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A company ofThyssenKruppTechnologies
ThyssenKrupp System Engineering
Thys
senK
rupp
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ThyssenKrupp System EngineeringDrauz Nothelfer I Krause I EGM
A company ofThyssenKruppTechnologies
ThyssenKrupp System Engineering
Thys
senK
rupp
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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
Sales:€ 8.7 bnEmployees:12,200
Sales:€ 16.7 bnEmployees:43,000
Sales:€ 4.7 bnEmployees:39,500
Sales:€ 11.5 bnEmployees:54,800
ServicesCapital Goods
ThyssenKrupp: Focused Industrial Group With Three Pillars
A company ofThyssenKruppTechnologies
ThyssenKrupp System Engineering
Thys
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rupp
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Sales 2006/07; Employees: 30. Sep. 2007; rounded
Transrapid
PlantTechnology
MarineSystems
Sales: € 2.0 bnEmployees: 8.800
Sales: € 2.6 bnEmployees: 8.300
Mechanical Components
Sales: € 3.8 bnEmployees: 22.800
AutomotiveSolutions
Sales: € 3.2 bnEmployees: 14.200
ThyssenKrupp TechnologiesSales: € 11.5 bn Employees: 54.762
ThyssenKrupp Technologies - Overview
A company ofThyssenKruppTechnologies
ThyssenKrupp System Engineering
Thys
senK
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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
ThyssenKrupp System Engineering
A company ofThyssenKruppTechnologies
ThyssenKrupp System Engineering
Thys
senK
rupp
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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
ThyssenKrupp System Engineering
Bernd Becker (CEO) Dr. Joachim Haats (CSO) Dr. Johannes Dippel (CFO)
A company ofThyssenKruppTechnologies
ThyssenKrupp System Engineering
Thys
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Div
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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
A company ofThyssenKruppTechnologies
ThyssenKrupp System Engineering
Thys
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Div
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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
A company ofThyssenKruppTechnologies
ThyssenKrupp System Engineering
Thys
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rupp
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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
A company ofThyssenKruppTechnologies
ThyssenKrupp System Engineering
Thys
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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
A company ofThyssenKruppTechnologies
ThyssenKrupp System Engineering
Thys
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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
A company ofThyssenKruppTechnologies
ThyssenKrupp System Engineering
Thys
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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
A company ofThyssenKruppTechnologies
ThyssenKrupp System Engineering
Thys
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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
Div
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rmin
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ies
Engineering Purchasing Tryout Matching Innovations Service
How to form QualityForming Dies – Business Activities
Prototypes
A company ofThyssenKruppTechnologies
ThyssenKrupp System Engineering
Thys
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• 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
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n Fo
rmin
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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
A company ofThyssenKruppTechnologies
ThyssenKrupp System Engineering
Thys
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Many of our Competencies join in ProductionPart Production – Business Activities
Div
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rt P
rodu
ctio
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• 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)
A company ofThyssenKruppTechnologies
ThyssenKrupp System Engineering
Thys
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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
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n Pa
rt P
rodu
ctio
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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
A company ofThyssenKruppTechnologies
ThyssenKrupp System Engineering
Thys
senK
rupp
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Products and Services along the Automotive Value ChainDrauz Nothelfer I Krause I EGM
Drauz Nothelfer
Krause and EGM
A company ofThyssenKruppTechnologies
ThyssenKrupp System Engineering
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
A company ofThyssenKruppTechnologies
ThyssenKrupp System Engineering
Thys
senK
rupp
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ThyssenKrupp System Engineering - Customer ReferencesAmerica Europe Asia/Australia
A company ofThyssenKruppTechnologies
ThyssenKrupp System Engineering
Thys
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rupp
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Global Company - Local Presence
Subsidiaries
Service branches
Commercial agencies
A company of ThyssenKrupp
TechnologiesThyssenKrupp System Engineering
Thys
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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
• 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