fluidInternational news & information of the fischer group

1 | 2015

Employees are our greatest assetOnly employee oriented companies can thrive

Employees are our greatest assetOnly employee oriented companies can thrive

fischer Canada: Growing and expanding

fischer Hydroforming: Cleaning better and deburring more efficiently

fischer South Africa:25 years of progress

2 3fluid 1 | 2015 // fluid 1 | 2015 //

News

Main Theme fischer group: Employees are our greatest asset ...................................... 4fischer team spirit:

For more than 40 years – Thomas Gaiser and Gebhard Schütt .............. 6

Germanyfischer Rohrtechnik: Moving heavy parts easily ..................................... 7fischer Rohrtechnik:

Prototype construction and start-up management ................................ 8fischer group Achern: Wire mesh containers in the flow ........................ 9fischer Germany: ACHEMA 2015 – valuable contacts in Frankfurt ....... 9fischer Hydroforming:

Cleaning better and deburring more efficiently .................................... 10

Eco Talkfischer group Achern: DIN EN ISO 50001:2011 certified ...................... 12fischer eco solutions: Fuel cells in maritime applications ..................... 13

International fischer Canada: Growing and expanding .............................................. 14fischer USA:

Full steam ahead – for Winglet tubes and a new 97,000 square foot

tube plant .............................................................................................. 15fischer Mexicana:

International collaboration with multiple benefits ................................ 16fischer Austria: From Domino Day to an intralogistical concept .......... 17fischer South Africa: 25 years of progress ............................................. 18

Team Talkfischer Mexicana: Blind and seeing children play together ................... 20

Editorial

Now and then – people make the difference

Great teams all over the world

Dear Business Partners,

Dear Colleagues,

Since 1969, our employees have been our greatest

asset. There were not so many employees in the

beginning as there are now. Nevertheless, we try

to deal with everyone today as personally and

like a family as we did in the beginning years.

Many of our employees have been with us for

many years. Loyalty, reliability, endurance, and

job satisfaction are key to the company’s history,

which is basically the history of one large family.

Two employees should be highlighted especially.

They have been with us for over 40 years: Thomas

Gaiser and Gebhard Schütt. They witnessed

the beginnings of tube production and many

turbulences on the path to the international fischer

group. They have been committed to and stood up

for the company. When it was necessary, they paid

no attention to closing time or weekends.

Dear Business Partners,

Dear Colleagues,

Our cover story is about our workers, without

whom we could not meet all the customer

requirements and challenges of tube production,

tube technology, and hydroforming, as well as

in the production of fuel cells and in machine

technology. Although the focus is in the report

of the main plant in Achern, the core message

applies to all fischer companies around the

world. Without these companies, our current

developments would not be at all possible:

The growth and accompanying expansions in

the United States and Canada

I am happy and proud to have these people for

so long in the company. Just like many other

colleagues who are devoting themselves to

the success of the fischer group – even among

younger workers, who are really going all out

in the training workshop. You are the ones who

make the difference. With you, the fischer group

will continue to move forward. Many thanks!

Yours sincerely,

Hans Fischer

Founder and Chairman

of the fischer group

The development of hydroforming capacities

in Mexico and China

The new intralogistics in Austria

25 successful years in South Africa.

All this – and much more – has been successfully

realized by fischer teams around the world.

Exchange of information within the group and

international collaboration play a major role in

the process. They make it possible for us to deliver

the same high fischer quality world-wide and to

react flexibly to customer requirements.

Sincere thanks to all who make this possible

every day.

Yours sincerely,

Hans-Peter Fischer

Managing Director

of the fischer group

fischer Germany

fischer group helps educates in the International Business program Student from the Cooperative State University is starting in October

The Baden-Württemberg Cooperative State University (DHBW)

is taking on the economic globalization and is offering the

“BWL – International Business” degree program. The fischer group

is supporting the program and has been training Ms. Silvia Huber

since October 1, 2015 together with DHBW.

With its global mind and intercontinental subsidiaries, the fischer

group was the perfect company to promote the degree program and

qualify committed young professionals. Linguistic and intercultural

skills as well as the mastery of international business activities are part

of the company’s daily operations. In the words of Hans-Peter Fischer:

“We wish Ms. Huber all the best and look forward to fresh ideas from

research and the university. ‹‹

Greeting

Publisher: fischer group, Gewerbegebiet 7, 77855 Achern, Germany

Editorial staff: Dr. Michael Kühner (responsible)

Contributors to this issue: Hans Fischer, Hans-Peter Fischer, Dr. Stefan Geißler, Thomas M. Prell, Dr. Heinz Paar, Erich Kotzenmacher, Horst Wiesenberger, Manfred Seewald, Thomas Jörger, Dr. Jochen Baurmeister, Daniel Hennig, Thomas Gaiser, Gebhard Schütt, and Jens Helmbrecht

Contact: Tel. +49 7841 6803-0, Email: sales@fischer-group.com

Design: Frank & Konsorten Werbeagentur, Lahr

Printed by: Straub Druck+Medien, Schramberg

Picture credits: fischer group, Jörg Wilhelm, fotolia

5fluid 1 | 2015 // 4fluid 1 | 2015 //

Employees are our gr eatest asset Only employee oriented companies can th rive

Lasting success is always the result of the continuing

commitment of dedicated people. Company founder

Hans Fischer is convinced of this: “We are happy that

our people are able to stick together so well. Only in this

way can we live up to our own high standards.”

The more people work together and the longer they are

with the company, the better the in-house expertise will be

able to develop, the growth and improvement comes from

experience and collaboration. This is true, by the way, not

only for the highly qualified foremen, technicians, and en-

gineers, who continue to develop the technical know-how

of the fischer group. It is also true for the workers and pro-

duction employees who mass produce the highest fischer

quality through their diligence and commitment. Hans

Fischer points out further: “For us it was never an option to

relocate our production to low-wage countries. The heart of

the fischer group lies in Achern. Here we have developed the

processes and technologies that today are used worldwide.

Without the local interaction here – and in the exchange of

information with our subsidiaries – this would never have

worked.”

High degree of satisfaction and many years of affiliationThe fischer group is fortunate to have a satisfied and highly

qualified workforce. This is reflected, among other things, in

an extremely low turnover rate and in most cases a very long

company affiliation in Achern. “Despite the size of the com-

pany, the atmosphere here is still very family-like,” stresses

Hans Fischer, who still likes to play a round of cards with

his colleagues at lunch break. Two employees in Achern have

been in the company almost as long as the founder himself.

(> more about this on the next page) Many have followed

their example, and it is not unusual that father and son or

daughter are working in the company.

Sowing expertise andharvesting top resultsIt is of course the human interaction that is the fertile

ground for putting into practice the leading professional

expertise for developing, manufacturing, and further pro-

cessing welded tubes and components of stainless steel

and other high quality materials and alloys. In doing so, the

fischer group has always relied on first-class qualifications

and development opportunities. Thomas Gaiser started his

career as an apprentice and is the production manager of

fischer Edelstahlrohre now. Hans Fischer is still confident:

“Today’s apprentices will be tomorrow’s top people.” Pro-

fessional expertise is sown here and top results are harvest-

ed. This has been true not only since the fischer group in

Achern has had its superbly equipped training workshop or

has been working together with regional universities. Based

on this conviction, many dedicated employees were trained

or became further qualified in the past as well.

Certainly a good

and modern working

environment with

solid social benefits

as well is conducive

to employee satisfac-

tion and the attrac-

tiveness of the fischer group as an employer. Other companies

are having great difficulties in finding qualified personnel in

Achern and the surrounding area. “We have been fortunate in

being able to cover our personnel needs from unsolicited ap-

plications,” Hans-Peter Fischer, one of the founder’s sons and

today’s Managing Director, is happy to say. “The children of

our employees frequently apply for an apprenticeship position

– apparently because their parents have really enjoyed work-

ing for us.” The fischer group will thus continue to be able to

develop its greatest asset – and thereby also realize its global

claim to leadership. With people who completely stand behind

it – with hand and heart. ‹‹

Main Theme Main Theme

6fluid 1 | 2015 // 7fluid 1 | 2015 //

Germany

fischer Rohrtechnik

Moving heavy parts easilyAutomatic material handling at the hydroforming press

The demand for hydroforming components

has developed spectacularly. At the same

time, the size and the weight of the com-

ponents has continued to grow. The tubes

weigh up to 7 kg before they go into the

press. After the hydroforming process, they

are half-filled with water and are there-

fore heavier. The weight, together with a

posture that requires bending far forward

while loading the press and removing the

parts, meant considerable physical stress

for the worker at the machine. That’s reason

enough to consider optimizations to facili-

tate health-conscious working conditions.

Individual gripper technology in continuous operationAfter two similar concepts had already

been successfully implemented at fischer

Hydroforming in Menden, a handling robot

with an individually adjustable gripper system

has been used in Achern since January 2015

and has taken over the heaviest work for the

worker. The worker must only insert the raw

parts into the parts buffer in front of the press –

and remove the wire mesh container loaded

with finished hydroforming parts after the

automatic unloading. The workstation at the

hydroforming press thus has now become

significantly healthier for the worker.

The parts automation also has additional

benefits. Quality management now takes place

during ongoing operation. Previously, parts

were removed individually by hand and tested.

Test parts are now automatically set aside on

demand or according to a programmed scheme.

While the worker performs all the required

measurements on the workpiece, production

continues to run automatically on the press.

Hans-Peter Fischer is pleased with the

results: “With the handling robot, we have taken

an additional step towards back-friendly work

in production – and improved the processes at

the same time.” ‹‹

Gebhard Schütt

At fischer since April 3, 1974 1974: apprenticeship as machinist Today: technical planner Motto: “Always be ahead” Hobbies: bicycle racing, tennis,

photography, concerts & festivals (Scorpions, Deep Purple, Pur, Grönemeyer)

Thomas Gaiser

At fischer since August 1, 1973 1973: apprenticeship as machinist Today: production manager of

fischer Edelstahlrohre Motto: “50 years at fischer is

a nice goal” Hobbies: his own cars (BMW M4 sports car, BMW E30

vintage car – Bauer Alpina Cabrio), mechanics, motor sport, bicycling and hiking, skiing and club work (vice-chairman of the Seebach ski club)

fischer team spirit

With us almost from the beginning For more than 40 years – Thomas Gaiser and Gebhard Schütt

Both men stood as machinist apprentices with Hans Fischer alongside

the machine. Both are certified Master Craftsmen in Metal. And both have

been in the company for over 40 years. Thomas Gaiser started on August 1,

1973, and Gebhard Schütt started eight months later, on April 3, 1974.

“For me, Hans Fischer is the best boss imaginable,” Gebhard Schütt, who

is today a technical planner, says with satisfaction. Thomas Gaiser, the current

production manager of fischer Edelstahlrohre, is also completely happy with

his employer: “We have of course also experienced hard times. But we were

always a super troupe, almost like a big family.” Gebhard Schütt adds, “We have

witnessed everything from the first tube machine until today. It all adds up

to a lot.” During the rapid growth, both men passed through different areas

of responsibility in the company. Both have worked internationally for the

fischer group. Gebhard Schütt helped in 1988 with installing the tube machines

at fischer Canada. Thomas Gaiser took inventory during a company takeover

in Mexico in 1999.

“Without such employees, the fischer group would not have come as far as

it has,” acknowledges Hans Fischer, still proud today of both of his previous

colleagues. And Gebhard Schütt adds, “No pain, no gain. That is still just as true

today. You have to always be way ahead of the pack if there is something to be

done.” He would also convey that to today’s apprentices. Thomas Gaiser nods

in agreement: “The commitment always paid off – and even after such a long

time, I still feel very good here.” ‹‹

Main Theme

8fluid 1 | 2015 //

Germany

9fluid 1 | 2015 //

Wire mesh containers are a proven storage and transport method

at the fischer group in Achern. However, problems have surfaced again

and again while transporting and handling the very practical contain-

ers. After being used, the containers must be brought to the production

floor with forklift trucks over a considerable distance from logistics.

This not only creates a considerable expense, but also increases the risk

of accidents. Furthermore, the containers require warehouse space that

could be better used, especially in production.

Transport and buffer storage rolled into one To improve the situation, the idea arose that the wire mesh containers be

transported automatically via a rail system. In doing so, a portion of the

existing transport distance could be used for the high-rack warehouse.

An additional section has been built recently. This section can today be

used as buffer storage for empty wire mesh containers. There is space for

80 containers respectively on two routes. With double stacking, a total of

320 empty containers can be stored temporarily and kept available for use

in production. The route leads over several hundred meters through the

logistics and shipping halls

over the roof of the shipping

hall to the existing convey-

ance path and from there

into the production hall.

Hans-Peter Fischer is very

satisfied with the new sys-

tem: “A typical example for

the fischer way of thinking – question things and solve several problems

at once with amazingly simple solutions.” This has been a total success

for the wire mesh container transport system. And all that in barely

eight months – from the first conversation in April 2014 to commission-

ing in December 2014. ‹‹

fischer group Achern

Wire mesh containers in the flowNew transport system for empties

Germanyfischer Rohrtechnik

Prototype construction and start-up managementA separate division – for optimized processes

In a sepa-

rate section of the

fischer Maschinentechnik’s

new hall, fischer Rohrtechnik

opened the new prototype construction

division in July 2014.

In an area specifically established for the

purpose, new tools for the further processing

of tubes can be tested and broken in

before mass production. Alex Huber

from fischer Rohrtechnik’s process

management is very pleased: “Previ-

ously we had to allocate machines

in production. This, of course,

always interrupted the

operational processes.

Now we have almost

ideal working condi-

tions here.” The new

possibilities increase

the process reliabili-

ty – and the ongoing mass

production is not interrupted. An additional

advantage is the spatial proximity to fischer

Maschinentechnik. Modifications to tools or ma-

chines can be performed within a short distance.

Furthermore, the division, which is equipped

with all the necessary machines, will facilitate

trials for the new development of components.

All in all, a number of advantages for develop-

ing more challenging and complex components

from fischer Rohrtechnik. ‹‹

66,444 participants from all over the world found their way to

ACHEMA 2015 from June 15-19, 2015 at the Frankfurt exhibition

grounds. Over 3,800 exhibitors from 56 countries presented their inno-

vations for the chemical, pharmaceutical, and food industry. The fischer

group was part of it. “The five days clearly exceeded our expectations,”

Manfred Seewald, Head of Sales for Industry & Trade at fischer, was

happy to report. The fischer group demonstrated their expertise in

industrial tubes for the toughest conditions at their trade show booth

around a glowing tube sculpture.

The sculpture, made of tubes with glowing

liquid-filled glass sections, symbolized the

special fischer qualities: wherever liquids and

gases have to be safely transported, fischer

tubes are the first choice. Even in highly cor-

rosive environments, at high or low tempera-

tures, in conjunction with aggressive acids or

alkaline solutions, salt water, or special me-

chanical requirements, fischer tubes do what

they are supposed to: they reliably withstand

physical stresses.

fischer group CEO Hans-Peter Fischer

emphasized in this regard: “We offer our

customers highly specialized solutions from

our wide range of products: optimal alloys,

ideal wall thicknesses, and the appropriate diameters and lengths.”

Our tube specialists highlight this in their many conversations with

existing and new customers. After these positive experiences, the next

ACHEMA 2018 is already on the company schedule. ‹‹

fischer Germany

ACHEMA 2015: Valuable contacts in Frankfurtfischer group exceeds expectations

Perfectly equipped

These machines are available for prototype construction:

CNC bending machine Radial end forming machine Axial end forming machine 100 ton hydraulic press Circular saw End cutting machine 3D measuring instrument Tool machines

fischer Hydroforming

Cleaning better and deburring more efficientlyNew rinsing and tumble belt shot blast machines in Menden

Convincing in quality and costsOur own comparative studies have shown that shot blasting is clearly superior in speed and quality compared to other methods, such as barrel finishing and deburring by hand.

11fluid 1 | 2015 //

GermanyGermany

10fluid 1 | 2015 //

fischer Hydroforming is now relying on a

new procedure to cleanly deburr the edges

of components. Instead of the previous

barrel finishing with abrasives, shot blas-

ting is being used in a new tumble belt shot

blasting machine. The blasting is comple-

mented by an innovative rinsing machine

with rotary drum. The procedure offers

several advantages with regard to the hand-

ling, grinding results, and also in energy

efficiency.

Where previously with barrel finishing blo-

cked abrasive stones could occur in particular

component cross sections, the new procedure

no longer displays any problems. It delivers the

same high degree of quality with regard to the

deburring as barrel finishing at only one third

of the process time.

A prerequisite for good blasting results is,

however, a high level of cleanliness of the com-

ponents before they go into the blast chamber.

This could not be achieved with the previous

cleaning procedures. A new rinsing machine was

thus also conceived. The parts are individually

rinsed in a rotary drum and thus become sig-

nificantly cleaner than in a plunge pool. In ad-

dition, the closed sink requires considerably less

energy than the open pools previously used. The

thoroughly cleaned parts are automatically fed

to the tumble belt shot blast machine and blas-

ted with fine stainless steel balls. Both process

steps may also be done separately. It is therefore

possible to rinse parts without blasting them.

A number of advantagesDr. Stefan Geißler, Managing Director of fischer

Hydroforming, is very satisfied: “The new ma-

chine combines a number of advantages: sim-

ple operation, faster processes, a higher degree

of cleanliness of the rinsed parts, less likely

to produce complaints, and higher energy ef-

ficiency with only a slightly increased surface

hardness. With the quality of the edge after the

grinding, we expect a drop in cost compared to

hand deburring, which was becoming increa-

singly frequent for design requirements after a

negative edge break. You will not achieve this

same requirement with grinding but often the

technically necessary quality.” ‹‹

Convincing in quality and costsOur own comparative studies have shown that shot blasting is clearly superior to other methods in speed and quality, such as barrel finishing and deburring by hand.

Raw edge condition after sawing processsharp (overhang up to 0.3 mm)The parts must still be rinsed, brushed, or deburred.

Edge condition using barrel finishingsharp-edged (tendency to a sharp overhang)

Edge condition, hand-deburred using air grindersharp-edged (slight overhang displaced by 90°)The parts must still be cleaned.

Edge condition processed using shot blasting sharp-edged (tendency to a rounded overhang)

Your advantages at a glance

No blocking of the cross sections by barrel finishing stones

Faster processing times

Increased surface tension: virtually free of oil and grease

Improved technical cleanliness and less residual contamination

Improved tactile perception

Improved visual perception

Dry component surface

Improved defect recognition

13fluid 1 | 2015 // 12fluid 1 | 2015 //

subsidiary Serenergy, is producing high tem-

perature fuel cells within the “Pa-X-ell” project,

which is intended to be tested on a passenger

ship under the aegis of the MEYER SHIPYARD

together with its project planners. The basis

for these standardized fuel cell units, which

have a modular design and can be scaled by

interconnecting to any output size desired.

The corresponding fuel cell systems are inte-

grated into standard 19-inch cabinets. In the

first phase, a 30 kW demonstration system is

currently being constructed on the MEYER

SHIPYARD premises. The system will demon-

strate the generation of electricity, heating,

and cooling (tri-generation). Based on this, a

120 kW system will be installed in the course

of next year on a passenger ship parallel to the

conventional energy supply, and the electricity

produced will be stored in the on-board elec-

trical system. The system will be operated by

means of an internal reformer with methanol

as the energy source. ‹‹

The “e4ships” lighthouse project, is part

of the National Innovation Program (NIP)

for hydrogen cell and fuel cell technology,

prominent German shipyards and shipping

companies, leading manufacturers of fuel

cells, and classification societies are col-

laborating with the goal of establishing the

functionality of fuel cells in the on-board

energy supply of ships under everyday con-

ditions. Compared with conventional ship

units, fuel cells can contribute significantly

to reducing emissions. Reducing pollut-

ants is a pressing requirement for shipping

companies, since strict environmental reg-

ulations are in force in more and more har-

bors, which are stipulating upper limits on

emissions (so-called ECA zones).

e4ships tests high temperature fuel cellsWithin this e4ships program, fischer eco solu-

tions, together with the Danish fischer group

Eco TalkEco Talkfischer group Achern

DIN EN ISO 50001:2011 certifiedEnergy management in the fischer group successfully launched

For further details: http://www.e4ships.de/e4ships-home.html

and recorded. Parallel to this and in accordance

with an ISO/TS 16949 quality management

system, which had been established in the com-

pany for years, an energy management system

in accordance with EN ISO 50001 is being de-

veloped and put into practice as per the Dem-

ing cycle of continual improvement process

(Plan-Do-Check-Act).

Shifting the focus on energy managementAfter the successful introduction of the system,

the focus is now directed toward establishing a

way of thinking and the procedures in the daily

operational practice. The stronger the motiva-

tion for employees to increase energy efficien-

cy an reduce resource consumption, the greater

the financial and environmental impact will be.

In the last issue of fluid, we reported on

our plans to introduce energy management

in the fischer group. fischer’s goals are to

monitor and reduce energy consumption,

be transparent about energy related per-

formance, and be careful with the use of

energy and the environmental impact. After

an introductory phase of around a year and a

half, the time has arrived: all producing fischer

companies in Germany are now certified in

accordance with DIN EN ISO 50001:2011 and

are thereby systematically pursuing the plan-

ning and control of their energy use, as well as

the environmental impacts connected with it.

PDCA cycles for over 80 large consumersAfter fischer Hydroforming in its Menden and

Chemnitz locations introduced and success-

fully accredited in December 2014 a uniform

system for both sites, the certification of fischer

Edelstahlrohre and fischer Rohrtechnik in the

main plant in Achern followed in July 2015.

In addition, the energy needs and production

emission of over 80 large consumers in 11 pro-

duction halls in Achern had to be examined

In addition, the fischer group is relying on

periodically informing and qualifying employ-

ees through oral and written discussions in

shift meetings and informational media. Fur-

thermore, we are promoting the participation

of the workforce by providing space for con-

tent-related discussions and actively use the

company’s suggestion system to generate new

ideas and to support the work of the energy

team.

Goal: Systematic environmental managementThe long-term company goal of introducing

and merging energy management with a sys-

tematic environmental management has now

made considerable progress. And since fischer

Hydroforming in Menden and Chemnitz and

also subsidiary companies abroad such as

fischer Austria in Griffen are already running

certified environmental management, the next

challenge for the fischer group in Achern is al-

ready in sight. ‹‹

fischer eco solutions

Fuel cells in maritime applications Collaborating in the National Innovation Program Hydrogen cell and fuel cell technology

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14 15fluid 1 | 2015 // fluid 1 | 2015 // 15

Internationalfischer USA

Full steam aheadfor Winglet tubes and a new 97,000 square foot tube plant

2014 represented a milestone year at fischer

USA in quite a number of ways. Many pre-

vious production records were smashed and

employment is at an all-time high. For this,

we would like to extend a big THANK YOU

to all our customers that have supported our

facility in Manchester, Tennessee over the

past years.

Busting at the seamsAs reported in the last edition of our fluid mag-

azine, one of the growth areas is in the exhaust

gas recirculation (EGR) arena. This technolo-

gy appears to be making inroads in the North

American marketplace and the production of

our Winglet tubes is reaching new heights. So

much so, that we are expanding our facility in

the USA by 21,500 square feet to make room for

a new Winglet mill. The building expansion is

to be completed in fall of 2015, just in time for

the arrival of the new mill. The new equipment

is currently being built in Germany by our own

fischer Maschinentechnik. Once the mill arrives

in Manchester, Tennessee, a team of specialists

from our parent company will be dispatched to

assemble the highly complex piece of machinery.

Once the parts coming off the new mill have

been PPAP’d by our customer and a window of

opportunity arises, the existing mill will be relo-

cated into the new addition so that both Winglet

mills are located in the same bay. The chipless

cutter that has been specifically engineered to

recut the master lengths coming off the Winglet

lines, will also be moved into the new addition.

The new Winglet line will add approximately

8 million pieces of EGR tubes into a growing

market on a yearly basis.

Answering the call: expanded production of stainless steel tubingFor years, many of our customers in the US have

been urging fischer to expand the production of

stainless steel tubing. After fischer Mexico re-

cently successfully launched a new large welded

tube plant, fischer has decided to answer the

call in the United States as well. An identical

mill to fischer Mexico’s line will be arriving in

Manchester, Tennessee, in February of 2016.

Currently, the site is being prepared to accept a

97,000 square foot building.

The plant will consist of three bays – a re-

ceiving and storage bay for raw material, a bay

that will house the machine itself, and a stor-

age / shipping bay that will hold finished prod-

uct and cut-to-length equipment. The building

will be completed just ahead of the arrival of the

mill in February.

It is anticipated that the commissioning of

the mill will be completed in the summer, 2016.

At that point, we will be able to offer our cus-

tomer base in the USA high quality stainless

steel tubing in a wide variety of materials and

designs.

With all this activity going on at fischer our

thanks also go out to the City of Manchester for

their assistance with permits to support both of

these projects in a timely manner.

We welcome your inquiries. ‹‹

fischer Canada

Growing and expanding Expansion of production and office space

will help to alleviate some capacity restraints

which have caused lots of overtime in the past

year.

In addition, a new RESY central coolant sys-

tem has also been installed in Waterloo to deal

with the various coolant streams in our facility

more efficiently and effectively. Currently, all

coolants are locally filtered at each machine

and then returned to a sump. This requires

the maintenance of individual filter beds and

consumption of filter paper at every machine.

The new system has a single filter bed installed,

further reducing the waste stream from our

facility. A win-win situation for fischer and the

environment. ‹‹

Steady continuous growth over the past 7

years has led to the decision to expand our

Canadian operation in Waterloo, ON. Two

major additions to the existing facility will

help to ensure that future needs are being

met. Commencing in the fourth quarter of

this year, a 30,000 square foot addition will

be attached to our existing manufacturing

facility to make room for further production

equipment. The first addition is expected to

be completed by year end. This will bring

the production space at this location to over

300,000 square feet.

The second addition will address the aging

office situation. Over the past 25 years the offic-

es had been expanded numerous times to cope

with the growing number of staff. Recent deci-

sions to consolidate some of our fischer Canada

and fischer USA departments in Waterloo have

increased the requirement for more space. The

construction of a 3 storey office tower will help

alleviate this bottleneck. The new offices will be

home for the Accounting, Human Resources, IT,

Health and Safety, Scheduling and the Inside

Sales departments, along with some executive

offices. Furthermore, additional meeting rooms

will be created to address the need for more pri-

vacy. The current office space will be remodeled

to function as a new lunch room / cafeteria. The

addition of the new office tower and renova-

tions of the existing space are anticipated to be

completed by Q1 of 2016.

New installationsIn June 2015 a new tube mill was commissioned

at our Canadian operation bringing the total

number of tube mills installed at that location

to 8. The new mill is of type RPA70 LS and is

capable of producing round, square and other

non-circular tube geometries. This new mill

International

The building will be completed just ahead of the arrival of the mill.

17fluid 1 | 2015 //

InternationalInternationalfischer Mexicana

International collaboration with multiple benefitsHow the entire fischer group is benefiting from a hydroforming press change

International collaboration for a new machine control In the course of the retrofit for the Dunkes

press, a new customized fischer control con-

cept was developed in collaboration with the

machine manufacturer. In the process, an in-

ternational project team from the fischer group

worked together very closely. Achim Galli from

fischer Maschinentechnik in Achern, Thomas

Weiß and Thomas Buchgeister from fischer

Hydroforming Menden, and Peter Franke from

fischer Tubtech in Mexico developed a custom-

ized specification for the new machine control.

Eighteen individual optimization points have

been integrated by Dunkes into the control of

the 1,500 ton press. And the result has been

so positive that the new control is being used

at fischer Hydroforming Menden and fischer

Rohrtechnik in Achern.

Another aspect of the international col-

laboration within the fischer group was the

instruction and training in Achern of several

employees from Puebla. For several weeks, they

learned there with their German colleagues all

the tricks for an optimal set-up and production

on the complex machine. Achim Galli empha-

sized the significance of the intra-group ex-

change: “Ultimately we wish to work within the

fischer group globally at the same high level of

quality in order to deliver optimal results to our

customers.”

On the whole, the project therefore paid off

several times over – and for 2016, an even bet-

ter utilization is already foreseeable today. ‹‹

We reported in the last fluid 1/2014 on the

relocation of the third hydroforming press

to Mexico. An existing press from fischer

Hydroforming in Menden underwent a

fundamental retrofitting in record time,

was re-built at fischer Tubtech in Mexico,

and put into operation. The background was

the relocation of component production for

an existing customer of the main plant in

Achern to Puebla, Mexico.

The quick decision for this action has

proven very successful in many respects. On

the one hand, the main practical objective

has been fully achieved: the relocation of part

production for an existing client has been re-

alized as planned. The new press is being very

well utilized for different components and has

significantly increased the flexibility of the

Mexican production. But several other addi-

tional benefits, which have emerged from the

overall project, have been added to this

primary objective.

Flexibly deployed: Three hydroforming presses with steadily increasing utilization.

concept of the milk-run principle.

As part of the reorganization of the process-

es, the non-value-creating temporary storage

areas could be transformed into value-creating

transport paths and acceptance zones. ‹‹

fischer Austria

From Domino Day to an intralogistical conceptProduction and processing along an “aorta”

With the expansion of the pure tube produc-

tion to include subsequent value creation

steps such as sawing, pressure testing, con-

tinuity tests, and grinding, the intralogisti-

cal demands increased at fischer Edelstahl-

rohre Austria. Because lift truck traffic was

precluded from the outset, an alternative solu-

tion was needed. At the same time, one want-

ed to implement the working principle of the

“U-cell” in order to transfer the textbook-based

experiences of manufacturers of piece goods

to a length goods manufacturer. Furthermore,

non-productive areas for temporary storage

were supposed to be eliminated.

Control of the value creation steps using a small train conceptA quality circle worked out an innovative solu-

tion as a combination of a track-based priority

control on the straight stretches of the main

supply line – internally called “aorta” as on

Domino Day – and non-track-based accessi-

bility of the kidney-

shaped affiliated pro-

cessing stations.

The main sup-

ply line was marked

within the company

by a distinctive color,

and the operability of

the small-train vehi-

cles was construed in

such a way that, as a

safeguard, the opera-

tor’s hands must not

be taken off the aorta

vehicles. The choice

between a non-track-based and a track-based

mode can be made with foot control.

Analogous to the physical material stream,

an EDP-based information stream has been in-

stalled, which is oriented toward the addressing

18 19fluid 1 | 2015 // fluid 1 | 2015 //

pany in 1990, based in Butterworth as fischer

Stainless Steel Tubing S.A. (Pty) Ltd., which then

later relocated to Centurion in 1991 with the goal

to service and better penetrate the South African

market. Specialising in manufacturing stainless

steel tubing, the company ran successfully on

its own for 10 years until a need for manipulat-

ed tubing emerged and therefore fischer Tube

Technik (Pty) Ltd. was founded in 2001. The first

orders received for manipulated tubing were des-

tined for the export market. The following year,

fischer Tube E.C. (Pty) Ltd. was also established

to cater for larger diameter tubing, specially for

the catalytic converter industry.

Entering this section of the market was very

risky as at the time of the investment, no enqui-

ries were yet received for larger diameter tubing.

Celebrating with mulled wine and African cultureTo celebrate the successful quarter century of

fischer South Africa, an event was held on the

premises on the 28th of May 2015. It was not an

easy task to accommodate the 500 plus guests,

including fischer South Africa staff, interna-

tional guests, local dignitaries, customers and

suppliers.

Thorough planning and organisation was

needed to ensure that the event ran smoothly

and would be enjoyed by everyone. The event

International International

fischer South Africa

25 years of progressIn the spirit of African and German collaboration

On the 28th of May 2015, fischer South Africa

celebrated 25 years of successful business

operations since its inception in 1990.

In the past 25 years, fischer South Africa

has experienced continuous growth and has

always kept abreast of its micro environment,

ensuring that the future is always secure.

Various expansions and investments were

made to facilitate this growth and optimise

production processes. These include the cre-

ation and construction of not only one, but

three operational companies, each specialising

in their own area.

fischer South Africa started as only one com-

There was a balanced mixture of German and …

fischer South Africa over the years

1990 fischer Stainless Steel Tubing S.A. (Pty) Ltd. was established in Butterworth, operating from a rented warehouse.

1991 fischer Stainless Steel Tubing S.A. (Pty) Ltd. built its own factory in, what was then known as Verwoerdburg, between Pretoria and Johannesburg. Roughly 2,000 square meters of factory space and 300 square meters of office space were constructed.

1993 fischer Stainless Steel Tubing S.A. (Pty) Ltd. needed to expand, 2,500 additional square meters of factory space were added.

2001 fischer Tube Technik (Pty) Ltd. was founded. Additional land was bought as office and factory space was needed of 2,300 square meters factory space and 220 square meters of office space was built.

2002 fischer Tube E.C. (Pty) Ltd. was established. New property was acquired nearby of 36,000 square meters, of which 1,850 square meters of factory space was built.

2004 Expansion of fischer Tube E.C. (Pty) Ltd. with a further 1,200 square meters factory space.

2005 fischer Stainless Steel Tubing S.A. (Pty) Ltd. expanded with an additional 2,400 square meters.

2007 fischer Tube Technik (Pty) Ltd. needed additional storage facilities for raw material and finished goods, therefore a new warehouse was built with 2,000 square meters of floor space.

2008 Dramatic restructuring of the three companies took place. fischer Stainless Steel Tubing S.A. (Pty) Ltd. was relocated next to fischer Tube E.C. (Pty) Ltd. Additional building became necessary and another 4,300 square meters was added to the existing facility. At the same time fischer Tube Technik (Pty) Ltd. expanded into the vacated premises of fischer Stainless Steel Tubing S.A. (Pty) Ltd.

fischer South Africa in 2015

fischer South Africa in 1991

… African elements on the anniversary program.

shared some history and future visions of

fischer South Africa. Hans-Peter Fischer,

shared his appreciation of the many years of

prosperous growth achieved and wished all

the best for the future. Anand Pather, from

Toyota also had kind words to share regarding

the longstanding relationship between the two

companies.

itself was African themed

to reflect the environment

that fischer South Africa is

part of, and to celebrate the

heritage of where fischer

South Africa comes from,

various German aspects were

included to show the mixture

of the two different lands.

A traditional Oompa band

welcomed guests while they

enjoyed canapés that were

themed to match all the countries where fischer

is present as well as some warming mulled

wine on the approaching winter afternoon.

Guests were ushered into a large 750 square

meter marque and were welcomed to a beau-

tifully decorated and aptly African themed

venue. Various speeches were held, including

the Managing director, Erich Kotzenmacher

A few traditional South African entertain-

ment acts were held during the course of the

evening, including a traditional Marimba Band,

an African Choir, singing traditional songs and

an African Drum Circle. The evening was a

great success and everyone, from near and far,

enjoyed themselves until the end. The festivities

carried on into the night and nobody left feeling

discontented. ‹‹Erich Kotzenmacher, Managing Director of fischer South Africa

Stay informed at:

www.fischer-group.com

Team Talk

http://www.institutoparaciegos.org/

Apprenticeship and in-service training certifications 2014

fischer Maschinentechnik

Martin Manz, Industrial Mechanic,

January 2014

Markus Fischer, Industrial Master

Craftsman, July 2014

Tobias Schnurr, State Certified

Technician, November 2014

Mario Rummel, State Certified

Technician, July 2014

fischer Edelstahlrohre

Sven von Germeten, Industrial

Mechanic, January 2014

Simon Haas, Electronics Technician,

January 2014

Corinna Kern, Specialist for Customs

Clearance, February 2014

Gerd Wiegert, EIB Specialist for

Building Services, November 2014

fischer Rohrtechnik

Patrick Lang, Parts Finisher / Specialist

for Metals Technology, July 2014

(transfer from FMT)

Jens-Manuel Lamm,

Industrial Mechanic, January 2014

(transfer from FMT)

Alexander Decker, Industrial Master

Craftsman in Metal, July 2014

Congratulations on your successful certifications!

120 children of the employees at fischer Mexicana celebrated Children’s Day on May 23rd

together with 30 children from the “Ezequiel Hernández Romo” Institute for the visually

impaired and blind. The home and its school have been in existence for 17 years in San Luis

Potosí and has been financially supported for 6 years by the fischer group. While playing together –

in part blindfolded – the sighted children got a feeling for the challenges of the visually impaired

children. Everyone had a lot of fun, and many new friendships were formed. ‹‹

fischer Mexicana

Blind and seeing children play togetherFestejo del día del niño – 23 de Mayo 2015