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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 Steel Stainless Materials Elevator Elevator
Plant Services
Components Marine
Europe Americas International Services Technology Technology Technology Systems
TK Steel EuropeCSA Nirosta Metals CENE Uhde Rothe Erde HDW
• Steel Europe Compass AST Services SEAME Polysius Berco BVN
• Processing Special AMS Fördertechni BVSS
NewStar
Services k
Mexinox AP Camshafts
Industrial
Stainless Services Steering
International ES/PBB System Forging
Engineering Group
SKS Accessibility
Transrapid
ThyssenKrupp
VDM Bilstein-
Gruppe
Division Materials Division Technologies
Waupaca
Umsatz 2007/08; Mitarbeiter: 30. Sept. 2008; gerundet
ThyssenKrupp System Engineering
Corporate (without Divsion) -2-
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 Assembly Body-in-White Forming Dies Part Production
Solutions Systems
Jean-Luc Guyon Josef Görgen Josef Görgen Bernd Becker
Peter Kohlwig
• Engine testing • Engine assembly • Body-in-White • Tools & Dies • Body assembly
• Transmission • Transmission • Final assembly • Prototypes • Hydroforming
testing assembly
• Axle testing • Axle assembly
ThyssenKrupp
• Measuring
3 Brands,
machines 4 Continents, 11 Countries, 4000 People, 800 million € Sales
ThyssenKrupp System Engineering
Corporate (without Divsion) -3-
Satisfied Customers Are Our Motivation
Testing Solutions – Product Range
Motor / Transmission / Axles
Turnkey solutions for test systems
End of Line Test Function & NVH test Test areas Complete test areas Component testing and integrated
bench quality assurance (IQA)
Division Testing Solutions
bench
• Engine • Dimensional
• Transmission measuring
• Axle • Part control
• Leak test
• ect.
Measuring technology Measuring Measuring UPS 32 Service • Simultaneous
Hardware computers technology Engineering
Software Extensive test
• Decentral • Training
applications
measuring • Production
UMS
electronic DME support
Dimensional
• Programmable • Retools
measurement and
measurnig IQA • Maintenance
ThyssenKrupp
electronic • Spare parts
PME • etc.
Sensors
• Laser
ThyssenKrupp System Engineering
Corporate (without Divsion) -4-
Satisfied Customers Are Our Motivation
Testing Solutions – Selected References
Test bench for dual clutch transmission
• 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
Division Testing Solutions
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
ThyssenKrupp
• Test of engine sensors and actuators
ThyssenKrupp System Engineering
Corporate (without Divsion) -5-
Why the Total Is More Than the Sum of Many Parts
Assembly Systems – Business Activities
Engine / Transmission / Axle Assembly
Turnkey Powertrain Assembly Systems
Automatic Stations Assembly Systems Manual Stations
Division Assembly Systems
• Assembly Complete assembly • Highly flexible
operation systems for • Ergonomically
• Tightening and engines, designed
press-in transmissions and • Modularly
operation axles including extendable
• Sealant measuring
application technology and
• Measurement and testing solutions
Transport Systems adjustment Pallet Systems (Pallet, Adapter) source
from one Service
• Friction roller • IMS+ • Simultaneous
conveyor • Multi-adapter Engineering
- horizontal •
- vertical system
- up to max. 2000 - flexible use Instruction/Training
kg - modular • Production
• Flex link conveyor
ThyssenKrupp
design attendance
(KSR)
• Modifications
• Components
(modular) • Maintenance
• Spare parts
ThyssenKrupp System Engineering
Corporate (without Divsion) -6-
Why the Total Is More Than the Sum of Many Parts
Assembly Systems – Selected References
Volvo Car / Fully automatic Cylinder Head Assembly Renault / Semi-automatic Engine Assembly System
• Standardized stations • Flexible ergonomically designed
• Different cylinder head manual work stations
versions on one assembly line • Adapter/pallet concept for
• Space allowance for further engine types prepared
Division Assembly Systems
integration of additional • Output up to 300.000
product variations engines/year
• I3-I6 cylinder • Ideal for “low cost” locations
Ford Commonality / Global System Supplier for 10 Assembly Navistar / 12.4 L I6 Truck Engine
Lines
• Flexibility: In-line 4-cylinder • Automatic assembly line for
up to V12 engine engine, cylinder head and final
• Modular concept dress
• Output: 10.000 up to • Automatic valve-lash
500.000 engines/year adjustment
• Automatic engine function test
and leak test
Volkswagen Double Clutch Transmission GM Automatic Transmission
• Overall responsibility for • Highly automated assembly and
complex controlled processes test facilities for 5 worldwide
• Early fault detection production locations
• Optimal work station layout • Same quality at all locations
ThyssenKrupp
• Fuel-saving future • Global project management by
technology utilization of 5 TK Krause
locations
ThyssenKrupp System Engineering
Corporate (without Divsion) -7-
How the Fascination With Car Design And Structure Is
Embraced
Body-in-White – Business Activities
Car Body
ManufacturingDigital factory
Turnkey Framing Laser application Hemming technology Service
Turnkey, Virtual process • Framing stations • Brazing, cutting, • Tabletop •
Division Body-in-White
customized body- safeguarding at an up to 8 models welding hemming Upgrade/Relocation
in-white plants early stage • Robot framing • Remote welding • Roller hemming • Plant optimization
• Hem dies • Spare part service
• Training
Planning – Virtual Safeguarding – Project Management - Commissioning - Service
Turnkey Sealer applications Marriage systems Window assembly systems Module assembly syst.
General contractor • Manual and • Marriage assembly Semi- and fully e.g. for bumpers,
for complete final automated systems automated glass gluing cockpit, frontend and
ThyssenKrupp
assemblies systems • Chassis equipment and flange seal center console
• Roller technology • Wheel assembly assembly
Final assembly
technology
ThyssenKrupp System Engineering
Corporate (without Divsion) -8-
How the Fascination With Car Design And Structure Is
Embraced
in White / Selected References
BodyMercedes C-Klasse–Remote laser welding Shanghai VW Santana 4000
• Industrialization of remote • Body equipment closures
laser • Planning in Germany, local
welding pro-
• Supplier for remote laser cell cessing
doors • > 40% local rate
equipment in Sindelfingen
Division Body in White
and
Opel Meriva /Doors and side panel Renault Logan Brasilien / Marriage
South Africa
• System partner doors (tools • 5 models, cycle time 55 sec.
and • Engineering in Germany
bodyshop) and side panel for • Co-operation with local
Zaragoza plant suppliers
• Quality responsibility for door • Local design and
module commissioning
VW Golf V / Side panel Audi A4 / Door sealer application
• Realisation of side panel • 3 sites: Ingolstadt,
equip- Neckarsulm,
ment in Wolfsburg, Brüssel Changchun
and Mosel • Use of the Drauz Nothelfer
ThyssenKrupp
• Processing via all German plate
Drauz technology for the
Nothelfer sites application of
door sealings
ThyssenKrupp System Engineering
Corporate (without Divsion) -9-
How To Form Quality
Forming Dies – Business Activities
Prototypes Tools for serial production
Division Forming Dies
Tools - Components – Fixtures - Assemblies Tools for outer body parts and structure – all
Engineering Purchasing Tryout materials
Matching Innovations Service
Simultaneous Individual Quality attainment From individual e..g. digitalization, Preventive
Engi-neering, operations/ value- of own and components to laser hardening/ mainte-
method planning, added levels up to supplied tools o.k. assembly, cladding, lean nance/maintenan
ThyssenKrupp
design full outsourcing respecively o.k. tooling standards ce, spare part
worldwide car body 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 -
How To Form Quality
Forming Dies – Selected References
Opel Corsa / System partner doors Ford Galaxy / Side panel
• System responsibility door • Manufacture and tryout of side
assy. panel
• Inhouse manufacture outer tooling for Genk
skin
and inner panel
• Sourcing in Eastern Europe
Division Forming Dies
and
BMW X5 / General contractor for about 700 tools Audi Q5 / High strength steel expertise
Asia
• Planning and consultation • 14 die sets e.g. longitudinal
regar- carrier
ding components axle support
• Prototypes with production • High strength dual phase
intent materials e.g. DP 600, up to
• Worldwide supplier 2mm thickness
management • High quality requirements
• supplier
Jaguar XF / Closures as systemTryout in press shop Fendt
• Integration of all TKDN sites
• Material aluminium / steel • Consultation regarding
in
• Responsibility for doors, component
Europe and North America
bonnets engineering
ThyssenKrupp
and tailgates/hatchbacks as • First sample parts
assy. • Prototype tooling
• Development tooling • Small-series tooling
• Sourcing China • Welding equipment
• Laser cutting equipment
ThyssenKrupp System Engineering
Corporate (without Divsion) - 11 -
Many of our competencies join in production
Part Production – Business Activities
Hydroforming (IHU) Part Production
Division Part Production
• Manufacture of low-weight • From individual assemblies up to complete body
and high-strength in steel or aluminium
hydroforming
• Planning, design and commissioning of
parts for ultimate stress
equipment and tooling by body-in-white and
• Manufacture of IHF tooling forming dies division
in own tool shop
• Support in Simultaneous Engineering
ThyssenKrupp
ThyssenKrupp System Engineering
Corporate (without Divsion) - 12 -
Many of our competencies join in production
Part Production – Selected References
Lamborghini Gallardo Coupe and Spider / Complete body Behr / Cage for heat exchanger in IHF
• Aluminium bodyframe • Material high-grade steel
construction • Different cages from one
• Small series manufacture, about modular
10 bodies per day tool
• Outer skin expertise • Multi-part production
Division Part Production
• Simultaneous Engineering • Close limit inside component
Mercedes S-Klasse / Main floor Audi Space Frame ® / different IHF parts A8, TT, R8
• Material steel • Material aluminium
• Highly automated • Serial components and equipment
manufacture with 400-500 • Patented sealing process for
assemblies per day multi-
• Successful trials with Bondal chamber extrusions
plates • Total forming process inhouse
Porsche 911 und Boxster / Back panel lower for spare wheel Porsche 911 / water tube IHF
• Material steel • Material aluminium
• Manufacture of 150-200 • Serial components and
assemblies per day equipment
• Manufacture of about 160
ThyssenKrupp
assemblies per day
ThyssenKrupp System Engineering
Corporate (without Divsion) - 13 -
Products and Services along the Automotive Value Chain
Drauz Nothelfer I Krause I EGM
Drauz Nothelfer
ThyssenKrupp
Krause and EGM
ThyssenKrupp System Engineering
Corporate (without Divsion) - 14 -
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 Boeing 787
Engineering Finishing of CFRP tools for front spar
and
• Management of complex turn-key assembly front spar bond assembly
system projects as general supplier
Airbus A400M
• Design and commissioning of customer- Design, manufacturing and delivery of
oriented optimized modular assembly the
equipment inner and outer flap rack
• Implementation and combination of proven Airbus - Next Generation Flaps
production and assembly technologies Development and Build of audit cells for
ThyssenKrupp
automated testing of integrated CFRP
• Development and use of advanced joining and flaps
testing technologies
ThyssenKrupp System Engineering
Corporate (without Divsion) - 15 -
Global Company - Local Presence
Subsidiaries
ThyssenKrupp
Service branches
Commercial
agencies
ThyssenKrupp System Engineering
Corporate (without Divsion) - 16 -
ThyssenKrupp System Engineering - Philosophy
Project-oriented organization Standardized, modular solutions Utilization and expansion of world-
structure with to the advantage of our customers wide low-cost production locations
• short decision-making channels • cost reduction • Americas: USA, Mexico, Brazil
• minimum number of interfaces • quality increase • Eastern Europe: Poland
• short reaction time • high system uptime • Asia: China
• high degree of customer • short delivery time • cooperation with local partners
orientation • reduced maintenance and
spare parts expenditure
ThyssenKrupp
• high degree of reuse for
modifications/extensions
ThyssenKrupp System Engineering
Corporate (without Divsion) - 17 -
ThyssenKrupp System Engineering - Customer References
America Europe Asia/Australia
ThyssenKrupp
ThyssenKrupp System Engineering
Corporate (without Divsion) - 18 -
Awards and Certificates
Recent Awards Certificates
• Ford - Q1 Award • DIN EN ISO 9001:2000
• Best Factory Award Quality Management System
• County of Saxonia Price for Quality • IQNet ISO 9001:2000 International
• BMW – “7-series Partner” Certification
Network for Quality Management System
• GM - Supplier of the Year: Body Shop Equipment & Service
• VDA 6.4 Quality Management System for
• VW - Global Supplier Award production equipment
• S-VW - Golden Prize for Best Commercial Performance • TS 16949 Quality System Management for
(China) the parts supply into the automotive
• Ford / Jaguar - Reliability & Maintainability compliment industry
• DIN EN ISO 14001 Environmental
ThyssenKrupp
Management
ThyssenKrupp System Engineering
Corporate (without Divsion) - 19 -
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: 232 sqm - 14 employees
- Huntsville, AL: 836 sqm - 13 employees
- Greer, SC: 520 sqm - 5 employees
12,600 sqm
Querétaro, Mexico
213 employees
3,600 sqm
89 employees
Selected References
GETRAG RDM Ford D3X GM 6R Chrysler Sebring Freightliner P3 BMW X5
646 Engine Assembly Transmission Sub- Decklid Assembly Turnkey Bodyshop Engineering,
Combined Balance & on a convertible assembly, Cell with Lazer for Aluminium Cab, Sourcing, Matching
ThyssenKrupp
NVH End-Of-Line & globally Assembly & Test Brazing Saltillo, Mexico and Launch
Test Stand for Rear common system for Europe, Mexico management
Axles architecture and the U.S.
Testing Assembly Systems Body in White Forming Dies
Solutions
ThyssenKrupp System Engineering
Corporate (without Divsion) - 20 -
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
Tata Small Car VW TS KOEL S-VW Fabia Tata ACE Opel Meriva
Engine Function Transmission Transport system, Framing and Minitruck New
ThyssenKrupp
Test Assembly Line pallets and Closure weld lines Engineering and Sourcing of door
(India) (China) verification stations (China) Turn-Key dies
(India) Bodyshop (India) (Korea)
Testing Assembly Systems Body in White Forming Dies
Solutions
ThyssenKrupp System Engineering
Corporate (without Divsion) - 21 -
Top League of South American Production Equipment Supplier
South-America Overview
Site Map Selected References
ThyssenKrupp Production Testing Solutions
Systems Ltda., FIAT Fire Motor
Sao Paulo, Brazil Engine function test, Belohorizonte,
- founded in 1973 Brazil
- 40 Mio. € Sales
- 125 employees
- 15.000 sqm shop floor Assembly Systems
- 35.000 sqm in total
VW power train EA-111
Filial Site in Buenos Aires, Powertrain line, São Carlos, Brazil
Argentina
Body in White
Mercedes Class C coupé and Class
A
Turn-Key Bodyshop, Juiz-de-Fora,
Ford Truck
Brazil
Chassis line, São Bernardo, Brazil
ThyssenKrupp
VW new Gol family
Turn-Key Bodyshop, Taubaté and
Anchieta, Brazil
ThyssenKrupp System Engineering
Corporate (without Divsion) - 22 -
