3|09 December 2009
4-21 Corporate development Remanu-
4-15 Remanufacturing in Magdeburg 4-15 facturing
16-17 Investing in the future As a pilot remanufacturing
18-19 Changing corporate culture center, the Magdeburg
factory reconditions Series
20-21 MTU brand profile raised 2000 and Series 4000
22-25 MTU centenary and engines.
Review and DVD
Company / Sales / Staff
36-43 Series 1600
Presenting the subprojects
44-45 Side glance
Pallet store control system
New genset production line
54-57 Training Big numbers
54-55 90 years of training Volume production of gensets is
being expanded in Mankato (pictured),
56-57 Training in practice
Magdeburg und Suzhou.
58 Work & Social
59 One of us Building bridges 59
Emel Coban helps promote understanding
between German and Turkish communities
in her spare time.
Tognum Insight – Magazine for Tognum Group associates and partners Publisher: Tognum Group management board For the publisher: Wolfgang Boller (wob),
Tel.: +49 (0) 7541/90-21 59, E-Mail: Wolfgang.Boller@tognum.com Editor-in-chief: Wolfgang Stolba (sto), Tel.: +49 (0) 7541/90-37 03, E-Mail: Wolfgang.Stolba@tognum.com
Other writers on this issue: Detlef Becker (db), Benjamin Brechtel, Lucie Dammann (ld), Mirko Gutemann (mgu), Anika Kannler (aka), Markus Keiper, Jenifer Riley (jr),
Melanie Staudacher, Alina Welsen (aw), Benjamin Wulle, Photographer and designer: Michael Bober, Michael Drews, Eidesvik, Robert Hack, Florin Heering, Magne Langaker,
MTU Asia, MTU Onsite Energy, Elma Riley, Stefan Söll Editorial assistant and dispatch: Sabine Ruderer, Tel.: +49 (0) 7541/90-21 49, E-Mail:Sabine.Ruderer@tognum.com
Editorial adress: Tognum AG, Abt. VCC, D-88040 Friedrichshafen Design and layout: Designbüro Klaus Schmieder, Vogt Litho: Wagner digitale Medien, Meersburg Printing: Holzer Druck &
Medien, Weiler ISSN-Nr. 1867-0997
“We should remain confident and continue to shape the future
ourselves – irrespective of whether that means dealing with
more crisis situations, developing new products, driving our
business forward or even increasing production output.“
Volker Heuer, Tognum CEO
just as at the beginning of the year we tend to think about what the future might bring, at the end
of the year we look back and consider whether it has matched our expectations. The year 2009 held a
number of surprises that went beyond what we expected. The financial and economic crisis exceeded
everything we had reckoned with about a year ago. At the end of this year, our turnover will be 15 to
New 20 percent less than the year before. The sometimes painful decisions we have had to take as a result
Series 1600 have affected all our locations. We have had to slim down staffing levels, for instance by saying good-
bye to temporary employees. Members of the core workforce have had to allow their flexitime accounts
Volume production of the new to go into deficit, which has enabled us to avoid short-time working. Company and staff have made
Series 1600 started in October. sacrifices to do so – it has been and continues to be a great effort.
Planning of the subprojects broke
new ground in many respects.
We are placing our trust in that proven team for the future of the business, which we expect to im-
prove again in the medium term. It includes the Rotorion employees in Friedrichshafen who will not
be relocating to the new production centers following the sale of the subsidiary to IFA Holding. Our
48-53 desire to find a solution for everyone affected shows that we do not treat our workforce indifferently.
What a great community the employees of a company can be has been illustrated by our MTU
centenary year. All three main events far exceeded the guests’ expectations. Who would have thought
that Wilhelm Maybach would appear ‘in person’ at the official ceremony or that German Chancellor,
Angela Merkel, would attend the gala evening? And the staff centenary party attended by over 16,000
people still managed to go beyond anything we could have imagined. The DVD enclosed with this issue
contains a film and photos of the event as a memento for those who were there and to provide an im-
pression of the proceedings for those for whom the trip to Friedrichshafen was too far.
So what about 2010? Of course, we are hoping that economically things will improve. But at this
moment in time, nobody can say whether that will be possible on a lasting basis within the next twelve
months. The earliest we can expect to have a better idea will be in the spring of 2010. But we should
remain confident and continue to shape the future ourselves – irrespective of whether that means
dealing with more crisis situations, developing new products, driving our business forward or even in-
creasing production output. We have shown confidence by spending more on development in the year
of the global crisis, starting production of the Series 1600, launching our new range of standard gensets
and preparing for the construction of a large materials planning center.
I wish you all a happy Christmas, a restorative holiday period and optimism for 2010.
Best regards, Volker Heuer
Reawakening Remanufacturing a
crankshaft at the
Jens Drewes operates
a modern CNC ma-
chine tool recently
New Magdeburg location integrating into purchased for recon-
ditioning Series 2000
Tognum Group as remanufacturing center and Series 4000
Tognum is breathing new life into old engines at its new subsidiary in Magdeburg
which, as the pilot remanufacturing center for Europe, is restoring Series 2000 and
4000 units to as-new condition. For the Magdeburg location it represents a reawaken-
ing. Other seeds of future growth such as the installation of the new genset production
line have also been planted.
AGDEBURG. When Tognum took over Reconditioning components and engines req-
SKL Motor GmbH of Magdeburg at uires equally demanding manufacturing and
the beginning of 2008, the aim was testing standards and equipment as normal pro-
already clearly defined – integration into the duction – from working with CNC machining
Tognum Group as a pilot remanufacturing cen- centers to high-precision metrology. The funda-
ter for the European region. Remanufacturing mental requirements for such a technologically
involves reconditioning engines and compo- and logistically sophisticated process (see article
nents so that they are as good as new. They can starting on p. 13) were already in place at the
then be sold at prices substantially cheaper than time of the takeover – a workforce with excellent
the equivalent new products. A total of 16 key diesel engine production skills, a healthy ap-
components of the Series 2000 and 4000 have be prenticeship program in the training depart-
identified for remanufacturing including the ment and expandable infrastructure in the areas
crankcase, con rods, pistons, crankshafts and of development, production, assembly and
intercooler. “It might sound easy at first, but it bench-testing. Not to mention plenty of space
isn’t at all,” emphasizes Martin Wendel, Head of for new machinery and plant in a total of six
Global After sales at Tognum and the man in factory sheds.
charge of the global remanufacturing project.
The road to the pilot remanufacturing center
The factory has been The first contacts with the new Tognum sub-
undergoing develop- sidiary date back to the late 1990s. In those days,
ment into the pilot MTU Friedrichshafen worked with Magdeburg
remanufacturing center on the development of Series 4000 gas engines
for Europe since 2008.
and on combustion process advancement for
The compact building
complex (top) comprises the Series 8000. Although the basic conditions
six factory sheds and for integration of the plant into the Tognum
an office area. Group were thus good, a large amount of human
and technical resource capacity for a remanu-
facturing process still had to be established in
2008. “One of the most urgent tasks, which we
… with Karl-Thomas Klingebiel, the man in charge of the Tognum
facility in Magdeburg.
in the space of a month”
A remanufacturing process is a demanding project.
What are the strengths that make Magdeburg parti-
cularly suited to it? New from old
Karl-Thomas Klingebiel is the (top):
The team is highly proficient in the technology, i.e.
man in charge in Magdeburg Series 2000 and
making diesel engines. The company also offers substantial
He has been general manager of the Series 4000 en-
Magdeburg plant since 2008. Born in Berlin, he plant and machinery infrastructure. gines that have
was in charge of production at Rotorion from been restored to
2000 to 2006 and subsequently manager of the How far are you with the project? as-new condition
Rotorion factory in Charleston, USA. “After a There is a master timetable with which we are completely on sche- by the remanu-
number of years in foreign-language situations facturing process
dule. In total, we will remanufacture 16 different components. So far
in southern Germany and America, I am now wait here for their
back in the comfort of my linguistic homeland there have been no delays with any of the components. Three quarters next assignment.
as a Berliner,” Klingebiel quips. of the components had been certified by September 2009. We will start
on the final part of the list at the end of 2009. From that you can see
how far we are with the remanufacturing of engines.
managed to complete in only six months with
the assistance of the HR Department in Fried- What does that mean?
richshafen, was to expand the existing work- So far we have produced roughly 60 remanufactured engines. As
force of about 70 people by a further 60 staff,” re- time progresses, they are made up increasingly of components that we
ports Reinhard Märsch, general manager of the have reconditioned here. As we have not yet received clearance for re-
facility in the early months. Both sides were very manufacturing all components, we fit new parts to the engines instead
cooperative in their approach to the job because at this point. The basic rule is that new parts are always fitted if there
it was a case of reorganizing all structures, pro- is no remanufactured part available. That means that customers have
cedures, roles and work stations, and ultimately been supplied with entirely as-new engines right from the start regard-
adapting them to the group-wide processes. “We less of the stage of progress of the project.
were received with open arms,” recalls Martin
Hatzelmann, who was dispatched from the HR How successful has the startup been with engines so far?
Department in Friedrichshafen to Magdeburg. We have created the fundamental conditions for operating a suc-
His successor, HR manager Sandy Eisenreich, is cessful remanufacturing business in components and engines. You can
currently in the process of setting up a series of see that from the fact that we placed the first engine on the test bench
welfare and training services ranging from a on 26th June 2008 and in August 2009 completed nine engines in the
new canteen to a continuing education program space of a month.
Dismantling a Series 4000: including computer and English courses. “Due ponents are sent to the parts center in Über-
One of the facilities set up for the remanu- to the close contacts with HR boss, Matthias lingen while the reman engines are held in stock
facturing process is a shed in which engines
Jobmann, and others, we are getting closer to on site ready for resale.
are dismantled and components examined,
assessed and cleaned. reaching the Tognum standards every week,” Many of the remanufacturing processes have
Sandy Eisenreich relates. to be coordinated in detail and globally stan-
dardized. From the start, the development of
Tight integration in the Group Magdeburg into a remanufacturing specialist in-
The reasons for that close assimila- volved not only colleagues from Friedrichshafen
tion are primarily to be found in but also from the Duisburg center. “The Duis-
the nature of the complex, burg staff helped us a lot with the establishment
cross-location remanufactu- of the remanufacturing center in Magdeburg
ring process itself. It can only and passed on their expertise,” Martin Wendel
Sandy Eisenreich, be made economically viable expands. In contrast with Magdeburg, Duisburg
HR manager if it is practiced on a large concentrates more on diverse and complex re-
Even after taking
charge of the HR Depart- scale, in other words in large pair projects and overhauls on classic series such
ment she continues to live in numbers. With that aim in as the 396.
her home town of Berlin, 170 kilometers away. Her duties mind, the worldwide Tog-
extend from initial and continuing training through to wel- num organization is being Integration of Series 2000 and 4000
fare services. The Training Department has traditionally
utilized and new remanu- components into production
played an important role in Magdeburg. At present there
are a total of 28 youth trainees completing an apprentice- facturing facilities being A particular strength which recommended
ship. In the area of ongoing in-service training, by contrast, established in all three sales the Magdeburg plant for the remanufacturing
she is reconstructing some areas to Tognum standards regions. Among them, of process is the availability of a whole series of
with language and computer courses and a new canteen. course, is the Magdeburg site machines capable of producing not only the
which is playing the van- components of the products previously made
guard role. The plant per- but also remanufactured Series 2000 and 4000
forms two functions for Europe: it is a collection parts. Modern CNC machine tools for making
center where used parts and engines are retur- crankcases and con rods are an example. While
ned by distributors or customers. And it is a re- substantial increases in unit production figures
manufacturing center. The reconditioned com- are being targeted in the remanufacturing pro-
cesses, output of the SKL Series 29/24 engines Investment largely completed
previously produced and of emergency backup The majority of the investment in new plant
gensets is being scaled down. At the same time, and machinery for reconditioning the Series
development work in Magdeburg under the di- 2000 and 4000 has already been made. It
rection of Karl-Ernst Schwarze is being focused includes an ultrasound tester for intercoolers,
increasingly on the remanufacturing process. a crankshaft machining station, a balancing
The requirements for it are being drawn up by machine and a crack testing system. Still re-
the remanufacturing subproject headed by Dr. quired are equipment such as a penetrating
Martin Kurreck. “At least 60 percent of our work agent system by which, in contrast to the exis-
is now closely coordinated with Dr. Kurreck’s ting crack testing system, cracks can be identi-
design team,” Karl-Ernst Schwarze elucidates. fied in non-magnetic components such as the
Remanufacturing is also a permanent part of piston crown or valve rockers. Investment in a
work on the test benches. Two of the four test recooling plant and more test bench equipment
benches are used for the Series 2000 and 4000, is also planned.
one single-cylinder test bench for the Series
8000 and one for the SKL VD 29/24 engine. Systematic inspection Testing a con rod for cracks (top):
The first stage of the classic re-manufacturing Thomas Hagedorn has sprayed a Series
8000 con rod sent in for repair with a
Hans-Jörg Kohrt, process is the examination of used parts.
fluorescent liquid that shows up green
Exhange Part Assemblies “There are various criteria for assess- in UV light.
Hans-Jörg Kohrt, who previously ment, which are also set down by
worked at the Hamburg center, has the development departments in Remanufacturing con rods:
moved to Magdeburg due to the Friedrichshafen and Magdeburg,” Denis Willberg can set up several used
relocation of exchange part as- con rods at a time on the CNC machining
explains Michael Kunze, mechani-
sembly repairs for the German center.
Navy to Magdeburg and has in-
cal production manager. Visual
ducted his new colleagues into the inspections, complete dimensional
job. “On the one hand, the move checks and crack tests are some of the
wasn’t easy but on the other it allowed methods used to determine, for exam-
me to continue doing my familiar job.” ple, whether a cylinder liner is damaged
and whether the dimensions are within the allo-
Michael Hoffmann (left), designer,
and Karl-Ernst Schwarze, head of
Development in Magdeburg
Reman Series 2000 engine: wable tolerances. For highly stressed compo- The Development team headed by Karl-
By having some of its components recon- nents such as con rods and crankcases, the crite- Ernst Schwarze has been strengthened for the
ditioned and others replaced with new remanufacturing process. Michael Hoffmann
ria are more numerous than for components not
parts, an engine is restored to as-new joined the Magdeburg remanufacturing team in
condition in the remanufacturing process. subject to such high loads. According to Michael
2009. His diploma thesis qualified him especial-
The picture shows Stefan Imgrund who Kunze, roughly 80 percent of components can ly for the work. He examined the technical and
was dispatched from Friedrichshafen to be remanufactured overall. The remaining 20 economic potential of the concept using the tur-
Magdeburg. percent are replaced with new parts. bocharger as his example. He also visited the
Of central importance among the techno- Detroit Diesel facility in Tooele near Salt Lake
logies used in the remanufacturing process is City where S60 engines are remanufactured.
grinding. It provides parts with a symmetrical
geometry, such as perfect circularity in the case
of bearings. Crankcase bores are remachined to to 162 mm from their original dimension of
a defined dimension from a series of set in- 160 mm when new in order to remove surface
crements depending on wear. Here too, the prin- damage. There are then precisely matched, over-
ciple of precise and consistent standardization sized cylinder liners that can be ordered using
applies. Cylinders, for example, are rebored the SAP system in Überlingen Parts Logistics
Center. So the reconditioned part and its design
shop-floor level: counterpart always fit together perfectly.
In order to adapt the One of the highlights of high-precision ma-
processes in Magdeburg chining is the grinding of crank-shafts on a new
to the Tognum stan- machine and the cleaning of intercoolers in a
dards, around 20 staff
chemical ultrasound bath. As long as the speci-
were dispatched there
from Friedrichshafen, fied criteria are satisfied, the parts can even be
among them Rene reconditioned a second time for a third life.
Hoffmann (right) seen After remanufacturing, the component is given
here with apprentice a unique reman number and entered into stock
ready for sale in Überlingen Parts Logistics
Well defined interfaces, board, the main components such as engines, Test benches for Series 2000 and 4000:
clear allocation of roles generators and radiators for the first three gen- Two of the four test benches in Magdeburg
are used for the Series 2000 and 4000, and
An important factor for successful integra- sets were waiting to be assembled in Hall 3. It’s
a third for the Series 8000. Frank Berlin is
tion of the Magdeburg facility is that there are hard to imagine a new Tognum plant being able one of the test bench staff.
clearly defined interfaces between it and the to integrate and mesh with a large-scale project
units in Friedrichshafen that are responsible for within the global Tognum Group any faster or
the group-wide specifications. Karl-Thomas more flexibly. “That is where we benefited from
Klingebiel elucidates: “To make sure we meet the system engineering expertise that we have
the Tognum standards, there are initial sample established over many years with our previous
approvals and process audits. The key technical gensets,” points out assembly manager Bernd
data are specified by the development sub- Gründel.
project. Magdeburg, on the other hand, is re- In addition, component sets known as “ex-
sponsible for the physical implementation.” That change part assemblies” are currently being re-
includes the production of drawings by a five- conditioned for German Navy frigates and
strong development team headed by Karl-Ernst high-speed patrol boats, and will also be
Schwarze and definition of the manufacturing supplied for corvettes in the future.
processes, as well as which technologies are to be Among the frigates are those involved in
used and in what order.
The fact that the Magdeburg center can do
Daniel Müller, Assembly Planning
much more than remanufacturing is demon-
and Work Preparation
strated by the assembly of the new generation of
The qualified model builder has worked in
MTU Onsite Energy-branded standard gensets the Series 4000 assembly section in Friedrichs-
based on the Series 1600, 2000 and 4000 en- hafen for three and a half years and was sent to
gines. Alongside Tognum’s US facility in Manka- Magdeburg from April to the end of the year. He has been
to, and before long the Chinese plant in Suzhou, working there with colleagues from Magdeburg on brin-
ging the processes and specifications up to a uniform
Magdeburg is to supply the new product line to
Tognum standard right through to documentation. His im-
the European market from 2010. Within a week pression is that, “Overall, cooperation runs very smoothly.
of the decision being taken by the executive I was received with open arms.”
counter-piracy in Somali waters at present.
Detlef Koch, Quality Inspector
These components were previously reconditio-
He works in a precision testing lab perfor-
ned in Hamburg but the work has now been ming quality checks on reman parts. The
transferred to Magdeburg and repre- dimensions and tolerances are mea-
sents a small but high-potential sured to within a thousandth of a
growth sector. “In 2009 we made millimeter. As a long-serving em-
ployee, he performed checks on
four times as many exchange part
SKL engines for many years.
assemblies as in 2008,” Michael “The changeover to MTU engines
Kunze expands. wasn’t a problem.” Detlef is one
of many employees who comple-
ted an apprenticeship at the com-
pany and have remained loyal to the
firm since. “Because of the difficult times
after reunification, I was made redundant in
1996, but was able to return twelve years later
in 2008 as part of another company.”
Remanufacturing cylinder heads (left):
Ulrich Malolepsy reconditions Series 956
cylinder heads for a German frigate.
171 years of engine-making tradition Traction engines
The history of the Tognum factory in Magdeburg goes all In the early days
the company was
the way back to the early days of steam shipping.
involved not only
Magdeburg is a center of cultural as well as industrial in steam ships and
history. The present-day SKL Motor GmbH can be traced engines but tracti-
back to the Magdeburger Dampfschifffahrt Compagnie on engines as well.
founded in 1838, which subsequently changed its name to
Maschinenfabrik Buckau and then merged with Maschi-
nenfabrik Wolf in 1928. Both companies made steam en-
gines. The production of diesel engines goes back to the
takeover of Grade-Motorenwerke and Ascherslebener
DK diesel engine
Maschinenbau AG in the early 20th century. After the 1930:
Second World War, with the creation of the German This static single-
Democratic Republic, the company became a state- cylinder unit pro-
owned combine known as Schwermaschinenbaukombi- duced 30 hp.
nat Karl Liebknecht or SKL. It employed 9,000 people and
was the leading diesel engine manufacturer, supplying as
many as 3,600 engines a year to eastern bloc countries.
Around 90,000 engines were supplied worldwide for
powering ships and emergency gensets. Roughly 20,000 1998:
of them are still in operation. The end of the GDR brought This Type 9VDS
down the curtain on SKL’s successful years. 29/24AL engine
develops 2,100 kW.
Remanufacturing of rail PowerPacks in
Friedrichshafen: At the beginning of the
process, the traction module is thoroughly
Reincarnation a technical possibility
Remanufacturing processes restore MTU products to as-new condition
This year, Tognum Global After Sales launched a remanufacturing service marketed
under the new name of Value_Exchange. It involves standardized complete overhauls
by which used components, engines and systems are transformed back into as-new
products that can be purchased at economical prices. The Magdeburg location provides
one of the pieces in a worldwide jigsaw.
RIEDRICHSHAFEN. MeIt is well known to be completed, a ferry or train operator can
that some human cultures believe people fit a remanufactured unit immediately. And
are reincarnated after death. Not so widely Tognum is able to control the grey market in
appreciated is that it is definitely the case with components more effectively. In contrast with
MTU diesel engines and components. This third-party components, the manufacturer-
technical kind of reincarnation is referred to as reconditioned parts come with the MTU war-
remanufacturing. Since 2008, the process has ranty and the quality of a new product.
been undergoing systematic expansion and The idea of remanufacturing is not new. Fuel
standardization as a strategic project on a major, injectors and high-pressure pumps for the Series
global scale and has recently been made avail- 4000 are reconditioned by Tognum subsidiary
able as an After-Sales product under the name L’Orange in Glatten, rail PowerPacks are re-
‘Value_Exchange’. stored in Friedrichshafen and Series 4000 cylin- Assembly of a rail PowerPack in Friedrichs-
Customers opting for the service obtain a re- der heads are refurbished at MTU Turkey. In hafen: The components are reassembled to
make an as-new rail traction module.
placement part with the properties, qualities and addition, S40, S50 and S60 units and 2-cycle
the warranty of a new part at a substantially engines are reconditioned in the USA.
lower price. In that way, MTU is helping them to
considerably reduce the life-cycle costs of their How to renew used parts
power units. Now, instead of waiting for repairs The remanufacturing process goes further
Materials flow dictable and efficient and can be offered at stan-
in remanufacturing dardized prices worldwide.
The process has been managed for around a
The Logistics sub-
project ensures the year by the Global Remanufacturing project
flow of materials is team headed by Martin Wendel, Head of Global
smooth and efficient. After-Sales. The main focus is on expansion and
Pictured, from left, marketing of the standardized complete over-
are Barbara Amann,
hauls for the Series 2000 and Series 4000 engines
Bernd Maurer, Logis- as the product MTU_ValueExchange. The de-
tics Center manager velopment and logistics subprojects provide
and Denise Kurtulus, further interesting insights into the special fea-
reman project tures of remanufacturing.
Development of remanufactured parts
than a conventional complete overhaul (QL4), In order to guarantee the properties, quality
which re-equips an engine for a specific period and dimensional accuracy of remanufactured
of service within a maintenance schedule, or a parts for refitting to engines, they undergo com-
repair, which replaces only specific, faulty com- puter analysis by the Development Department.
ponents. By contrast, remanufacturing reinsta- Specimen parts are examined on the test bench.
tes major component, an engine or a system to a “We specify the dimensions to which the parts
condition whereby quality is equivalent without are to be remanufactured in our design draw-
qualification to a new product. Used parts are ings, for example,” explains Dr. Martin Kurreck,
generally re-usable. Development subproject manager.
The process sequence is basically the same
in all cases – the engine or component is com-
pletely dismantled, cleaned and examined. Then
a decision is taken as to whether the unit can be Overview …
reconditioned or needs to be replaced with a
new one. The reconditioning requires various Global process
technologies depending on the component, ran-
ging from re-grinding a bearing to treatment in Remanufacturing is a worldwide process. Several sites
work together as part of a network. Used parts are
a chemical bath. But there is a fundamental dif-
collected at various centers, reconditioned at others
Rail PowerPack 1800 project team: ference from a regular repair or complete over- and stored for resale at yet other locations.
The concept for the remanufacturing haul. All processes are standardized down to the
process for the rail PowerPack 1800 was very last detail, offered at fixed prices in defined
developed by a team led by Oliver Moll.
completion times, and are fully documented to
Seen here, from left, are Martin Walser,
Patrik Tulburean, Oliver Moll, Eugen Wil- unified standards. And finally, they are given a
helm, Alexander Coronini, Rudolf Reich and quality management approval certificate. The
Adrian Bessler. advantage is that the processes are more pre-
Tooele (MTU Turkey)
Logistics network and Mercedes-Benz off-highway engines can
Another essential difference between rema- also be returned to the collection centers. Exter-
nufacturing and overhauling or repairing is in nal suppliers then restore those parts to a con-
the complex, worldwide logistics. “For remanu- dition such that they can be purchased as new-
facturing of engines to be economically viable, quality products from the Tognum sales team.
an adequate supply of remanufacturing compo- All fully overhauled products then find their
nents is required,” emphasizes Barbara Amann, way via the After Sales logistics centers in Über-
Logistics subproject manager. A standardized lingen, Canton or Singapore back to distributors
deposit system is designed to incentivize cus- or end users all over the world, and can be put to
tomers to return their used parts. All compo- full use again until the next complete overhaul
nents from S40-S60 models, Mercedes-Benz by Tognum.
off-highway engines and 2-cycle units can be
returned to the collection centers. Components Words: Anika Kannler, Wolfgang Stolba,
of the S40/60 Series models, the 2-stroke range Pictures: Robert Hack
Con rod on the test bench in Friedrichs-
hafen: The Development subproject tests
reman parts before they are approved for
use in production. Pictured here are Dr. Rei-
ner Böschen (left) and Dr. Martin Kurreck.
Global remanufacturing team:
The remanufacturing cycle From left, Dr. Martin Kurreck,
Denise Kurtulus, Wilfried Pro-
Reman HQ/ / bian, Barbara Amann, Wilfried
Powerpack Reman Center Baur, Hubert Ammedick, Lutz
Schütte, Werner Hussal, Hen-
Reman Center Europe The product is resold as a reman A customer buys a new or ner Wolf, Reinhard Märsch,
Reman Center Asia engine/component. ValueExchange product from Martin Wendel and Alexander
MTU. Tesch. Not present for the
Core Collection Center
photo were Harald Rudolf,
Karl-Thomas Klingebiel and
Cylinder head (Series 4000)
Spare Parts Center
Used engines or components
Enginges and components are are returned to the MTU reman
) reconditioned at remanufactu- center. The core collection cen-
ring centers using standardized ter checks that the items meet
processes. the acceptance criteria and
reimburses any outstanding
Singapore deposit. The customer gets an
Rawang exchange or reman engine/
Investment in the future
The global financial and economic crisis isn’t
over yet. Even producers of short-lived goods
who react quickly to economic changes are
cautiously optimistic at best. Manufacturers of
high-value durables such as are made by Tognum
usually feel the effects of changes in the economy
with something of a delay. Nevertheless, Tognum
has prepared itself at its centers across the globe
to utilize the opportunities of the future and is
investing in new products, production plant and
F RIEDRICHSHAFEN. „In years
gone by, the Friedrichshafen en-
gine makers were wont to call the
at the individual
Tognum Group plants
frantic business of the last three Pictured: the production
months of a year the “winter battle“. section in Friedrichs-
And Friedrichshafen has certainly hafen last summer with
finished gensets for
had plenty to do in production in the
the new Berlin airport
last quarter of 2009 – apart from any- awaiting dispatch.
thing else, to make sure the Tognum
Group reaches its financial targets.
After all, the crisis has left deep scars. average monthly output over the rest moment,“ Wehrle relates. Detroit is
It is true that large-scale engine pro- of the year“. But he adds a cautionary continuing to build variants that are
duction in terms of the Series 8000 note against premature optimism: not made in Friedrichshafen.
and the classic models has been well “Whether that is a first sign of a
up to capacity throughout the year. recovery that will continue into the Fewer Series 4000 engines also
But nevertheless, the demand for the new year, I can’t say. Customers are means fewer orders for Tognum sub-
normally high-volume Series 2000 ordering at much shorter notice. And sidiary L’Orange, which manufactures
and 4000 has contracted considerably. that makes reliable predictions im- fuel injection systems. “The effect on
As a consequence, staff have had to possible.“ us is directly proportional,“ reveals
stay at home due to lack of orders. Olav Altmann, sales manager at
Their flexitime accounts have gone The assembly plant in Suzhou/ L’Orange. Orders for injection sys-
into deficit, holiday owing has been China is continuing to produce “at a tems for medium-fast running engi-
used up and temporary staff have relatively high level“, Wehrle reports. nes made by other manufacturers
stopped being employed. In the last It makes Series 2000 engines for have not seen such a marked
three months of 2009, Production power generation applications. The downturn, as they are ordered longer
and Assembly have, by contrast, been consequences of the crisis have been in advance. With those products, the
working three shifts a day some of the more severe at MTU Detroit Diesel effects of the crisis may not show un-
time so that the engines can be sent where unit output has dropped signi- til later on.
out and the receipts booked before ficantly. “We have relocated assembly
the end of 2009. Production manager of the Series 2000 and 4000 engines, The development trend is clear
Hans-Peter Wehrle cites an example: which are normally produced at both from the sales figures. Turnover will
“In November we will be producing sites, to Friedrichshafen for the time probably be 15 to 20 percent below
twice as many Series 4000 units as our being. It is more economical at the the 2008 figure. Tognum remains
How Tognum is preparing for when the economic crisis is over
to rise again and is, therefore, inves-
ting in the future. It has been well re-
ported that substantially more money
was made available for research and
development in 2009 than in previous
years. Following the start of volume
production of the 12-cylinder Series
1600 in Überlingen in October, the
10-cylinder version will follow suit in
January. And money is also being
invested in the important Chinese
market. The new factory in Datong
in northern China, where the joint
venture between Tognum and the Tognum sells Rotorion to IFA
Chinese Norinco Group will assemble
emergency backup gensets for Chi- FRIEDRICHSHAFEN (wob). Tognum AG has sold
nese nuclear power plants, is almost its driveshafts division to the IFA Group in Hal-
complete. Proximity to the market is densleben near Magdeburg. The prop shaft ope-
the reason for a new sales office in rations of the two groups will be merged to form
Dalian in the industrial north-east of IFA Maschinenbau Verwaltungsgesellschaft.
China. Five staff handle the sales of Tognum will take a 25-percent stake in that
MTU and MTU Onsite Energy pro- holding company but will withdraw from it in five
ducts and after sales services in the re- years’ time. While the factory in Charleston, where
gion. In Pune, the industrial center in around 140 staff are employed, will be retained, the
India’s west, MTU India has taken up Friedrichshafen production facility, which employs
residence in a new building housing a workforce of 490, will be relocated to Haldens-
office and workshop space. And final- leben and Gardelegen in eastern Germany by the
profitable but the operating result ly, preparations are well advanced for end of 2011. The first machines are to be moved at
shrank by 65 percent in the first 9 the construction of a new materials the turn of the year 2009/2010.
months. The crisis has not hit so hard planning center in Kluftern near The Human Resources Department has set up
everywhere, however. The subsidi- Friedrichshafen. the „Future Active“ program, by which it aims to of-
aries in the UK and South Africa re- fer all Rotorion staff future prospects. Although it is
port respectable revenues despite the Words: Wolfgang Boller foreseeable that only some of the workforce will relo-
crisis. And in Asia business continues Pictures: Robert Hack, MTU Asia, MTU-Archiv cate, employees are not to be left jobless. „We will help
to grow – just not as quickly as before. wherever we can,“ promises Tognum HR director,
Matthias Jobmann. Enforced redundancies are to be
In the medium term, after the cri- avoided. „Future Active“ offers a broad span of pos-
sis, the Tognum Group expects sales sibilities. Because the Tognum Group expects busi-
ness to grow in the medium term, more staff will be
required for the production of engines, propulsion
systems and energy plants in Friedrichshafen and ot-
her locations as well. Present employees of Rotorion
will be given preference in the recruitment process
for those positions, provided they have the appro-
priate qualifications or can acquire them. In addition,
A new branch of MTU India
part-time and early retirement and voluntary redun-
is shortly due to open in
new premises providing dancies with severance payments will be offered.
workshop and office space There are five HR professionals assigned specifically
in Pune on the western side to looking after the future of the workforce.
of the country.
More than smoke and mirrors
A change of culture in a company can alter the way people interact measured by the same standards does not appear to have
been fully realized as yet.
and their use of language – and vice versa. Even the meaning of
such simple and clear terms as staff, management and team spirit Internal company communication, on the other hand,
has already overcome a number of obstacles. Fifteen
is not set in stone. And so the cultural shift at Tognum, especially
years ago, a printed A6 form headed “Memo“ on which
since becoming stock-market listed, has changed much in the way the message normally started
with the words “Dear
words are used, as can be illustrated by a few examples.
Mr./Mrs./Miss ...“ and
with a header section offe-
FRIEDRICHSHAFEN. Who hasn’t occasionally been ring check-boxes for indica-
enchanted by tasteful interior decor immersed in ting a total of twelve
atmospherically indirect lighting? But what on options including
Earth has indirect lighting to do with a cultural change in whether the mis-
the Tognum Group? At first sight, nothing at all. But didn’t sive was for infor-
the company jargon used to refer to “directly productive“
and “indirectly productive“ staff? The latter presumably
don’t tend to hide their light any more under bushel or
even behind a stylish stained-wood screen
than the “directly productive“ employees.
Although they are modern terms, that
does not make them any more comprehen-
sible. And whatever they mean, the unintended
associations are a problem. Why is someone on the shop mation, acknowledgement, approval or to be actioned, was
floor or in a technical department “directly productive“ the least to be expected in terms of formality. The notifica-
and an office worker only “indirectly productive“ when tion was sent by internal post and reached the recipient the
everyone contributes directly to the success of the busi- same or next day. Today’s e-mails are much quicker and
ness. One thing is certain – the terms have gained a foot- easier. The standard salutation is a simple “Hi ...“ even
hold in the German-speaking parts of the Tognum Group, across hierarchical and departmental boundaries. That
even though the new General Remuneration Agreement progress has been somewhat inhibited in more recent
(ERA) in Germany in 2008 ended the decades of distinc- times by the deluge of electronic epistles in which we are
tion between waged and salaried employees. The linguistic now in danger of drowning. A new set of regulations – the
transition to a new corporate culture envisaged by rules of e-mail etiquette – have had to be instigated.
the parties to that agreement and
in which everyone would be Corporate culture as success factor
If we understand culture as meaning the
entirety of attitudes, modes of behavior,
standards, values and aims – both indivi-
dual and collective – then it is clear that
corporate culture is something funda-
mental that is expressed in every word, every
gesture and, ultimately, every executive board decision,
and so is decisive to the wellbeing or otherwise of the com-
pany. “That is why we should not be indifferent about the
way we use many terms,“ stresses Matthias Jobmann,
Tognum HR director.
How words can promote or inhibit a change of culture in the Tognum Group
Terms that have positive connotations, are not too long That is something that is experienced anywhere where
and are well understood can be brought out of the people, groups and businesses join together to form a larger
shadows of a former existence to convey and promote pre- entity. The creation of the Tognum Group is the best
sent new ways of thinking. Examples cited by Matthias Job- example. Tognum is the name of a new, larger and more in-
mann are the terms project work and teamwork. These dependent corporate unit. The associated cross-location
days, a project is a meticulously planned process in which and cross-company orientation has shaped a far-reaching
the opportunities, risks and costs are systematically identi- cultural transformation since the Group’s public listing in
fied from the outset. Whereas in the past, project 2007. In view of the ever advancing globalization, terms
team members largely remained within the such as service center or agent, which carry connotations
strictly defined boundaries of their depart- of dependence on the head office, have been superseded by
mental line management func-tions, today the more active and independent concept of the distribu-
tor. The Compass project explicitly underpinned the prin-
ciple of decentralization. That may sound abstract but has
a profoundly practical effect in terms of greater proximity
to the customer – worldwide.
The new self-image is also expressed in the Tognum
vision. Terms such as “preferred partner“ and
“best solutions“ convey a new and more
acute awareness of the customer-supplier
relation-ships, including in internal
dealings. Tognum represents the
unifying link between all employees.
their tasks and responsibilities are Tognum is also the “home of power
focused on the project objectives. If necessary, brands“. “Effective brand communica-
previously accepted norms and standards are re-examined. tion with the markets is the decisive factor for the success
And the concept of teamwork enjoys a position of high of the corporation, whereas the old company names are
standing. It places the emphasis on partnership rather than not, even if it is painful in the beginning to lose them,“
a specific organizational unit. In the same vein, the travel Matthias Jobmann assures.
and expenses unit has been replaced by travel management
and the vehicle fleet by the car pool. The focus is on the Is the internal identity of the company lagging behind
service, the customer-supplier relationship, and not the its external image? A listed-stock company should also
organizational unit. Using the term “manager“ places the strive towards a fresh appearance on the inside believes
emphasis on the function rather than referring to a “supe- HR boss, Matthias Jobmann. But he also emphasizes that it
rior“, which focuses on the hierarchical position. should not miss the target altogether and get lost in empty
jargon and marketing speak.
Cultural change in its broadest sense has always gone
on at this company. Processes have been made more flex- Words: Wolfgang Stolba, Pictures: Robert Hack
ible and less constrained by freeing them from the corsets
of pedantic terminology. When MTU engines were named
strictly according to the cylinder capacity, they ended up
with clumsy designations such as 396, 595 or 1163. But
there is a more elegant alternative. Much more effective in
marketing and outward image terms are the name tags
2000, 4000, 8000 and 1600. But one thing is also clear,
“You only create a distinct profile outwardly and inter-
nally at the price of a certain degree of uniformity on
the part of everyone concerned,“ Matthias Jobmann
Advertising with peligators
New corporate design sharpens image of Tognum brand MTU
F RIEDRICHSHAFEN (aka/sto). The MTU brand is to have a higher profile in the marketplace, reach a broader
audience and distinguish itself more sharply from other brands. For this reason MTU brand valves have been
further developed this year and a new corporate design has been introduced to match these valves. First of all, an
unusual image campaign was launched to familiarize the market with these valves. The campaign used ‘hybrid’
animal motifs to symbolize specific product strengths.
“The three brand values of partnership, power and passion express more emphatically and precisely what makes MTU
stand out and differentiates it from others than has been the case in the past,“ explains Walter Scherg, Head of Marketing
Communication and Distribution Development. Before now there have been too many different messages about the
brand circulating around the market. Based on the brand values, VMD first of all created a new corporate design. Every-
thing that is definitive in the visual appearance of advertisements, calendars, trade show stands, websites and other media
was redefined in the process. The new cornerstones of the corporate design (CD) first appeared in an image campaign
launched in August featuring fantastical animal motifs such as peligators (cross between pelican and alligator). They
graphically express the strengths that MTU products combine. The central message is that MTU is your best partner for
the perfect propulsion solution irrespective of how specialized and demanding your requirements may be.
Daring image campaign:
The MTU core values are sym-
bolized by imaginary animals.
A rhinoceros with kangaroo’s legs
represents engines in the C&I
sector. It combines the power to
move a substantial mass with
speed, strength and endurance.
An armadillo with leopard’s legs
(Defense) combines the aspects of
protection and compactness with
speed and power. A pelican with a
crocodile’s torso (Oil & Gas) is
equally at home on land and in the
water, and is tough and strong
enough to cope with extreme con-
ditions. A sheep with horse’s legs
(Agriculture) combines the bene-
fits of a domesticated animal with
strength, speed and stamina.
Ten MTU T-shirts featuring current advertising motifs to be won!
Simply complete the coupon, cut it out or photocopy it, and mail or fax it
(+7541-90-3918) to Department VCC by 30th January 2010. There is no
recourse to legal action. Winners will be notified in writing.
Please answer the following question:
What are the three brand values of the MTU brand?
New brand design:
Answer The core values of the MTU brand have
been encapsulated in a new corporate de-
sign. It includes the use of specific colors
First name, last name
(see illustration) and layout and formatting
rules for communication media.
Tognum company, department
E-mail address (business or personal)
History and celebrations
Important politicians make speeches on big
occasions. So was it any surprise that German
Chancellor, Angela Merkel, was a guest at the
gala event in May to celebrate the MTU centen-
ary in Friedrichshafen? On 23rd March, the
Prime Minister of Baden-Württemberg, Günther
Oettinger, had been present at the official anni-
versary cere-mony. The three big celebratory
events were as unique as the company itself.
Karl Maybach in gold and silver
Karl Maybach, founder of the company that
became MTU Friedrichshafen, was such an un-
usual inventor that the Baden-Württemberg
Mint has honored his achievements with a
series of gold and silver medals. “It is a great
accolade for Karl Maybach,” attested Tognum
COO, Christof von Branconi (right). The presen-
tation was also attended by Karl Maybach’s
daughter Irmgard Schmid-Maybach and Baden-
Württemberg permanent secretary Gundolf
2009 should not be remembered only as the year of the global financial and economic crisis.
For many Tognum Group employees and their families it was also a year of great celebration.
The centenary of Tognum subsidiary MTU Friedrichshafen will remain in the memories of
many as a time when the company’s great history was given due recognition.
MTU Detroit Diesel celebrates centenary picnic
Over 400 MTU Detroit Diesel employees and
their families celebrated the company’s 100
years of existence with a picnic on 30th August.
Those attending the Sunday event enjoyed
food, drink, music and games of football and
volleyball. Face-painting, a bouncy castle and
an inflatable obstacle course also provided
plenty of entertainment for kids. And every
guest received an MTU centenary T-shirt as
a memento of the occasion.
The grounds of the “Singapore Flyer“ giant
Ferris wheel were the venue for a centenary
celebration attended by 470 MTU Asia staff and
their families. With balloon sculptures, a jugg-
ler, an “amazing“ race and lots of family games,
it was an entertaining event for MTU’s Asian
relations. “We are proud to work in a century-
old company that is playing such a healthy part
in the economy,“ related MTU Asia employee,
Chua Kee Yat.
DVD of the century
For many Tognum staff it was an unforgettable experience – the centenary party celebrating 100 years of
Tognum subsidiary MTU Friedrichshafen on 11th July. Thousands of employees and their families enjoyed a
fantastic all-day festival. For them, and also for all those who could not be present because of the distance,
we have made a souvenir DVD of photos and video footage.
Many visitors though the centenary party was
so good that they even took the trouble to ex-
press their thanks in writing. Here are a few
excerpts: “We were able to enjoy a celebratory
event that meant more than free food and
drink.“ – the Wietzel family. “It was a great
success all round. I am certain MTU Plant 2
has never experienced anything like it before.“
– Heike Fleisch. “We just had a great time –
and hopefully you could tell that from our per-
formance.“ – Sven Claussen of “Celebration“.
Film and photos on DVD
What was the best thing about the MTU centen-
ary party? The games for all the family? The
summertime setting on the banks of Lake Con-
stance? The exhibition of engines and applica-
tions? The concert with Nena? Was it simply the
pleasure of relaxing with workmates and former
colleagues? Or was it all of those things toget-
her? The film and photos on the DVD attached
on the right will hopefully keep the memories of
a unique social event in the company’s history
alive, as well as offering some unusual perspec-
tives and a peek behind the scenes.
The MTU IRIS project team at Friedrichshafen
railway station: The interdepartmental team
has designed new processes and adapted and
precisely defined a large number of existing
ones. Pictured, from left, are Rudolf Sievers,
Thomas Bierwagen, Hans Wiemer, Carmen
Dienel, Erhan Agamola (back), Harald
MTU meets strictest rail standard
FRIEDRICHSHAFEN (sto). Being a good and reliable sys- contact point for customers has been more clearly defined.
tem supplier for railway stock means coordinating an The availability of spare parts over the entire lifecycle of
array of interfaces and components with the client be- products and the effective control of component modifica-
yond the engine on its own and providing generally tions throughout the added-value process right through to
effective and efficient business procedures. How impor- the customer have been guaranteed. Other examples are
tant the subject is to the European Rail Industry Asso- contingency plans for machine failures, a new, centralized
ciation, UNIFE, is illustrated by a highly detailed inter- documentation system for all calibrated measurement and
national industrial standard that came into force this testing equipment and new processes for project-based
year and which UNIFE is keen to promote. MTU Fried- system supply business.
richshafen was awarded accreditation to that standard
in May. It is known as the International Railway Indus-
try Standard (IRIS).
IRIS is based on the requirements of ISO 9001:2000,
which MTU already complied with, and includes a number
of additional rail-specific specifications. So IRIS guaran-
tees clients the highest recognized standard in Europe and
the strictest anywhere in the world for efficient planning
and project management of traction system installation.
“Everything that makes cooperation better, easier, speedier,
more efficient and more economical we have comprehen-
sively optimized – from quality management through do-
cumentation to process stability – a total of 260 require-
ments,“ points out Stefan Jochum, leader of the IRIS pro-
ject team. For example, the role of key account manager as
Twin MTU units
for unusual locomotive
FRIEDRICHSHAFEN (db). The first two MTU Power-
Modules fitted with Type 12V 4000 R43L rail engines
were recently installed in the new 120-kph BITRAC 3600
heavy-duty locomotive made by Spanish rolling stock
manufacturer CAF. A further eight BITRAC locomotives
each driven by twin MTU traction systems have been
ordered from CAF by the Spanish freight train operator
FESUR in Seville.
With a total power output of 3,600 kW, the CAF
BITRAC is one of the most powerful hybrid locomotives
currently in use on goods and mainline passenger services.
The electricity to power the traction motors can either be
supplied by the diesel-driven PowerModules or, on electri-
fied routes, drawn directly from the overhead power lines. of pure power:
The dual power supply capability allows fuel savings of up Two PowerModules
to 40 percent on some routes. When the diesel engines are based on Type 12V
not running, a new crankshaft lock developed by MTU 4000 engines form
the heart of the new
prevents damage to the crankshaft bearings from shocks or
vibration. The MTU rail traction engines are distinguished locomotive made by
by fuel consumption of less than 200 g/kWh and are also Spanish manufactu-
among the first to comply with the EU Stage IIIa nitrogen rer CAF.
MTU rail traction modules
FRIEDRICHSHAFEN (aka). As part of a contract
worth 11 million euro, Tognum is to supply com-
plete traction systems consisting of engine and
components such as gearbox and cooling system
to the Korean railcar manufacturer Rotem star-
ting at the end of 2009.
The PowerPacks supplied will enter service in
Ireland from 2011 with operator Irish Rail in re-
gional and long-distance railcar trains. The
traction modules are based on the envi-
ronmentally friendly Type 6H 1800 R83
engine which has a power rating of 360
kilowatts and meets the EU Stage IIIA oxide and particulate matter emission
emission standard. The units are dis- limits that came into force this year.
tinguished by fast acceleration, econo- The CAF BITRAC is fitted with the latest-
mical life cycle costs and low noise and generation MTU Powerline rail automation system.
vibration levels. As well as the ADEC engine management system, it in-
cludes the POM power output module for starting and
power current regulation and the PAU STAR power auto-
mation unit that provides a multiplicity of control, sensor
Change management subproject:
One of the subprojects handles the management and modulation functions such as constant monitoring of
of modified parts. Pictured, from left, are Herbert fan operation and coolant level.
Dengler, Wolfram Wiggenhauser (Series 4000 There are also ten more BITRAC orders on the books
assembly foreman), Rolf Wiggenhauser for power car versions with diesel-electric-only traction
and Rudolf Sievers.
systems destined for passenger services in Saudi Arabia.
Paul Vincent and
Robert Braithwaite of
Sunseeker, Mike Ferris
of MTU UK and Chris-
tos Ramnialis, Head of
Sales and After Sales
Region 1, signed the
extension to the gene-
ral contract to supply
MTU engines for Sun-
seeker yachts at the
engine plant in Fried-
MTU yacht engines in demand
FRIEDRICHSHAFEN (aka). Tognum has recently arranged Tier 2 and IMO – and are supplied with SOLAS certifica-
an early expansion to its existing framework agreement tion as standard.
to supply the Sunseeker shipyard with MTU yacht engines. Tognum power units for motor yachts score highly
Under the new agreement, which was extended to in North America too. The Tognum subsidiary MTU
2012, Tognum will supply V8, V10, V12 and V16 diesel en- launched the performance-enhanced version of the yacht
gines from its Series 2000 range and V12 and V16 Series engine at the Miami Boat Show in the spring of this year;
4000 units covering an overall power range from 810 to at the end of July, the first two 16-cylinder units were de-
3,440kW (1,086 to 4,613 bhp). MTU will potentially sup- livered to the yacht builder Viking. „The engine will be
ply 450 engines dependant on market forces, up to 2012. installed in a new Viking 82-foot sport fishing yacht“, said
Propulsion plants for high-speed yachts have traditionally Alexa Swindell of Marine Sales at MTU Detroit Diesel. The
belonged to MTU’s core areas of expertise. The latest new Series 2000 engine will build on the success of its
model in the Series 2000 range, the 2000 M94, produces predecessors, delivering greater power and enhanced acce-
the highest performance figures in its class as well leration.
as delivering an enhanced power-to-weight
ratio. In addition, Series 2000 and 4000 en- MTU
gines comply with all valid ship exhaust
standards worldwide – including EPA
Viking contract: The US MTU distributor Johnson & Towners has
supplied its first two Series 2000 M94 units to Viking in New
Jersey. Pictured, from left, are Pat Healey and Bill Healey of Viking,
Walter Johnson III, Dave Johnson and Bob Shomo of Johnson &
Iron men for Lake Constance Ferry
FRIEDRICHSHAFEN (kh). The first two eight-cylinder versions of the new for Lake Constance:
The first two 8-cylin-
generation of MTU “Iron Men“ engines for working vessels will power the
der Series 4000 “Iron
longest Lake Constance ferry operated by the municipal transport authority Men” working vessel
of the city of Konstanz. engines power the
The first engine was fitted in the 82-meter ferry prior to its launch at the be- new Lake Constance
ginning of October at the Bodan shipyard in Kressbronn . The second followed ferry launched in
a day later. The optimized “Iron Men” engines are extremely clean-running,
even without an exhaust treatment system. But with the added benefit of a diesel
particulate filter, the new 746-kW propulsion units are well inside the appli-
cable emission limits. Particulate matter emissions are reduced by as much as 99
Patented propulsion system
PERTH (ld). Australian shipbuilders Austal are currently
building a globally unique trimaran. Unlike other tri-
marans, it is powered not by four but only three
engines housed in the ship’s center hull. And they
are supplied by MTU.
Each of the three 20-cylinder Series 8000 units
delivers 9,100 kilowatts of power at 1150 rpm and
will propel the fast ferry at speeds up to 39 knots.
The patented propulsion system concept and the
craft’s corresponding hydrodynamics will primarily
save the operator fuel costs. Not just because the en-
gines are light and offer the best power-to-weight ratio
in their power class. The trimaran itself is a whole engine
lighter than previous designs.
The next generation of superfast trimarans (left) from Austal is propelled
by triple MTU Series 8000 engines (right, during installation).
New Series 2000 in 2011
FRIEDRICHSHAFEN (wob). The first of a new generation Friedrichshafen, Suzhou and Detroit and incorporate unit-
of Series 2000 engines are already going through their pump injection. However, the Mercedes-Benz commercial
paces on the test stands at Tognum subsidiary MTU vehicle engine, from which the MTU units were originally
Friedrichshafen, with the engines’ market debut sche- derived, is now being phased out so that MTU will no
duled for summer 2011. longer have access to economically-priced large-volume
The new engine has been comprehensively enhanced components for the series. The Series 2000 common rail
in order to meet future exhaust regulations and its intro- engine already used in marine applications will therefore
duction will see a slimming-down of the Series 2000 pro- be at the heart of the future 2000 series. „From 2014, we
duction range in future. According to Rainer Breidenbach, will be producing just one basic drive unit, one core en-
Tognum Executive Board member and ‘Engines’ COO, the gine, for all applications“, explained Klaus Pöpsel.
2000 engine is not „some exotic special edition but a bre- All components have been revised and enhanced and
ad-and-butter engine“. The significance of the new unit is the crankcase has been reinforced. As a result, ignition
likely to increase with time because, as project leader Klaus pressure can be increased by 30% as compared with the
Pöpsel reckons, considerably more 2000 engines will be unit-pump version and that means reductions in both fuel
built. One reason for this is a growing market. Another is consumption and emissions. One of the most crucial steps
that the MTU engine is simply better than the competition will be certification of engine compliance with the specifi-
in crucial areas which are decisive for purchasers, thus cations of the US Environmental Protection Agency
opening opportunities for increasing market share. (EPA).
The appearance of the
new engines will also mark
the beginning of the end for
the first generation of Series
2000 units introduced for C&I
(Construction & Industrial),
Genset and Oil & Gas applica-
tions in 1996. These original
engines are currently built in
New Series 2000 model:
The next generation of the MTU Series 2000 engine
(top) is due to come on the market in the summer of
2011. In August this year, the project team handed over
two prototypes for bench-testing (right).
400 Deutsche Bahn
V290 Class locomo-
tives have been
Type 8V 4000
400th Deutsche Bahn locomotive fitted with MTU engine
COTTBUS (mgu). On 8th October, Tognum subsidiary without having to invest in com-
MTU and German railway operator Deutsche Bahn (DB) plete locomotives. The new power
celebrated the 400th repowering of a V290 Class multi- units provide higher performance
purpose locomotive at DB’s Cottbus depot. Between while also reducing operating and
2002 and September 2009, MTU supplied a total of 412 maintenance costs. Due to their com-
Series 4000 diesel engines to Deutsche Bahn for the pact dimensions, they fit easily inside
modernization program. the available space in the engine bay and
The Type 8V 4000 R41 engines have a power rating of can also make use of the existing peripherals.
1,000 kilowatts (1,360 bhp) and have replaced MTU 12V Customized interface technology between the MTU engine
652 units, some of which have given over 30 years’ reliable management system and the train control system makes
service. By opting for repowering, the operator Deutsche for simplified traction unit installation.
Bahn is able to benefit from the advantages of new engines
New administrative HQ for Tognum
FRIEDRICHSHAFEN (aw). Tognum’s new administra-
tive headquarters building in Friedrichshafen is due to
be completed by June 2010.
The five-storey office block directly adjacent to Plant 1
will accommodate 400 staff from in the Corporate Func-
tions (V) and Corporate Service (C) divisions. That inclu-
des, for example, the Legal Department, Marketing and
Distribution, Quality Management, Auditing and Risk
Management, Strategy and Project Consultancy, Commu-
nications, Corporate Finance, Controlling, Human Re-
sources, Training and parts of Technical Services. Offices
which are vacated at Plants 1 and 2 will be occupied by
departments which were temporarly relocated to other
sites during recent years due to a lack of space. Tognum
will rent the L-shaped building on a long-term lease from
the investment group, although the contract also includes
an option to buy. The new Tognum admin building is growing:
Around 400 staff are due to move into the new office block in
Friedrichshafen which Tognum is renting from the developer.
First Large Engine
Service Center :
MTU Detroit Diesel
„Field Service Coor-
dinator Alameda“ –
at the sreen.
MTU DETR0IT DIESEL
First large engine service center opens in California
SAN LEANDRO/CALIFORNIA (jr). MTU Detroit Diesel MTU has been a supplier to the Marine Defense
marked the grand opening of its first Large Engine Ser- Market and specifically the U.S. Coast Guard for many
vice Center on May 27th in San Leandro, California, just years. This long standing relationship dates back to the
nine miles from the U.S. Coast Guard station in Alameda. first installation of twin 8V 396 engines in the Coast Guard
It enables us to provide the best maintenance and fleet – a fleet that today includes more than 70 Coastal
service support to the Coast Guard and also further Patrol Boats, over 100 Motor Life Boats, the Response Boat
demonstrates MTU’s ongoing commitment to the U.S. Medium, the new multi-mission capability boats, and the
Armed Forces. It has an 800 square feet office space and an National Security Cutter (NSC).
additional 4,450 square feet of warehouse. We consider this At 418 feet, the NSC is the largest and newest ship in
facility a model for future MTU Large Engine Service the Coast Guard’s fleet, powered by two 20V 1163 TB93
Center locations and plan to open additional service cen- engines including an LM 2500 GE turbine and MCS 5 Type
ters for the Coast Guard and the Navy as their MTU- 2 electronic controls and monitoring system. With its
powered fleets continue to grow. homeport of Alameda, the USCGC Bertholf is the first of
eight Northrup Grumman built National Security Cutters.
MTU DETROIT DIESEL
Customer satisfaction initiative
DETROIT (jr). In July, MTU Detroit Diesel launched a
Customer Satisfaction Initiative to enhance the cus-
tomer experience in Region 3.
Focusing first on the basics, MTU Detroit Diesel
set out to improve the process in four key areas: quo-
ting prices and products to customers; timeliness of de-
livery; availability of spare parts; and ownership of pro-
blems, i.e. standing behind what is built and taking re- her 50 are scheduled to be trained before the end of the
sponsibility for MTU products and services. year.
To measure its success, MTU Detroit Diesel has “Changes like these work to our benefit to establish
established customer-oriented Key Performance Indi- MTU as the company that truly cares about its custo-
cators. The company has also made strategic invest- mers, both in Region 3 and on a global basis,” said Ron
ments in company-wide business communication and Broekman, Project Manager Customer Satisfaction
customer service training. So far, over 125 employees Initiative.
have taken the MTU Start Service Training and anot-
MTU DETROIT DIESEL
Online employee compliance training training:
Thanks to the new
online training, Dis-
DETROIT (jr). Thanks to its newly launched online com- bursements Analysis
pliance training program, employees at MTU Detroit Manager, Shauna
Diesel now have the convenience of completing required Weathers, can com-
training from the comfort of their own workstations. plete her required
training in the com-
They also have the flexibility to start and stop a training
fort of her own work
module as their work schedule allows. station. Training
„We’ve received a lot of positive feedback from coordinator, Rebecca
employees,“ says Rebecca Reiter, MTU Detroit Diesel’s Reiter, is always
training coordinator. „Employees like the new system so ready to offer assis-
much more than the DVD-based version, which we used
to have. With the DVD based version, employees had little
opportunity for interaction and were without an assess- information. This is especially important when addressing
ment to prove if they did indeed retain the information.” topics that may change with new state and federal regula-
The online compliance training option improves upon tions, such as sexual harassment, discrimination, work-
the DVD-based system both in terms of engagement and place safety, ethics and hazardous materials.
information retention. The modules are completely inter- All employees will be required to complete the new
active, allowing for employees to complete exercises, which training, a task that will be completed by March 2010. „We
help reinforce the information, throughout the modules. In are excited about the opportunities that the online training
addition, employees must complete a quiz at the end of each platform provides,“ says Patrick Kapusta, MTU Detroit
module and receive a passing score on each quiz in order to Diesel’s Senior Manager of Human Resources. „Initially, it
obtain credit for the training. As these online courses are re- will be used for compliance training, but it has the func-
quired training, employees who do not receive a passing tionality to do much more. This has been a long-term pro-
score must retake the training until they are able to do so. ject that is coming to fruition and in the future we hope to
Another benefit of the online compliance training pro- offer more MTU Detroit Diesel specific training courses in
gram is that it is easily updated to provide the most current this type of web-based forum.“
FRIEDRICHSHAFEN (sto). Well trained new recruits with an academic education and experience of working abroad
do not grow on trees. That is why, last year, Tognum AG set up an 18-month trainee program for six recent further
education and university graduates.
This year the number of participants has almost doubled to eleven. „The positive experiences with the first year’s
intake encouraged the HR department and the mentors in the specialist units to increase the numbers,“ em-
phasizes recruitment marketing specialist Regine Siemann. Also the interest shown by new graduates
substantially increased. One reason is the broadening of international horizons in the shape
of the six-month placement in each of the three Tognum regions. Trainee Dirk Patzelt, who
is completing his posting at MTU Asia in Singapore, observes, „Learning to understand
Tognum as a globally active corporation means experiencing globalization at first
hand. A healthy portion of open-mindedness, curiosity and a willingness to
immerse yourself in the local culture are/were the essential requirements for
gaining fascinating insights and experience in a variety of sales projects.“
The new Tognum graduate trainees, from left: 1st row: Felix Köhler, After Sales; Björn Ibach,
Operations, Production; Georg Müller, Operations, Logistics; 2nd row: Markus Gerich, Finance and
Controlling; Martina Müller, Human Resources; Bastian Hanfeld, Operations, Assembly;
3rd row: Klaus Goffart, Research and Development; Matthias Schweitzer, Research and Develop-
ment; 4th row: Julian Jürgens, IT consultant; Sebastian Gieser, Marketing; Tetje Henning Dietrich,
Finance and Controlling
In brief … MTU Turkey starts cylinder liner production
Ekrem Kuraloglu is new CEO at MTU Turkey
ISTANBUL/TURKEY (sto). Since 1st Octo- ISTANBUL (sto). The phase-in of cylinder liner production at MTU Turkey is now in full
ber 2009, Tognum Group company MTU swing. In December 2009, the Tognum subsidiary will already be supplying over 90 Series
Turkey in Istanbul has had a new CEO in the 4000 cylinder liners per shift for engine production in Friedrichshafen and Detroit.
person of Ekrem Kuraloglu (46). He suc- By the Insight copy deadline in October, the trial and pilot production phase that
ceeds Muammer Iyi in the post. Ekrem
started right on schedule on 2nd September had already produced around 2,000 cy-
Kuraloglu – seen here on the right
with Tognum COO Rainer Breiden- linder liners. And so MTU Turkey has become the first-ever MTU production
bach (left) and subregional ma- site for MTU engine components outside Friedrichshafen.
nager Ingo Metzer (right) – pre-
viously spent 22 years in the
automotive industry. For the Cylinder liner pro-
past 15 years, he has been run- duction in Istanbul:
ning the bus sales division of Series production
Mercedes-Benz Turkey. was launched with
The new CEO studied business ad- a small celebration
ministration. Before joining Mercedes- in Turkey. In Fried-
Benz Turkey, he managed major projects richshafen there
for Caterpillar. He was also sales manager was a small farewell
at Honda and responsible for expanding the party for the project
sales and service network in Turkey. team members.
In his new position, he is currently in
charge of a workforce of 110 people. He sees
his key tasks centering around cylinder liner
production for the Series 4000, improving
utilization of workshop capacity and the two
test benches, and above all intensification of
sales activities in the local market. He also
aims to make MTU Turkey fit for future chal-
lenges through modern organization.
MTU presents supplier awards
FRIEDRICHSHAFEN (aka). Tognum
subsidiary MTU Friedrichshafen GmbH has Factory building in Datong completed
chosen Gienanth Eisenberg GmbH, the
Swiss company Peter Fuchs and ZF Marine DATONG/CHINA (sto). The new factory of Shanxi
of Padua as the recipients of its supplier
awards for 2008. North MTU Diesel Co. Ltd (SNMD) in Datong, 300 kilo-
meters west of Beijing was completed at the end of
Effective service in Asia October 2009.
DEHLI/DALIAN (aka). The MTU India The workforce of around 60 employees will move
office in Delhi moved into new premises in
into the premises at the end of the year and production
September. A new service agency was also
opened in Dalian in China in October. is due to start in June. The company was established in
2007 as a joint venture between the Chinese Norinco
Group and MTU Asia. The general manager of SNMD
is Bernd Lemkamp. Peter Kneipp, CEO of MTU Asia
is also a director. The main focus is on Chinese nuclear New factory takes shape in Datong, China:
power stations, marine applications and after-sales in Pictured (from left) are Bernd Lemkamp,
General Manager of Shanxi North MTU
the mining sector. By establishing the factory in Da-
Diesel Co. Ltd., Rodney Chang and the site
tong, the operation has satisfied the Chinese govern- manager, Mr. Du.
ment requirement for local investment and produc-
tion by foreign companies.
In honor of the fallen:
A new fireboat for the New York
City Fire Department is powered
by four 12-cylinder MTU Series
MTU DETROIT DIESEL
Fallen heroes remembered
NEW YORK (jr). During the terrible events of reminding us all of the incredible sacrifices so
September 11, 2001 when terrorists attacked the many of our members made eight years ago.“
World Trade Center in New York City, 343 New The Three Forty Three is the first of two new
York firefighters and paramedics lost their lives state-of-the-art vessels, and it has been specially
while trying to save the lives of others. designed to allow firefighters to operate even in
Eight years later, on September 11, 2009, the extreme circumstances such as another terrorist
New York City Fire Department (FDNY) remem- attack. Each vessel has four MTU 12V4000 M70
bered those fallen comrades with the launch of its engines provided through Atlantic Detroit Diesel-
newest firefighting vessel – the „Three Forty Allison. Management of the engines, gears, and
Three“ – named in their honor. As a fitting memo- shipboard monitoring is also part of the scope of
rial, the steel numbers 3 - 4 - 3 on the ship’s supply.
bulwarks forward and in the transom were cut by The new 140-foot, 500-ton, $27 million dollar
the FDNY crew using actual steel from the World boat will be the country’s largest fireboat with a
Trade Center. maximum speed of 18 knots. The Three Forty
„On September 11th, we all saw how impor- Three will provide the FDNY with the latest tech-
tant fireboats are to New York City. The FDNY nology available, including the capability of pum-
Marine Division rescued and transported hun- ping 50,000 gallons of water per minute; nearly
dreds of citizens and provided the only supply of 30,000 gallons more than its predecessor.
water to battle the fires at the World Trade Center The Three Forty Three was launched from
for many days,“ said Fire Commissioner Nicholas Eastern Shipbuilding of Panama City, Florida and
Scoppetta. „The Three Forty Three will signifi- is expected to arrive in New York City in Decem-
cantly improve our ability to respond to emergen- ber. It will be assigned to Marine 1, stationed on
cies in and around New York Harbor, while also the Hudson River in Manhattan, New York.
The standard production Series 1600 engines have been coming Dream start:
Production of the
off the assembly line in the Überlingen plant since 1st October. Series 1600 in
Although the new model has made a discreet entry into the en- in October.
gine range, on closer inspection of a number of subprojects it is
clear that the overall Series 1600 project is having an extensive
dynamic effect that is providing impetus for many changes.
The new Series 1600 has been in volume production since 1st October
RIEDRICHSHAFEN/ÜBERLINGEN. up, mostly by hand, on display boards and flip-
The newest and smallest engine charts – production plans, flowcharts, job tasks,
made by Tognum company MTU suggested improvements. “Aims and tasks have
has been in series production as a to be made visible,” Dr. Beulker expounds.
12-cylinder version for power gene- So the production area is also a super-sized
ration applications at the pilot plant meeting room. And what is constantly planned
in Überlingen since the beginning of October. and improved there is implemented on the spot.
Behind that simple fact lies an enormous “We don’t want to be a team fighting for survival
achievement. Not only processes and structures but a learning, forward looking organization,”
but also the tasks, authorities and role percep- states Dr. Beulker. So practical production has
tions of managers and staff have been intensive- been accompanied by constant discussions at all
ly rethought and redesigned. levels from the very first day. And almost always
at the center of the action is plant manager,
Learning factory Dr. Klaus Beulker. Everyone has a line of com-
“The idea of setting up an entirely new fac- munication leading directly to him. The various
tory for a new product has proven correct,” un- threads of production, quality management and
derlines plant manager Dr. Klaus Beulker. The logistics all join up with him – a boss within
generously dimensioned rented premises pro- reaching distance. He combines the roles of ma-
vide the framework for perfectly harmonizing nager and foreman. Which is why he is able to
office, production, bench-testing and warehou- motivate his staff personally, permanently and Production launch on 1st October:
se areas. The production plant has been desig- while imparting a wealth of knowledge to During an inspection of the assembly plant
in Überlingen project manager, Thomas
ned as an integrated factory in which all proces- greater achievements and responsibility. “Our
Harr (right) and plant manager Dr. Klaus
ses are closely interlinked. In that way, two appa- target is the employee concerned, who looks Beulker (center) showed Tognum Chairman
rently contradictory principles can be success- beyond his or her immediate job and, by doing Volker Heuer the various stages of engine
fully combined – sound, reliable processes on so, understands it better.“ production.
the one hand and flexibility, constant advance-
ment and change on the other. The guiding High-capacity production
principle is that of material flow. Across all pro- In order to accomplish high process reliabi-
cess stages, only what can be used by the next lity, fast throughput times and the highest levels
stage is planned and produced. of production quality, new methods were intro-
As abstract as that might sound, its applica- duced. Thus every station is connected to the
tion on the factory floor could not be more electronic brains of Series 1600 assembly, the
practical. Directly adjacent to the assembly line PS2 system (see IT below). The cylinder heads
and in many other places, all the information are completely preassembled alongside the main
that immediately advances the project is written assembly line so that they can then be bolted
Every day the managers discuss the
pending tasks right next to the assembly
line – assisted by display boards and
flipcharts showing the latest production
figures, work schedules and suggested
onto the cylinder blocks in a single operation. within a few seconds it is up to maximum out-
The cylinder head mounting station bolts down put. The legal requirement is only 35 percent. As
the cylinder heads automatically within a matter Jens Schneemann points out, “For a generator
of seconds to precisely the correct torque. The set to deliver that sort of per-formance, a client
production plant design unit in the Plant 1 Spe- would normally have to order a much more
cial Production Department designed around powerful and more expensive engine with an
180 different items of production equipment for output well above the actual demand.”
assembling the Series 1600, from simple drifts to Another aim was a clear and simple engine
the cylinder head pre-assembly station. concept. The unit had to match the strict cost
targets, comprise components that are straight-
Inspection with lean production manager: Highly automated hot test bench forward to assemble, offer high performance, ef-
Plant manager Dr. Klaus Beulker (right) In the immediate vicinity of the assembly ficient fuel consumption and be optimized for
regularly tours the facility with his lean line, a highly automated hot test bench has been low emissions. Moreover, a fully developed de-
production manager Roland Schiele
(center). Here they are also accompanied
installed on which the complete test sequence sign capable of proving itself in practice from
by logistics expert Armin Jeschin. including setting up is completed in only 17 mi- the outset was to be produced in a short space of
nutes. “The engine is drawn onto the test bench time. “We work closely with our suppliers and so
in a special fit-up cage. The connections for fuel, often benefit from their system engineering
water and electricity go through the cage and are skills, including in the automotive supplier in-
automatically connected up to the test bench dustry,” Jens Schneemann relates.
system as soon as the fit-up cage is in position,”
explains Ralf Orthober, test bench project ma- Evolution of new parts
nager, who developed the concept together with Decisive for intensive and rapid develop-
a supplier. ment is the evolutionary development method.
It involves developing a series of incremental
Series 1600 development – improvements. The aim was not a high-end
simply ingenious, ingeniously simple solution but one which was at the same time the
Production and handling equipment: “The stress on an engine as it gets off to a ra- best technical and most economical concept. A
The Plant and Equipment Design unit has cing start, with tires screeching, is nothing com- good example is the exhaust system, which is
supplied over 180 items of equipment.
pared to the demands made on a gendrive engi- subjected to extremely high thermal stresses of
ne during ramp-up,” says Jens Schneemann, de- over 700 degrees Celsius. Although even the first
velopment subproject manager – and he is not design model (the “A“ specimen) was competi-
exaggerating. When there is a mains power ou- tive, a subsequent series of individual measures,
tage, an emergency backup generator has to res- which also improved functionality, achieved a
pond as quickly as possible. In such circumstan- saving of around 45 percent.
ces, the Series 1600 gendrive engine is in pole
position among its rivals. It can take up 65 per-
cent of maximum load instantly on startup. And
Fast-throughput prototype assembly One of them is the V12 version for agricultural
and test benches and industrial applications. It will meet the
Prototype assembly for the Series 1600 ultra-strict EPA Tier 4 final emission require-
allows up to nine trial engines to be worked on ments that come into force from 2015. The en-
simultaneously. Without such high efficiency gine shown in the group photo on page 41 was
combined with the flexibility of the three spe- exhibited at the “Agritechnica” trade fair for
cial Series 1600 test benches, time and cost-op- agricultural machinery in November.
timized design testing based on fast throughput
times would not be possible. As with the new hot Value engineering plays central role
test bench, special adaptor cages for assembling “We have saved around 30 percent of the
the engines on test bench pallets ensure quick cost of producing the camshaft for the Series Production-friendly design:
setting-up times. The test benches have been 1600,” Werner Dillmann, a member of the Value Eduard Görner bolts completely
preassembled cylinder heads onto
equipped specially for engine development. The Engineering Department proudly reports. In
the cylinder blocks.
temperature and humidity of the intake air can contrast with the original plans, the camshaft is
be precisely adjusted so that the readings taken not a solid shaft but a tube. That saves metal.
are much more meaningful. As well as two test Finding cheaper solutions that still perform the
benches with water brakes, there is also a tran- same function is generally the prime task of
Automated hot test bench:
Ralf Orthober, test bench project
manager, helped to design the
new hot test bench. The en-
gine is automatically drawn
onto the test bench (right)
on a fit-up cage.
Fuel, water and electrical
connections to the test
bench are also joined up
sient test bench equipped with a 4-quadrant value engineering. Examining all aspects toget-
asynchronous motor which can be used to her, from materials through manufacturing
apply dynamic load-change cycles. Such facili- technology to packaging, is what makes the
ties are absolutely essential nowadays in order to work an interdisciplinary exercise. “First of all,
obtain the emission certificates for certain en- we bring the right people together. Then col-
gine types. lectively we work out all the technical possibili-
At present, developers are working fever- ties for fulfilling the intended purpose, assess
ishly on more variants of the Series 1600 engine. them in terms of overall cost and then decide
Testing the new Cameo software:
The new Cameo program that is
subsequently to be used on other test
benches as well is tried out on the
Series 1600 test bench. Development
specialists like Dr. Thomas Bubolz (left)
and Gerd Rupp (right) work closely with
the test bench operators such as
Yeison Kratofil pictured here.
which is the most economical solution,” explains hour test was used to verify that the new method
Volker Wachter, value engineering manager. was effective. Another simpler and more econo-
Value engineering plays a central role in the mical solution was a new method of detecting
Series 1600 project in particular because the cost engine speed. Instead of using a laser-machined
targets are so ambitious. One value engineering disc with teeth as in the past, holes were drilled
method that results in more economical solu- in the flywheel to perform the same function.
tions and, above all, ones that offer greater pro- “We have been able to utilize a lot of cost-saving
cess reliability is simultaneous engineering with potential with the help of our suppliers in that
suppliers. “In contrast with conventional rela- way,” stresses Volker Wachter.
tionships with suppliers, the starting point for
Series 1600 design: the discussions was a detailed examination of the Local marketing
The Series 1600 was designed entirely supplier’s production technology and capacities. “Customers have recognized the benefits of-
by the Development subproject team
By site visits to the suppliers, we found out about fered by the world’s first thoroughbred gendrive
of which Ralf Gunkel is a member.
their facilities and got a feel for the production engine – and the demand has been accordingly
processes,” Werner Dillmann elucidates. high,” Harry Günthör of the sales subproject
That makes sure that the components can team is happy to report. The successful sales
actually be manufactured economically and reli- debut of the new Series 1600 can be attributed
ably on the available machinery. In that regard not least to the numerous marketing activities
too, the suppliers played a very active role. As that the subproject team put together with the
a result of a suggestion by one supplier, for in- assistance of other specialist units. Among the
stance, it was possible to dispense with the highlights were the initial product launch in
usual method of hardening gear-shaft surfaces. Konstanz, the PowerGen trade fair in Cologne
Instead, they were hardened by rolling. A 1,000- in May, the Powergen show in Las Vegas in Sep-
tember and other exhibitions around the world.
Numerous other distributors, OEM clients and
Component test bench:
Development engineer Daniel Speiser
Background … customers attended Series 1600 road shows in
countries across Europe, Asia and the USA from
(left) and test bench fitter Leo Wagner Cameo role in engine optimization
The new Cameo software is being trialed Spain to Indonesia, and from Thailand to China
with an oil pump that is being tested in
conjunction with an oil filter module. on the Series 1600 test benches. With its help, and Japan. The initial invitees comprised all
statistical test planning, also called Design of major clients plus a broad selection of potential
Experience (DoE), can be carried out. It enables new customers. “Because we are aiming to ex-
empirical models of engine interrelationships to
ploit new markets, to that extent we spared no
be pro-duced with the minimum of work. “That
means you can optimize an engine’s fuel con- expense in our efforts to convince the world-
sumption in relation to the legally required wide market of the benefits of the new Series
emission limits, for instance,” explains develop- 1600,” reveals subproject manager Nadine Buh-
ment engineer Dr. Sven Christian Fritz. mann.
The events focused heavily on the product’s
strengths – the engines are tough, economically well – and we will be able to use that as a good
priced, environmentally friendly, fuel-efficient sales pitch in our future marketing activities,”
and technologically state-of-the-art. And the expands Harry Günthör.
fact that the power unit offers a diversity of cus-
tomer-oriented options despite its high degree “Webshop” sales
of standardization is an achievement attribut- A special software program was provided for
able not least to Product Line Management who, sales and distribution of the production engines
together with the Sales Department, conducted and the sales technicians were given training on
exhaustive market studies which identified not it. The “webshop” is simple for distributors to
only what customers required but also the high use. It allows all a customer’s desired options to
sales potential of the new product before de- be put together into an order. “The system is
velopment was started. easier to use than our standard tool IPAS,” stres-
ses Gudrun Patulski, who set up the system and
System development with clients also reconfigured SAP CS2 for the purpose. “So
using pilot series engines far, the new webshop has already been very ac-
A decisive aspect for the sales of the genset tively used,” Harry Günthör confirms.
engines is their system-compatibility. In terms
Test shop (top):
The prototype engines are built on
three assembly lines in all.
Development subproject team:
Back, from left: D. Speiser, J. A. Reitz,
S. Conrad, T. Bildstein, H. Conrad,
U. Fissenewert, Y. El Filali, T. Heise,
S. Gessler, J. Schneemann.
Front: M. Herrenknecht, M. Arndt
(assistant to Dr. Dohle, former Series
1600 subproject manager), F. Henssler,
J. Engelhardt, J. Hiry and M. Wiedmann.
of their dimensions and also a large number of Further network expansion for After Sales
interfaces, they have to be capable of integration The After Sales department has also seen
in a complete genset unit as easily as possible. So some reorganization. The service network is
from July 2009 prior to their market launch, being further expanded hand in hand with Sales.
pilot series engines were sold to a number of Petra Kinder, After Sales network developer, held
OEM clients including Tognum subsidiary workshops for distributors to prepare them for
MTU Onsite Energy Corporation in Mankato. the establishment of a closer service network and
The advantage was that customers were able to inform them about the service targets, service
build prototype gensets with the engines and re- center equipment and staff qualification. For
port back any modifications they would like. their part, the attendees set out their require-
The development department at MTU was thus ments. Especially those customers whose appli-
in a position to adapt the design of the standard cations operate in tough continuous duty condi-
production engines. “In that way we established tions demand rapid availability of support ser-
solid foundations at an early stage for an all- vices. “In all regions we have a relatively close-
round, on-schedule production launch and meshed network in the coastal areas due to the
created a high level of demand for the future as numerous marine applications. So, above all, we
Testing for tightness:
Achim Wegerer checks for leaks. Every
conceivable device for the purpose is
available at assembly station 18.
need to expand the network in the inland areas ty control, production and financial controlling
for the Series 1600’s many genset and other ap- to after sales. In PS2-BR1600 all subsystems are
plications. Generally, our aim is to be available highly integrated into a harmonized overall sys-
24/7,“ Petra Kinder relates. “Due to the high unit tem – the essential foundation for high-quality
production figures there will also be a large de- volume production similar to the automotive
mand for spare parts,” explains Jochen Kling, Af- industry with a comparable variety of options.
ter Sales subproject manager. It will primarily be “The basis for all of those processes,” relates
covered by the new parts depot in Überlingen. Marian Klem, subproject manager, “is a central
Low life-cycle costs (LCC) are achieved by parts list for all business processes which is pro-
low consumption, but also by durable materials duced by the Development Department.”
Camshaft value engineering: and components. In addition, all components Among the system’s highlights is an integrated
Werner Dillmann (left) of Value Enginee- are easily accessible and can be replaced or ser- option configuration facility.
ring and designer Christian Haug present
viced in a relatively short time. The mainten-
the cost-optimized camshaft.
ance concept for the Series 1600 was designed in Customer order registration and sales planning
close cooperation with the LCC team headed by Distributors anywhere in the world can
Patrick Stöckle. Once again it involved bringing order engines around the clock from the “web-
several different groups together around the shop”. The order configuration is recorded from
table to make the engine competitive from the the very first point at which the customer order
start – the Development Department, the After is registered. On that basis, all components re-
Sales LCC team and Quality Management. To quired are automatically identified via the parts
make sure that the engines are serviced on site list. The customer orders are also automatically
by well qualified technicians, the trainers at the offset against the sales planning figures (MRF)
20 training centers around the world themselves of all three sales regions.
undergo intensive training at the Friedrichs-
hafen Training Center where they benefit from Procurement based on sales code
the very latest training media including inter- The ordering process with suppliers is also
Sales activities close to the market: active 3D graphics.
Subproject manager Nadine Buhmann
(right), Harry Günthör and other
colleagues organize the market launch.
PS2-BR1600 – Terms explained …
the brains behind all core processes
It is one of the most powerful and complex is a systematically planned method of
systems in the whole project. We are talking finding the most economical way of producing
about the SAP IT (information technology) sys- a product for a specific purpose without dimini-
tem PS2-BR1600 which was developed by the shing its quality, reliability or marketability. It
aims to identify the lowest-cost option at every
Series 1600 IT subproject. It keeps all Series
stage of the product life cycle. Value enginee-
1600 core processes working from customer or- ring provides the means by which a company
ders through development, procurement, quali- can become or remain competitive.
After Sales: “The maintenance concept is
customer-friendly and competitive,” accor-
ding to subproject manager Jochen Kling.
highly automated. The sales codes in the cus-
tomer orders serve as the basis on which the ma-
terial requirements planning system automatic-
ally identifies all the components needed. The
system then raises an order/requisition and for-
wards it to the supplier on the same day. The
supplier then delivers the goods just in time for
production, thereby minimizing stock quanti-
ties and the associated costs, and enabling high
The system can also manage, pre-sort and
prepare the assembly data for various processes.
A work schedule sets out all assembly processes
in Überlingen. Every station has a small monitor
networked to PS2-BR1600. As an engine reaches
each station, the data sheet on the trolley is scan-
SAP IT system PSR2 in Series 1600
ned by a barcode reader. PS2-BR1600 then lists
assembly: When an engine reaches the
the required operations on the monitor screen – next assembly station, the data sheet on
an important contribution to process reliability. the trolley is scanned by a barcode reader.
“It allows staff to concentrate better on the ac- PS2-BR1600 then lists the operations re-
tual assembly tasks,” emphasizes assembly fore- quired on the screen in the background.
man Uwe Gundelsweiler.
Teamwork in project rooms
PS2-BR1600 was produced by the IT core
team together with representatives of Engineer-
ing, Operations, Sales, After Sales, Quality Ma-
nagement, Logistics, Finance and Controlling, IT subproject: The IT System PSR2 supports all core
and Infrastructure. A total of around 140 staff processes for the Series 1600. the picture shows
subproject manager Mirian Klen (right) and Norman
contributed to the work. As Marian Klem points
Koselowski, IT infrastructure project manager.
out, “To cope with the scale of the assignment,
special project rooms were set up in Building
30/4 in Plant 1.”
Words: Wolfgang Stolba, Pictures: Robert Hack
F RIEDRICHSHAFEN (sto). This might look like airport runway lights. But it is actually
the command center of the pallet store in Hall 34 of Plant 2 in Friedrichshafen. As many as
1,000 containers pass through here on roller conveyors every day. The items they contain are put
together with supplies from other
parts of the warehouse for delivery
to the production, assembly and
dispatch departments. There are
around 19,000 storage locations
available for the purpose including
the pallet store. Markus Burkardt
(left) and trainee Philipp Wied-
mann are part of the team that
operates the control panel.
Pictures: Robert Hack
1. Boxer MRAV: 1
A Type 8V-199 engine
capable of 530 kW
drives the 33-tonne
2. Husky mine
Its engine is a
150-kW Type 6R 106
unit supplied by MTU.
The 500th Type
6R 106 for the Husky
and the excellent
were celebrated in
proper fashion at
MTU South Africa.
In attendance were
(from left) Paul
Bower, Lyall Volkwyn,
Dave Nicol, Emil
Stohr, Kobus Janse
van Rensburg, Mark
Barrett and Hilton
Lightweights getting heavier
The Series 106 and 199 engines are offered by MTU Light but powerful drivetrains for the new light vehicle
types. The South African Husky is a prime example. It has
as bespoke power units for light and medium-
been successfully deployed by Canadian and US forces on
heavy military vehicles. The more so in the light of UN missions and for protecting personnel and vehicle
convoys in Iraq and Afghanistan. MRAVs such as the
the latest trend – light wheeled vehicles are getting
Boxer can be transported quickly by aircraft to virtually
heavier. So now they need greater reserves of any deployment zone. Thanks to their power units,
they are also very fast over the
ground once in the field.
The 530 kW (721 bhp)
F RIEDRICHSHAFEN/CAPE TOWN (sto). The Series
106 and 109 engines for military vehicles place Tog-
num right up with the pace. A total of 228 MTU Type 8V
Type 8V 199 can move
the Boxer at a top speed
of 103 kph. And with its
199 engines (530 kW) have been ordered by the Dutch and compact 150-kW Type
German armed forces for the Boxer multirole armored
vehicle (MRAV). Another 187 units had previously been
ordered by the German army in 2007. And a whopping 500
Type 6R 106engines have been sold by Tognum subsidiary Technical Data
MTU South Africa to the manufacturer DCD Dorbyl in Engine: 8V 199
Johannesburg for its mine detection and clearance vehicle. Power: 530 kW (721 PS)
Now known as the Husky, the vehicle has become a top- Torque: 2.700 Nm
… with Knut Müller, head of Defense on the strengths
and potential of the Series 106 and 199.
Mr. Müller, the sales figures for the Series
106 and 199 are impressive. How important
are they to our defense business?
They form a broad product range together
with the larger engines and so contribute to the
long-term stabilization of our business. They have their
own independent product cycle and so have been able to
counterbalance other less successful areas in the past year of
Light vehicles are getting heavier. Does that mean
that some time or other we will no longer need smaller
In the future we require more engines with a broad range
of power outputs, i.e. with a choice of cylinder configurations.
That means the client can equip vehicles of different weights
with engines of the same basic model, which offers logistical
and economic advantages. In addition, military vehicles are
constantly updated over a period of service extending to at
least 30 years, becoming heavier in the process. Therefore, the
engine requires enough power in reserve. The new vehicles are
more heavily armored than their predecessors and so heavier
from the outset. That is where our Series 106 and 199 engines
come into their own.
units indemand for military vehicles
The Series 199 is derived from the Mercedes-Benz OM 500
6R 106 engine, the Husky easily tackles rough terrain and engine. Is a truck engine the right basis to start from?
steep gradients. Yes, because for the light and medium-heavy vehicles, we
Many armed forces no longer use vehicles without ar- need engines that are powerful and economical at the same
mor protection in crisis deployment zones. The risk of at- time. The truck engine has an economical basis as it is made
tack by improvised explosive devices is too great. So vehi- in large numbers. We turn it into a high-performance engine
cles are now more heavily armored and carry additional that meets military requirements.
protection against mine attacks. As a result, the
weight of the vehicles is considerably greater in That sounds good. But isn’t there still some doubt as to
some cases. More weight without losing agility whether the substantial orders in 2009 might prove to be
thus demands compact and even more power- a flash in the pan in 2010?
ful engines. „That trend is very welcome for The technological and economic potential of the Series
MTU because our enhanced-power Series 199 is a long way from being exhausted. The top-selling
199 units derived from the OM500 truck en- Piranha V made by the Swiss manufacturer Mowag is being
gines cover precisely the range of outputs re- tested out right now with the new V6 version (6V 199). And
quired,“ points out Knut Müller, the man in we have increased the engine’s power to 430 kW. Its starter
charge of the Defense Department in Fried- generator and its outstanding torque mean that this engine
richshafen. will be setting the benchmark in the near future.
Words: Wolfgang Stolba
Pictures: MTU, Deutsche Bundeswehr, MTU South Africa
Gensets from Mankato:
Tognum’s US plant in
has been making the new
Series 2000 gensets since
July 2009 and the Series
4000 and 12V 1600 ver-si-
ons since 1st October.
They will be joined by the
other Series 1600 cylinder
configurations by the end
MTU ONSITE ENERGY
in large numbers
Tognum expands high-volume business
in electricity generator modules
MTU is establishing a new genset product line for sale in large numbers. The new gene-
ration of MTU Onsite Energy diesel generator sets based on the Series 1600, 2000 and
4000 engines will be sold directly to end users via the global distribution network.
Designed for use as emergency backup, peak-load and continuous-duty generators,
they are already being produced at the Tognum plant in Mankato/USA and, since
November, at the Togum facility in Magdeburg, and will soon be made at the factory
in Suzhou, China, as well.
M ANKATO/USA. “Everything was just right
– the Bavarian Oktoberfest ambience, the
atmosphere and, of course, the great interest
Energy diesel generator sets. Center stage at the
event was occupied by the prototype of a stan-
dard genset based on the new Series 1600.
shown by the guests in our new standard gen- “With these new gensets we are expanding
sets,” was the verdict of Christof von Branconi, our involvement in the standard-system busi-
Tognum COO with responsibility for the Onsite ness, and thus developing a closer relationship
Energy & Components Division, on a customer with the end user,” emphasizes Christof von
event organized by the company at its facility in Branconi. Up to now, MTU has primarily sup-
Mankato, USA, at the beginning of October. plied engines to genset producers who make
Over the course of the three-day event attended them up into generator sets, or produced cus-
by 70 distributors and 230 end users from the tomized project-based system solutions for Oktoberfest atmosphere in Mankato
USA, Tognum presented its new MTU Onsite individual clients. In addition to those types of (above and below):
Energy brand product line called MTU Onsite business, which will continue to enjoy a position The Onsite Energy & Components Division
presented the new genset product line at a
of importance, the gensets produced indepen- Bavarian-style customer event in Mankato.
dently by Tognum will be offered directly to a Center-stage was a prototype based on the
wider market of end users. That includes the Series 1600 (left).
owners of large buildings such as banks, data
centers or administrative offices, and applica-
tions in industry and agriculture.
The new gensets will be produced as stan-
dardized models available with short delivery
lead times. They will meet a broad range of cus-
tomer requirements. Depending on the power
rating needed by the customer,
they consist of a choice of
either a Series 1600,
2000 or 4000 engine,
an electricity gene-
rator, the electronic
control system and a
radiator, all mounted
MTU ONSITE ENERGY
Modular design concept
Depending on the output required by the
on a common baseframe. The choice of power customer, the gensets now consist of a choice
outputs ranges from approximately 270 to 3,250 of Series 1600, 2000 or 4000 engine, an elec-
kW. Although the gensets are supplied as basic tricity generator, the electronic control system
and a radiator, all mounted on a common base-
models with a standard specification, buyers will
frame. The basic components are complemen-
have numerous individualization options avail- ted by a comprehensive range of additional op-
able from their local contacts, the distributors. tions such as electrical power switchgear, sound
They will be able to select from a choice of stan- insulation covers and coolers. The client can
dardized variations at fixed prices. create a custom configuration from the choice
of high-quality components. The modular de-
sign concept offers the buyer an economical
solution and short lead times.
Development team in Mankato: Sale of the first units based on the Series 2000
The team that made the first proto- started in July 2009. From 1st November, the pro-
type of the new Series 1600 gensets
duct line was expanded at the top and bottom end
comprises, from left, K. John, ODA ma-
nager; K. Snaza, designer; N. Majeski, by the addition of the Series 4000 and the new V12
Applications team leader; K. Black, Series 1600 respectively. By the end of 2010, the
Electrics team leader; C. Dieken, lower end of the range will be completed with the IPAS system and the distributors given training on
Applications; T. Riemann, COO; introduction of the other cylinder configurations it, so that ultimately they are able to exploit the
K. Schäfer, Electronics; T. Bode, fitter;
of the Series 1600, so that Tognum can claim to be markets. “A trained distributor can order a stan-
W. Farr, Series 1600 Genset Develop-
ment subproject manager. a genuine full-line supplier. dard genset on the IPAS system in ten minutes; the
According to Christof von Branconi, the main delivery times are around six to twelve weeks, de-
focus of the sales activities, apart from the already pending on model,” Frank Forberger indicates.
well established business in Region 3 (North Ame- The Mankato plant is playing the lead role in
rica), will be on around 20 other countries in Sales the production of the new units. The factory has
Regions 1 and 2. Especially places where gensets been building gensets with Series 2000 engines sin-
with MTU engines have previously not been sold ce July this year, with the Series 4000 since August
or only sold in small numbers, such as the Middle and with the Series 1600 units since November.
East, Latin America, North Africa, Australia and Mankato is also responsible for developing the Se-
Eastern Europe. This significant step from engine- ries 1600 gensets, while the Friedrichshafen plant
only to standardized system business involves ma- is responsible for the Series 2000 and Series 4000
jor challenges for the worldwide sales and service models. In order to bring production closer to the
organization, which includes the distributor net- market and so save costs in the other regions as
work as well as the sales regions. The team around well, the gensets will also be assembled in Magde-
Frank Forberger, Head of Onsite Energy Sales, will burg, Germany and Suzhou, China, from 2010.
have the job of bringing the distributors up to
speed in terms of sales and service. The corpora- Strategy for the energy market
tion has had to adapt to the new product line in- For the first time in the company’s history, a
ternally as well. Orders will be processed using the special image was developed specifically for the
energy market for the introduction of the new
gensets. Because, historically, the business has its
roots in other areas. “Although we have been sup-
plying highly sophisticated emergency backup
gensets for nuclear power stations for some time,
and to a limited extent for airports, hospitals and
data centers – most of which are ‘on our own
doorstep’ so to speak – we never paid special at-
tention to the energy market,“ elucidates Christof
von Branconi. That only started in 2008 with the
creation of the new Tognum brand, MTU Onsite
Energy. Tognum is now tackling the energy mar-
ket in earnest and, with diesel and gas-fueled gen-
sets and fuel cells, is venturing into new markets
with the aim of selling more products in that way.
With the new standard gensets, the group is
pursuing three aims in particular, as Christof von
Branconi explains: “Firstly, we want to wrest as
many customers as we can from our competitors. – and not for stock but only when they are orde- Project team in Friedrichshafen:
Secondly, we are fundamentally technically capa- red. MTU Onsite Energy Corporation in Manka- Back, from left: Amanda Fischer,
Bettina Ernst, Anne Heiland,
ble of doing that on our own by selling complete to is ideally equipped for such demands. Having
systems and now want to do so to a greater degree. produced gensets under the name of Katolight Front, from left: Andreas Ruess,
And thirdly, we want to find a direct route to the from the 1950s until 2008, the company enjoys an Siegfried Metzger, Peter Bossert,
end user.“ Generally, he points out, the genset outstanding reputation. “My staff have substantial Armin Allgaier, Armin Gröber, Susanne
business is a better means, compared with the experience and exceptional skills not only in de- Wolter and Melanie Meschenmoser.
other applications, of reaching the end users and velopment but also in production, logistics and
so ultimately selling more engines – in a market sales,“ points out Armin Gröber, CEO of MTU
that is growing with the expanding population Onsite Energy Corporation in Mankato.
and rising standards of living. The plant has built impressive numbers of
The biggest challenge is volume-producing gensets with Series 2000 and 4000 engines since
model variants that reflect customer requirements 2006 – including in 2009, the year of the financial
System engineering experts:
The Mankato factory has decades of
experience. On that basis it now makes
gensets using the Series 2000, 4000
(pictured) and 1600 in large numbers
and with short lead times.
MTU ONSITE ENERGY
crisis – though not as yet as the new standardized “Advantage of the newcomer”
system modules. Thirty-one gensets were made
with Series 2000 engines in 2006 and 166 in 2008, Christof von Branconi, Tognum COO with responsibility
while ten were built with the Series 4000 in 2006 for the Onsite Energy & Components Division, and
and 240 in 2008. Reviewing those figures, Armin Armin Gröber, CEO of MTU Onsite Energy Corporation in
Gröber observes, “We created the necessary capa- Mankato, talk about the new genset product line.
cities at exactly the right time and have set up a The production of standardized gensets opens up new
new plant in leased premises for the smaller units markets. However, only the development and production
up to the Series 1600. The existing factory will be expertise of the Mankato plant combined with the expan-
used for the larger gensets with Series 2000 and sion of sales and distribution activities can ensure that
4000 engines. And our Mankato work- the opportunities those products offer are actual-
force did all of that without outside ly utilized. That is made clear by the following
assistance. Experts have certified interview with Tognum COO, Christof von
that it is state-of-the-art.” Branconi, and CEO of MTU Onsite Energy
Corporation, Armin Gröber.
Words: Wolfgang Stolba
Pictures: Robert Hack, MTU DD Mr. von Branconi, what are the oppor-
tunities that the genset market offers?
Christof von Branconi: It offers us a
good opportunity to sell more engines, speci-
fically by continuing to supply OEM clients on
the one hand, and on the other by establishing
ourselves as complete system suppliers and thus gai-
ning access to end users in markets where we have not done
business in the past. Markets that are growing with the ex-
panding population and rising standards of living. Overall,
we are targeting a market share of around 15 percent.
By pushing out competitors?
Christof von Branconi: In some countries, yes, but
overall it is a growing market and therefore not just a case
of predatory competition. Especially in Africa, Latin Ame-
rica, the Middle East and Asia, we are looking to profit
from market growth.
Aren’t major genset producers already there?
Christof von Branconi: Not everywhere. Every large
tower block, data center and hospital has an emergency ge-
nerator. In total there is a vast demand for distribution and
still numerous large and small areas that haven’t been co-
vered. But basically you are right: we also have to challenge
the position of our competitors by our unique selling points.
… which are?
Christof von Branconi: The price alone is not the deci-
ding factor. It is a case of the right mixture of a number of
factors, intelligent solutions, such things as flexibility, tech-
Worldwide production: The gensets are produced at the nology, proximity to the customer. And it is important that
American facility in Mankato, Minnesota (pictured), and in we offer a range of defined individual variations.
future will also be made at Magdeburg in Germany and
Suzhou in China.
Why did we buy the US company Katolight, or MTU successor to the De-
Onsite Energy Corporation as it is now known? troit Diesel name. If
Christof von Branconi: There is a vast difference be- we market our pro-
tween selling comparatively small numbers of gensets as ducts systematically,
part of specialized project contracts or else just engines to a we have fantastic po-
few OEM clients, as we have done up to now, and volume- tential. Even in the
producing complete gensets for sale to hundreds of buyers. USA, which is a satu-
It would not serve a useful purpose for us to attempt to rated market. The
acquire the necessary capabilities ourselves. MTU Onsite customer event in
Energy Corporation in the USA are specialists who know Mankato at the begin-
how to make gensets in large volumes, how to sell the them ning of October pro-
in large quantities and how the logistics work. ved that. The interest
from the trade was
Why is the advantage of Tognum’s subsidiary in the enormous and buyers
USA? now see us as possible future suppliers. Interview:
Christof von Branconi: It gives us access to the North Tognum COO Christof
von Branconi (right)
American market. Geographical proximity is a key factor in What have been the consequences of the global finan-
and Armin Gröber,
selling directly to the end user. In addition, we have already cial and economic crisis? CEO of MTU Onsite
sold gensets there, but only products made by third parties. Armin Gröber: The financial crisis has caused a no- Energy Corporation,
In future we intend to combine the two and so cover more ticeable slow-down in orders and a four-week shutdown at explain the opportu-
of the market. the Mankato plant. But overall there is still high demand nities, aims and im-
plementation of the
for our products. IT companies, hospitals and data centers
new genset produc-
Mr. von Branconi, how do you explain the sales success still need emergency generators even in an economic crisis. tion line.
of the large gensets so far built between 2006 and 2008? However, many of our main competitors are moving more
Christof von Branconi: As we are still relatively small into onsite power generation due to loss of sales in other
as system suppliers without a great deal of market penetra- sectors. That considerably increases the pressure on dead-
tion, we have been able to make decent inroads and return lines and, in certain cases, on prices as well. In addition,
figures better than the market as a whole. That is the ad- clients are putting off many projects until the very last
vantage of the newcomer. Basically, the crisis has shown minute. And that means we have to deliver them to the
that the decision taken two years ago to move in this di- tightest schedules.
rection has made us considerably less susceptible to market
fluctuations. But that cannot disguise the fact that we still The standard gensets are also to be built at SKL in
need to substantially expand our sales capabilities in parti- Magdeburg and at the Chinese plant in Suzhou. Why?
cular. Christof von Branconi: Our aim is to be involved
in this business worldwide for the long term.
Why? After all, we have sold gensets Because, as we have said, proximity to the
before! market is a key factor and the business
Christof von Branconi: Yes, and in has to be optimized with respect to
the USA our distributors already know transport costs as well, we also have to
our systems well. But in Region 1 and in produce in Magdeburg and Suzhou.
Asia we still have to develop our sales to The Magdeburg plant has a lot of expe-
end users. Step by step. And in particu- rience in genset production. It will be
lar, train the distributors. That means in making the 50-hertz versions of all three
2010 we will not be marketing worldwide models there. We are already producing
but beginning with about 20 countries. They Series 2000 engines in Suzhou, which will be
are primarily countries where our OEM clients do made up into gensets in the same factory. Specia-
not operate. It is important that we make the MTU Onsite lists are being sent out from Mankato to train up the Chi-
Energy brand better known worldwide. Especially in the nese workforce. Production is due to start in 2010.
USA, we have to get the message across that MTU is the
MTU FRIEDRICHSHAFEN vocation
90 years of training in Friedrichshafen
2009 is a special year for anniversaries. As well as Tognum subsidiary MTU Friedrichs-
hafen’s centenary, the company’s training department is celebrating its 90th birthday.
The company has always looked upon ensuring a continual supply of highly qualified
staff as one of the most important foundations for success, and as the basis for a suc-
cessful career in the industry.
F RIEDRICHSHAFEN. A Friday afternoon in
1963. The apprentices in the Maybach trai-
ning workshop can hardly wait for the end of the
rather authoritarian style of the training in those
days. Hermann Hoher, who eventually ended up
in charge of industrial technical training himself,
working day. But as yet they are all standing to observes, „That was the past. Today we conduct
Old-school training: attention by their workbenches. With a certain things as a partnership between trainers and
Top: in the early decades, craftsmanship amount of apprehension they are waiting for the trainees.“
skills such as filing were high on the agenda.
training foreman to inspect their carefully arran- To prepare young people for the high pro-
The picture shows the training
workshop in the 1950s. ged rows of files and tools. Fifteen-year-old ap- fessional demands from an early stage, MTU
Right: the relationship prentice machine fitter Hermann Hoher is rather Training introduced project-based learning in
with the trainer was nervous. Unfortunately he has bro- the mid-1970s. Instead of spending months
for a long time strictly ken the tip off one of his practicing filing skills, apprentices had to design
files. He is fervently hoping and build small 2-stroke diesel engines, small
the strict foreman doesn’t generator sets or waste disposal stations in order
notice. That small anec- to gain an understanding of technical and or-
dote, which by the way ganizational aspects early on.
had a happy The need for highly qualified staff as the ba-
ending, clearly sis for the success of any business was something
illustrates the that Karl Maybach recognized 90 years ago. The
company had already set up a training workshop lights Martin Stocker, Head of Industrial Tech-
for women in 1917 due the lack of male workers. nical Training.
The apprentice training workshop established in Industrial technical training was joined by
1919 was the first in the Upper Swabia region commercial subjects and in the 1970s by electro-
and a pioneer of cooperative courses in Ger- nics. Other additions have been industrial
many. Maybach-Motorenbau provided the rooms, practice semesters for mechanical engineering,
teaching models, projection equipment and business engineering and electrical engineering
other teaching materials and the training staff courses at the Ravensburg Vocational Training
for the practical subjects. The local education Academy, which is now known as the Baden-
authorities supplied the teaching staff for the Württemberg Cooperative State University
theoretical training at the company’s own voca- (Duale Hochschule Baden-Württemberg).
tional college. Today, a total of 310 young people are com-
An important factor in practice-based and pleting their training at MTU Friedrichshafen,
forward-looking industrial technical training the vast majority of them as industrial mecha-
was always the proximity to production. The nics, mechatronics engineers or electronic en-
fact that learning does not take place in ivory gineers in automation technology, others in
towers is made obvious by the concept introdu- commercial subjects. How important the next
ced in the mid-1980s of „training stations“ that generation of qualified employees is to MTU is
are directly incorporated in the production shown by the new training workshop officially
areas. There, apprentices are directly integrated opened in February this year. Its 2000 square Modern vocational training at MTU Plant 1:
in the production process and learn the latest meters of space offer trainers and trainees the Top: mechatronics trainees A. Heiss (left)
and J. Baumann program handling equip-
manufacturing techniques on modern CNC perfect new home.
machines. The apprentices also gain plenty of Center: the previous training manager
practical experience in the „long-term training“ Words: Wolfgang Stolba Mr. Hoher (right) with Simon Amman at
phase. It involves working for seven to eight Pictures: MTU-Archiv, Robert Hack the production training station.
months in the same area. „That means that by Bottom: Mr. Krug, Electronics training
manager with Roman Ungern-Sternberg
their first day on the job, they can already mas-
(right) and Volker Altenhof, DHBW electri-
ter 80 to 90 percent of the work involved,“ high- cal engineering/automation students.
Practice is (almost) everything
Ninety years’ experience in apprentice training have shown one thing above all: training
is only as good as its practical reference. To reinforce that aspect, Tognum offers exter-
nal practical training placements and extensive project work, among other things.
gineers attending to the propulsion units. But as
the time drew closer, I started to worry if I had
what it takes. How would I manage? Having only
recently passed my driving test, I was a little ap-
prehensive about the 800-kilometer car journey.
But as soon as I was on my way, I found that as
each hour and each day passes, you can achieve a
little more than you could before.
I especially became aware of that in the days
that followed in Wilhelmshaven. One of the MTU
engineers there looked after me for the whole two-
week placement, and even met me on the evening
I first arrived. No, I wasn’t thrown in at the deep
end. On the first day he showed me the gigantic
port installations in Wilhelmshaven, the frigates,
the engine rooms, the workshops on board ship
and on the dockside, and the spare parts depot for
the MTU engines. And then I went with him to
watch a Series 956 unit being hoisted out of the
Benjamintomer engine room because there is too little space inside
23, cus engineer for certain repairs. I realized that you need a lot of
service knowledge and skills beyond just knowing about
Benjamin Br the engine in order to be a customer service spe-
ports on tw
acements Smelling cialist. I also helped to completely dismantle a
that he comp ship in
practical Series 396 genset engine in the hot and sticky at-
his apprentice reality at mosphere of an engine room heated by summer-
the waterside time weather. I learned what order the first parts
al l over the have to be removed in to get at the ones underneath,
he has been ments for
on service ch as the
Benjamin Brechtel, 23, custo- how you pick spare parts from the warehouse and
la rge ships su nchijigua mer service engineer in Fried- to put them away properly. And I found out how
trimaran fe d) that serv
es richshafen, completed two pe- important it is for your own comfort in the hot
Express (picture La Palma.
of riods of practical training in weather to change your dirty and oily overalls re-
north Germany during his gularly. I got through three sets in a week.
apprenticeship in 2006. One
of them was a service placement at the German On the way to the Hamburg office I found out
Navy dockyards in Wilhelmshaven. what it’s like when your sat nav fails and you have
to find your way around the concrete jungle on
A t first I was quite elated. A practical trai-
ning placement! At the Wilhelmshaven
naval dockyards. It covers a vast area in
which 15 frigates were waiting to be serviced
alongside its quays. There were ten MTU en-
your own. The tour of the MTU center made up
for it though. In Berlin, I learned how customer
service jobs in the genset and rail sectors are dealt
with at short notice. Another thing that became
clear was the key role of the electronics, such as
How MTU apprentices grow into the world of work
when a rail PowerPack management computer
has to be reprogrammed with new software.
I have now worked as a service engineer for
two years and have already been abroad several
times to places like La Palma, Singapore and
Australia. I wouldn’t want to have done without
the practical training, especially because of the ex-
cellent support I was given and the practical un-
derstanding I gained.
Benjamin Wulle, 21, is studying engineering
economics at the Baden-Württemberg Coope-
rative State University in Ravensburg (DHBW).
This year he had to produce a product-related
viability study which gave him a comprehensive
insight into the world of heavy-duty diesel en-
gines in the penultimate semester of his univer- Benjamin Wu
sity course. sights and opportunities is studying lle, 21,
ring eco enginee-
for development. Among all of those subject-
the DHBW nomics at
W hen, in my fifth semester, I opted for a via-
bility study in the area of engine manu-
facturing, I thought, “No problem, I can
just research it“. I couldn’t have been wider of the
mark. In my first conversation with my mentor,
related and organizational tasks, the one job
that was the toughest of the decathlon of dis-
ciplines was undoubtedly finding the right
people for each job and winning them over.
If there is one general observation I have
As part of
produced a lle
Gebhard Happle, who helped me fantastically about this course it is that it gives you prod
study. In th uct-related
throughout the project, it became clear what a dif- direct practical experience at exactly the gained usef e process he
ficult, even Olympic-proportion challenge it was. right time – just before you finish. I can’t many depart
ments and ho
In my scientific study, I examined all the technical imagine a better preparation for the po- work togeth w they
and economic aspects on which the success of a tential culture shock of entering the real
potential new product depends. They extend from world of work.
the business management level where the basic
strategic and operational questions are considered Words: Benjamin Brechtel, Benjamin Wulle,
right through to the details of technology, physics Wolfgang Stolba, Pictures: private, Robert Hack
and mechanics, engine and gearbox design, pro-
duction processes and procedures, and after-sales
issues. Added to that, there were economic via-
bility calculations, analyses of the market and
competitors, sales activities and pricing conside-
I spoke to more specialists and arranged more
meetings than I can remember. It was not always
an easy task, either organizationally or on a per-
sonal level, but it gave me many important in-
Work & Social
Spirit of enterprise at MTU Asia
MTU Asia celebrates traditional Chinese festival of spirits
Burning money to appease
the spirits? To western eyes it
S INGAPORE. In Chinese culture, the seventh month of the lunar calendar –
that is the period from mid-August to mid-September on the western calen-
dar – is a very important time of the year. It is when the gates of hell open for
might at first appear to be a rather roughly 30 days and the spirits of the underworld are on Earth. That is the time
when the Chinese celebrate the festival of the hungry spirit – their version of
unusual custom – but it is just one Hallowe’en. To appease the spirits of the dead souls, people offer them ritual
of many observed in countries meals or burn money. It is a custom properly observed at MTU Asia in Singa-
pore. The celebrations for the festival started with an auction of all sorts of items
where Tognum Group companies and ended with a dinner for the staff taking part. An essential part of observan-
are represented. ce is that no events with a bearing on future prosperity such as weddings or busi-
ness meetings are held during the period – because the spirits, so the tradition
says, are the real masters of those days. Whether the efforts to appease them will
meet with success, remains to be seen – perhaps business developments in 2010
will reveal the answer.
Words: Markus Keiper, Anika Kannler, Pictures: MTU Asia
Appeasing the spirits:
In the Chinese Festival of the Hungry Spirit,
ritual meals are offered up and money burned.
One of us
festival at Mehmet
Top: Emel Coban
with visitors in
the prayer room.
into the Koran.
guests to the
Emel Coban helps to promote understanding
between German and Turkish communities
F RIEDRICHSHAFEN. A Sunday in May. Below the glit-
tering gold dome of the Mehmet Akif Mosque in Fried-
richshafen, market stands offer oriental delicacies for sale.
is that Islam is also taught in schools as part of religious
She is currently a committee member of the DITIP, the
But what particularly attracts the German visitors to the an- “German-Turkish Union of the Institute for Religion“ and is
nual community event is the chance to gain an insight into a founder member of the “Friedrichshafen Dialogue Com-
the interior of the mosque, the Islamic religion and, ultima- mittee“. As deputy leader of the General Parents’ Associa-
tely, the culture of their 3,000 or so co-citizens of Fried- tion in Friedrichshafen, she works for greater equality of
richshafen. For devout Muslim Emel Coban, who works at opportunity for all migrant children. She chairs the Parents’
the MTU Electronics Center, the event is a welcome oppor- Association at the Graf-Soden-Realschule secondary
tunity to pursue her “greatest commitment after the family“ school. She has also helped to produce a concept for migrant
– promoting understanding between Christians and Mus- children in the City of Friedrichshafen’s
lims, Germans and Turks. She provides guided tours of the Cooperative Planning Group. As well as all
mosque, explains the Koran to the visitors together with the that, she also gives Turkish lessons for
imam (leader of prayers), tries to overcome prejudices and Germans at the local community college.
points out all the things that unite the two cultures. Where does that strength of commit-
On their way around the fete and the mosque, many feel ment come from? “When I came to Ger-
that what is being explained has to be experienced together many at the age of nine, I learned German
with all the other impressions here in order to fully under- quickly and easily. But many other ethnic
stand it – the robes, the prayers, the colorful carpets, the or- Turkish schoolmates fell behind,“ she re-
naments and scriptures. Emel Coban elucidates the impor- lates. Because she is so well assimilated in
tance of the mosque as a place where the generations come both communities, her aim is to help
together: “The family and the mosque play a decisive role in build bridges between the cultures.
the religious upbringing of our children“. Her greatest wish Words + Pictures: Wolfgang Stolba