementation and combination of proven
production and assembly technologies
Development and Build of audit cells for
automated testing of integrated CFRP
flaps
• Development and use of advanced joining and
testing technologies
ThyssenKrupp System Engineering
Corporate (without Divsion)
- 15 -
ThyssenKrupp
Airbus - Next Generation Flaps
Global Company - Local Presence
Service branches
Commercial agencies
ThyssenKrupp System Engineering
Corporate (without Divsion)
- 16 -
ThyssenKrupp
Subsidiaries
ThyssenKrupp System Engineering - Philosophy
Project-oriented organization
structure with
Standardized, modular solutions
to the advantage of our customers
Utilization and expansion of worldwide low-cost production locations
• 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
•
•
•
•
ThyssenKrupp System Engineering
Corporate (without Divsion)
- 17 -
ThyssenKrupp
modifications/extensions
Americas: USA, Mexico, Brazil
Eastern Europe: Poland
Asia: China
cooperation with local partners
ThyssenKrupp System Engineering - Customer References
Europe
Asia/Australia
ThyssenKrupp System Engineering
Corporate (without Divsion)
- 18 -
ThyssenKrupp
America
Recent Awards
Certificates
• 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
ThyssenKrupp System Engineering
Corporate (without Divsion)
- 19 -
ThyssenKrupp
Awards and Certificates
TKSE is well established in North America
NAFTA Region Overview - 40 yrs experience, 5 Sites, 100 Mio. $ Sales, 370 Employees
Site Map
Detroit, MI - Auburn Hills
Sales & Service Sites
- Janesville, WI:
- Huntsville, AL:
- Greer, SC:
12,600 sqm
213 employees
232 sqm - 14 employees
836 sqm - 13 employees
520 sqm - 5 employees
Querétaro, Mexico
3,600 sqm
89 employees
Selected References
Ford D3X
Engine Assembly on
Combined Balance & a convertible &
NVH End-Of-Line Test globally common
Stand for Rear Axles system architecture
Testing
Solutions
GM 6R
Chrysler Sebring
Transmission Subassembly, Assembly
& Test for Europe,
Mexico and the U.S.
Decklid Assembly Cell Turnkey Bodyshop
with Lazer Brazing
for Aluminium Cab,
Saltillo, Mexico
Assembly Systems
Body in White
ThyssenKrupp System Engineering
Corporate (without Divsion)
- 20 -
Freightliner P3
BMW X5
Engineering, Sourcing,
Matching and Launch
management
Forming Dies
ThyssenKrupp
GETRAG RDM
646
Fast Growth in Asia
Far East Region Overview
Site Map
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
Selected References
VW TS
KOEL
S-VW Fabia
Engine Function Test
(India)
Transmission
Assembly Line
(China)
Transport system,
pallets and
verification stations
(India)
Framing and Closure
weld lines (China)
Testing
Solutions
Assembly Systems
Body in White
ThyssenKrupp System Engineering
Corporate (without Divsion)
- 21 -
Tata ACE
Minitruck
Engineering and
Turn-Key Bodyshop
(India)
Opel Meriva New
Sourcing of door dies
(Korea)
Forming Dies
ThyssenKrupp
Tata Small Car
Top League of South American Production Equipment Supplier
South-America Overview
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 total
Testing Solutions
FIAT Fire Motor
Engine function test, Belohorizonte, Brazil
Assembly Systems
VW power train EA-111
Powertrain line, São Carlos, Brazil
Filial Site in Buenos Aires,
Argentina
Body in White
Mercedes Class C coupé and Class A
Turn-Key Bodyshop, Juiz-de-Fora, Brazil
Ford Truck
VW new Gol family
Turn-Key Bodyshop, Taubaté and Anchieta,
Brazil
ThyssenKrupp System Engineering
Corporate (without Divsion)
- 22 -
ThyssenKrupp
Chassis line, São Bernardo, Brazil