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Tognum Dynamometers


									INsight                 Magazine for
                         M agazine for
              Tognum Group associates
              Tognum Group associates

          The new Series 4000 sets
       the standard in its class . . . 6

             Closer to the customer:
                 Tognum realigns its
            Sales Organization . . . 4

                Workshops: Service
               enhances value . . . 26


           3|10                                    November 2010

           4-5   Company
                 New Sales Organization

       6-17      Technology
       6-12      New-generation Series 4000
            13   Series 1600
       14-17     Production network

      18-23      News
                                                                                                                                Series 4000
                                                                                                             The new-generation Series 4000 meets the
                 Company / Sales / Staff                                                                  emissions standards of the future. The engines
                                                                                                             underwent comprehensive technological re-
                                                                                                                    development to achieve compliance.
      24-29      Sales
                 “Innotrans” rail exhibition
                 Locomotives for Switzerland
      26-29      Workshop planning

      30-31      Side glance                                                                                                                             Workshops
                                                                                                                                                         Workshops are increasingly impor-
                 Components test stand                                                                                                                   tant for reliable service worldwide.

      32-42      Work & Social
      32-33      IT Applications
      34-35      Project “Future Active”
      36-37      Compliance
           38    Training start
           39    Assembly taster
      40-42      News

           43    Tognum al dente                                                                                                 Potjie                                                    43
                 Potjie from South Africa                                                    David Stuck from MTU South Africa is a
                                                                                           master when it comes to preparing “potjie”
                                                                                                   – a traditional South African stew.

                 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: Editor-in-chief: Wolfgang Stolba (sto), Tel.: +49 (0) 7541/90-37 03, E-Mail:
                 Other writers on this issue: Lucie Dammann (ld), Anika Kannler (aka), Jenifer Riley Photographer and designer: Michael Bober, Deutsche Bundeswehr, dpa, Robert Hack,
                 Robert Kardas, Markus Keiper, Kai Kröger, Todd Lista, Thomas Moser, MTU Archiv, MTU Asia, MTU Detroit Diesel, MTU Italia, MTU Onsite Energy Corporation, MTU South Africa,
                 MTU UK, Elma Riley, Henry Schulze, US Marine, Victor Waling Editorial assistant and dispatch: Sabine Ruderer, Tel.: +49 (0) 7541/90-21 49,
                 Editorial adress: Tognum AG, Abt. VCC,D-88040 Friedrichshafen Design and layout: Designbüro Klaus Schmieder, Vogt Litho: Wagner digitale Medien, Meersburg Printing: Eberl Print GmbH,
                 Immenstadt i.A. ISSN-Nr. 1867-0997


                                                   „By consolidating our sales structure

6-12                                                at a local level with ten sales regions
                                                    initially and by significantly shorten-
                                                    ing internal channels, we can beat a
                                                    faster path to the customer’s door.“
                                                    Volker Heuer, Tognum CEO

            We are sometimes ambivalent about change. What we cherish, we do not like to give up. At
       the same time, our routines and habits give us the security we need to cope with new challenges.
       Human beings are constantly having to cope with this dilemma and that is the situation in which
       I also see our company at present.

           Take our new Series 4000 engine – a fantastic product. With less emissions and lower fuel con-
       sumption, it represents a major step forward. Everyone who contributed to its development is proud
       that such a great technological advance could be made. The 'old' Series 4000 engine was good, the
       new one is better. That is the way our business has worked for decades.

            The same applies to the improvement of internal procedures, processes and organizations, al-
       though it might be more difficult to justify on the basis of technical facts. The re-structuring of our
       sales organization at the end of the year is a case in point. We have put in a good performance with
       the help of our three sales regions. But if we want to gain the competitive edge, we need to be more
       than just good. By consolidating our sales structure at a local level with ten sales regions initially
       and by significantly shortening internal channels, we can beat a faster path to the customer’s door.
       To achieve this, we have to depart from the familiar – from the role played by our foreign subsidia-
       ries, and from our many-tiered decision-making and hierarchical structures. In the same way, re-
       allocating responsibility for distribution – which at present lies solely with the Engines and Onsite
       Energy units – will be important for winning brand new customers, but will also demand a great
       deal of commitment and untiring effort from us all. I am confident that once we can recognize how
       re-organization has made us even more successful, we will not look back to the old way of doing

           Our IFA-Rotorion colleagues, for whom a workable solution for the future was found after drive
       shaft production was transferred to Haldensleben, have exemplified for us how it is possible to suc-
       cessfully change direction after many years of routine.

           We have been able to adjust fairly quickly to the recovery in business which has brought us
       more orders, larger quantities and higher revenues than in the crisis year of 2009. We are glad that
       we did not have to resign ourselves to a permanently ailing economy. Working at peak capacity in
       our factories is a challenge we would much prefer.

           I wish you all a very happy Christmas and all the best for your New Year celebrations, in what-
       ever month they happen to fall. Let us hope that 2011 will be a year of positive change for us all.

       Best regards, Volker Heuer



          New ways – a new approach
                                                  The road to Tognum’s future Sales Organization
          Faster growth via short routes to both existing and new customers - that is the aim underlying the new
          Sales Organization with which the Tognum Group will be starting out into the new year on 1. January 2011.
          The preparations are in place. The essential details will be clarified by the end of 2010. However, it is not
          just the organization itself which is new but also the way it is to be achieved – it is a step toward a diffe-
          rent corporate culture.

          F   RIEDRICHSHAFEN. The globally standardized Sales
              Organization of the future will provide the Business
          Units “Engines” and “Onsite Energy & Components”, more
                                                                         After-Sales section which will be of considerably greater
                                                                         significance. The new structure will also bring change for
                                                                         some employees as teams and departments are realigned
          than any others, with direct access to sales structures.       and organized globally and on a transnational basis and as
          Until now, there were three large sales regions with Asia      activities are re-allocated and centers of excellence for par-
          and the USA organized as autonomous companies. In fu-          ticular business areas are created.
          ture, sales activities will take place via ten decentralized
          Sales Regions which will be able to align themselves more          The general character of realignment was prepared in a
          closely with the distinctive features of their own markets.    relatively small project group and its implementation will
          In future, the present Regional managements in the USA         be developed by specialists from within the company. “It
          (MTU Detroit Diesel) and Asia (MTU Asia) will provide          was our deliberate intention not to create a new structure
          the legal, commercial platform for conducting business but     which was worked out down to the last precise detail as
          they will no longer have any autonomous ‘profit-center’        some people may have expected. Instead, we specified only
          role. Short decision-making routes will connect the Sales      the framework. If it is going to work, we need to build it
          Regions with the central business sections and with the        with the expertise of our practical specialists,” said Chair-

                    Tognum’s ten new sales regions

                                                             Central              Eastern                   North East
                                                             Europe               Europe                      Asia
                                   North                                           & CIS                     (w/o China)

                                                                            Turkey,               South East
                                                                           ME & Africa               Asia
          New Sales                      Latin                                                     (incl. India)
          organisation:                 America
          In future, sales
          activities will take
          place via ten decentralized
          Sales Regions which will                                                                             Australia/
          be able to align them-                                                                                Pacific
          selves more closely with
          the distinctive features
          of their own markets.


    Opinion …
    Wrestling with the best path forward
    28 experts from Asia, the USA and Europe identified and defined essential processes at workshop events.
    Our reporter asked some of them what they expect from the future Sales Organization and how they see the
    process developing.

    Alex Choe, Singapore:
        “I expect the new Sales Organization to create better market coverage and business growth – both in depth, by
    enhancing direct sales, and in width, by increasing distribution sales. Growth in direct sales will come because we will
    be more focused to serve our key customers and that, in turn, will foster strategic alliances. The increase in distribu-
    tion sales will result from the further enhancement of distributors’ competences and the expansion of our distribution
    networks into the mass markets. This is essential for sales of our existing and new Lower Power Range products.
    The workshop provided a forum for an intense and pellucid exchange of ideas amongst a global team of managers
    and it generated more efficient working guidelines and processes for the new organization.”

    Doug Schwedland, Detroit (USA):
        “Another participant said he expected to see the ‘global coordination of decentralized resources’. I see a much
    more focused effort toward global customers and I see Tognum exercising a stronger leadership role in bringing our
    products to the marketplace. In the past few years we have relied heavily on others, such as our distributors, to take
    our products to the field without growing a parallel channel within our direct focus. The result should be a greater
    market share for Tognum and more after-sales business. The workshop was a mentally exhausting yet thoroughly
    exhilarating process. It was a real chance for some of the company’s management to wrestle with the best path for-
    ward for Tognum. The event allowed all sides to be heard and, in the end, the process saw the development of a uni-
    fied vision.”

man of the Tognum Executive Board, Volker Heuer. The             cept was not planned right down to the very last detail
essential processes were delineated at two workshops each        when the future organizational structure was made known.
lasting several days and involving 28 specialists from Asia,     Those affected become participants in the process and the
the USA and Europe and representing various sections of          end of that process will see the creation of an organizatio-
the company. The issues covered questions such as how the        nal structure which was tailor-made for Tognum. “We are
relationships between the Business Units and the Regions         quite intentionally setting out on routes which are very dif-
were to be regulated and who was to have what responsibi-        ferent from those of our competitors,” said Coers.
lities for which sections of the business. For example, it was
decided at the workshop that Tognum-owned sales com-                 Thus, Tognum is setting out to increase the business it
panies would be placed largely on a par with external dis-       does directly with large customers whilst simultaneously
tributorships. Their experience often allows the professio-      enlisting the distributorships to create a consistent and
nals to recognize very quickly whether something which           comprehensive presence. The primary task of the ten Sales
has been thought out in theory is also capable of being im-      Regions will be to cultivate and expand the network of re-
plemented successfully in practice. “A lot of people have gi-    lationships with distributors. Sales of distributed power ge-
ven a lot of thought to how our organization can be impro-       neration systems and After-Sales activities are particularly
ved. Now they have the chance to put their ideas into            promising areas which are expected to grow more vigo-
practice,” said Joachim Coers, Deputy Chairman of the            rously than business with engines and drive systems alt-
Tognum Executive Board and head of the re-alignment              hough these areas can also expect to see growth as a result
project. “Syntegration” – a fusion of ‘synergy’ (cooperation,    of the realignment.
joint action) and ‘integration’ (creation of a complete enti-
ty) – is the name given to the process by the consultancy            “At the workshops we reached a consensus that the par-
company advising the Tognum Group.                               ticipants should and would ensure that relevant informati-
                                                                 on is passed on to colleagues. In that way we will be crea-
    “This approach shows that we are changing the way we         ting our organization from within the company itself,” said
think and the way we deal with the issues involved. We are       Coers. In the weeks running up to the end of December,
not simply adapting our Sales Organization (and therefore,       progress will continue on a range of aspects to ensure that
necessarily, several other areas of the company) to suit the     work with the new organization can begin from the start of
changed markets. Far rather, we are also continuing to de-       2011. “We will keep the workforce closely informed at
velop the company and its corporate culture,” added Volker       every stage,” emphasized Coers.
Heuer, explaining the process. That explains why the con-                              Words: Wolfgang Boller, Picture: Robert Hack


    Not just clean, but super-clean
             In terms of emissions, the new generation of Series 4000
                             engines is setting the technological pace.


                                                              RESEARCH & DEVELOPMENT

                                                              Never before have so many new technologies
                                                              come together in a standard production engine. In
                                                              the new Series 4000 engine generation, virtually
                                                              no system has stayed the same as on the previous
                                                              version. That applies to the two-stage turbo-
                                                              charger, the cooled exhaust recirculation system,
                                                              the high-pressure fuel injection system, the com-
                                                              pact diesel particulate filter, the new combustion
                                                              process and the cylinders with increased peak

                                                              F  RIEDRICHSHAFEN. The new generation of Series
                                                                  4000 engines unveiled at the Innotrans International
                                                              Trade Fair for Transport Technology in Berlin sets the
                                                              future standard for its class: the engines already meet the
                                                              stringent EU Stage III B emission requirements. These are
                                                              due to supersede Stage III A regulations for drive systems
                                                              used in rail applications. They took effect in 2009 to re-
                                                              duce NOx emissions by 43 percent and particulate emis-
                                                              sions by 88 percent, which was an enormous challenge.
                                                              And these are not the only demands: there are also the
                                                              needs of locomotive manufacturers and rail operators with
                                                              respect to lower overall costs, reliability, power-to-weight
                                                              ratios, and optimal installation in the vehicle.

                                                                   Underpinning all of this is powerful project organiza-
                                                              tion headed by Dr. Ingo Wintruff and extending from de-
                                                              velopment and production to sales, logistics and After-
                                                              Sales service. The subproject Development is coordinated
                                                              by subproject manager Otto Bücheler. A major part of de-
                                                              velopment work is carried out in the TKF department led
                                                              by Norbert Veser which is responsible for engine series
                                                              development. A major contribution to success has also
                                                              come from the TKA development departments,
                                                              one of whose tasks is to develop basic engine
                                                              components. The section is led by Dr. Martin
                                                              Kurreck. Dr. Johannes Kech manages depart-
                                                              ment TKT, which deals with turbocharging,
                                                              fuel injection, cooling and exhaust aftertreat-
Trailblazer (large photo): At the Innotrans rail exhibition   ment. Engine and exhaust management sys-
in Berlin in September, the new Series 4000 unit was the      tems are the province of department TKE under
only engine of its size to hold III B certification.
                                                              Dr. Dietmar von Zwehl. The New Technologies
Small photo: Together with a diesel particulate filter, the
16-cylinder version has already been installed in a new       and Design Studies department (TSV) performed
Siemens Vectron Series diesel locomotive which was a          much of the groundwork for the new engine generation,
surprise exhibit at the exhibition.                           most notably development and testing of the exhaust re-
                                                              circulation system and of the diesel particulate filter. The
                                                              latter was subsequently tried out in a PowerPack on a rail-


                           RESEARCH & DEVELOPMENT

2-stage turbocharging

ECU9 -Electronics

LEAD2 injection system

                                                                                         In-engine technology for emissions reduction: The philosophy un-
                                                                                         derlying the development of the new Series 4000 concentrates on
                                                                                         maximizing utilization of in-engine technologies to spare the ope-
                                                                                         rator the expense associated with additional assemblies.

                        car operated by Taunus railways. Department TSV is also          Internal and external engine measures
                        responsible for developing new combustion processes.                 Emission reduction centers on nitrogen oxide and soot
                                                                                         particulates. There are two ways of reducing them: in-
                             The successful new 4000-04 engine series will be divi-      engine measures can be taken, for example, in the field of
                        ded into two product lines for meeting different require-        combustion or injection. Or externally integrated equip-
                        ments: a mobile version for rail applications which, being       ment such as diesel particulate filters or SCR systems for
                        subject to strict soot particulate limits, must contain a        reducing nitrogen oxide can be installed. However these
                        diesel particulate filter. For oil and gas applications, the     impose additional weight and space requirements on the
                        mobile version will also be used, but with no particulate fil-   customer. “In contrast to our competitors, our philosophy
                        ter. The stationary version for power generation purposes        is that as much time and effort as possible has to go into
                        requires an SCR system with urea injection, because the          developing in-engine measures first, so that the customer
                        NOx emission requirements in this case are more stringent.                is saved the cost of adding peripheral compo-
                        This article focuses on the engine designed for rail appli-                   nents,” emphasized project manager Dr. Win-
                        cations, which will be available in 8, 12, 16 and 20-                           truff.
                        cylinder versions and covers a power range of 1,000 to
                        2,700 kilowatts.                                                                      The key in-engine technologies used to
                                                                                                          reduce emissions are cooled exhaust re-


                           Cooled exhaust gas recirculation
                                                                        EU III A                      2009
                                                                                                                              EU III B
                                                                                        6,0 g/kWh

                                                                                         0,5 g/kWh              HC     NOx
                                                                                                       CO              +HC    4,0 g/kWh
                                                                                         3,5 g/kWh

                                                                                                     Particle          CO     3,5 g/kWh
                                                                                       0,20 g/kWh
                                                                                                                              0,025 g/kWh
                                                                     More stringent emissions limits: The technologies employed in the new generation
                                                                     of Series 4000 engines center around increasingly stringent emissions limits. For rail
                                                                     drive systems above 130kW, Stage III B, which is due to come into force in 2012, drasti-
                                                                     cally reduces the limits for air pollutants such as nitrogen oxide (NOx), hydrocarbons
                                             Miller process          (CO) and particulate matter. The new regulations will replace the previous regime
                                                                     (Stage III A) which came into force in 2009.

                                    Peak pressure increase

                                                                    Members of the project management team, from left: Otto Bücheler, Sub-Project
                                                                    Leader for Development; Norbert Veser, Leader, Series 4000 Development;
                                                                    Helmut Rall, Function Team Leader; Dr. Ingo Wintruff, Project Leader, Series 4000;
                                                                    Function Team Leaders Stephan Fuß, Martin Rauh and Tobias Weiß.

circulation, the latest generation of common rail system,        is used to reduce nitrogen oxides. The exhaust gas is taken
2-stage controlled turbocharging and the new ECU 9 elec-         from one or several ‘donor’ cylinders and returned to the
tronic engine control system. An important new feature on        fresh air intake. This leads to combustion at a lower tempe-
the engine version for rail applications is standard installa-   rature, resulting in less nitrogen oxide being produced.
tion of a diesel particulate filter (DPF). To comply with        Control valves allow the setting of exhaust recirculation
limits in the long-term, all systems … from injection and        rates anywhere between 0 and 25 percent, with up to
turbocharging to electronics – must operate and interact         50 percent possible for future emissions requirements.
with a much higher degree of precision than is presently         Exhaust recirculation is being integrated into standard
the case. To handle the greater complexity this entails,         production engines for the first time at MTU. Basic inves-
Cameo, the electronic development program, is used at the        tigations were carried out at an early project stage on test
test stands.                                                     engines.

Exhaust recirculation and                                            Closely linked to this development is a 2-stage control-
two-stage exhaust turbocharging                                  led turbocharging system. Even at high exhaust recircu-
    To comply with emission limits, the in-engine measu-         lation rates, this system achieves high power density,
re of cooled exhaust recirculation (EGR) is to go into series    excellent engine back pressure characteristics and low
production for the first time. Cooled exhaust recirculation      soot emissions. Here again, development engineers were


                             RESEARCH & DEVELOPMENT

                                                                                              Series 4000 engines, we needed ten times more computing
                                                                                              power than the ECU 7,” explained subproject manager Jörg
                                                                                              Remele. Building on the features of the ECU 7 predecessor
                                                                                              model, a lambda controller, a charge pressure controller
                                                                                              and a nitrogen adapter have been added to ensure that
                                                                                              emission standards are precisely met. Depending on appli-
                                                                                              cation, exhaust aftertreatment elements are also planned,
                                                                                              which will require additional control loops. Finely-tuned
                                                                                              interaction of different emission technologies is essentially
                                                                                              a matter of electronics.

     Turbocharging viewed in 3D: In the Virtual Reality Room (VR) in Friedrichshafen,
     it is possible to see whether components will fit together efficiently and whether
     they can be removed without any problems. Shown here (from left): VR specialist
     Friedrich Schley and R&D engineers Ronald Hegner (center) and Steffen Harscher.

                        moving into unknown territory: “We already had 2-stage
                        turbocharging in the 1163 engine, but one with three
                        turbochargers was new,” pointed out team leader Steffen
                        Harscher. Managing to fit all three turbochargers into a
                        space previously housing just two was a considerable chal-                 New electronics: The new engine management system
                        lenge. It was a good thing that the turbochargers had been                 ECU 9 facilitates finely tuned interaction between engine
                        developed and built by MTU. “We would never have found                     technologies. Shown here (from left): R&D specialists
                                                                                                   Alexander Bernhard, Albrecht Debelak, Tim Späder,
                        anything like them on the market,” said Harscher. The
                                                                                                   Dr. Jens Niemeyer and Jörg Remele (Manager).
                        principle is as follows: air is compressed in a low-pressure
                        phase using two turbochargers, and then passes through
                        two intercoolers. Intercooling enables optimum turbo-                 L’Orange: from 1,800 to 2,200 bar
                        charging efficiency. Then follows the high-pressure stage                 Tognum subsidiary L’Orange put a lot of effort into
                        with one turbocharger and downstream intercooler.                     further development of the common rail fuel injection sys-
                                                                                              tem for the new generation of Series 4000 engines for rail
                            Apart from the exhaust recirculation system, the Miller           applications. The turning point was the change from
                        process used in the 03 engine version also serves to reduce           LEAD1 to the new LEAD2 system, which increased the
                        nitrogen oxides and at the same time lower fuel consump-              injection pressure from 1,800 to a formidable 2,200 bar.
                        tion. In the Miller cycle, the inlet valves are closed earlier,
                        resulting in the gas expanding during the downward                    As a result, the fuel is atomized even more finely, enabling
                        movement of the piston and cooling down.                              it to burn more efficiently, i.e. with fewer emissions. The
                                                                                              higher injection pressure significantly reduces raw parti-
                        ECU 9: Electronics with 10 times more computing power                 culate emissions. That means that in the field of oil and gas
                            An enormous leap forward has also been made in                    applications, the new-generation engine can satisfy Tier 4i
                        electronics with the new ECU 9 engine control system. “In             emissions limits without the need for a diesel particulate
                        order to handle the complexity of the new generation of               filter. In rail applications, the low level of raw particulate

                      “Although the engine has been technologically upgraded in order to meet
                       the future Stage III B emission standards, it is still more economical and
                       no bigger in size than its predecessor.”
                                                                 Dr. Ingo Wintruff, Series 4000-04 project manager and Head of Thermodynamics and Fluid System


                                                                  various types of locomotive, and easy for the customer to
                                                                  maintain. To save installation space, the DPF also operates
                                                                  as a silencer or can be integrated into the installation space
                                                                  of a standard silencer.

                                                                      The most important requirement in DPF operation is
                                                                  the complete burning-off of soot deposits – called “regene-
                                                                  ration” – with only a minor increase in consumption if pos-
                                                                  sible. To ensure this is achieved, the exhaust gas first passes
                                                                  through an oxidation catalytic converter (DOC = Diesel
                                                                  Oxidation Catalyst), which is fitted upstream of the DPF
   System test stand at L’Orange, Stuttgart/Zuffenhausen:         and contains a precious metal such as platinum as the
   Entire injection systems can be tested here. A Plexiglas       catalyst.
   hood guards against spray if leaks occur. Seen here: Kevin
                                                                  With this method, the organic parts of the soot are oxidi-
                                                                  zed, rendering them harmless. The soot deposited on the
emissions allows the use of what is called a passive diesel       specially coated filter can be burned off using nitrogen di-
particulate filter system without burner. The filter enables      oxide at a temperature of 250 degrees Celsius. Under nor-
regeneration intervals to be extended.                            mal operating conditions therefore, exhaust temperatures
                                                                  are sufficient for continual removal of the soot.
    The high injection pressure brought new challenges to
L’Orange. “It was one thing increasing the pressure from
1,400 to 1,800 bar on LEAD1, but raising it from 1,800 to
2,200 bar for the LEAD2 generation was quite another
matter,” said LEAD2 project manager Thomas Ziegler. The
general interplay of components had to be improved and
made more precise. The tank volume, for example, had to
be increased by 50 percent to absorb pressure waves. The
mass of the pilot valve for controlling injection had to be
halved to allow it to work more precisely. A new electrical-
ly-driven system test bench on which engine components
had been mounted allowed the entire fuel injection system
to be fine-tuned directly at the L’Orange site.

The diesel particulate filter makes its debut
    A diesel engine designed for rail applications that com-
plies with EU Stage III B standards may only emit 0.025               The heart of a diesel particulate filter: Function Team Leader Guido Schäffner
grams of soot particulates per kWh. That makes exhaust                shows a ceramic filter element for diesel particulate filters such as those used in
                                                                      passenger vehicles. Exhaust gases are routed through thousands of fine channels
aftertreatment with diesel particulate filter indispensable.
                                                                      where the soot is filtered out.
During development of the DPF, several challenges had to
be overcome at the same time: a large filter volume was
needed in a limited space, whilst keeping weight low and          Applications engineering: setup in the test center
ensuring that soot deposits were completely burned off.               To be absolutely sure that all design details and inter-
The system had to be as universal as possible for use in          faces of the engine and DPF mounted above it were as they
                                                                  should be in the new Vectron generation of locomotives
                                                                  from Siemens, configuration of the test unit in the test
                                                                  center of Plant 1 in Friedrichshafen was overseen by
                                            More technology       Harald Gottschalch, team leader for rail applications.
                                            in the same space:
                                            The new Series
                                            4000 units take       Transatlantic collaboration with Detroit
                                            up no more space          Test stands played a major role in development of the
                                            than the previous     new Series 4000 engine generation. Besides Friedrichs-
                                            “03” version (red).   hafen, the company’s Detroit location is the only other site
                                                                  equipped with a state-of-the-art transient R&D test bench
                                                                  on which engines can be tested with precise definition of


                 RESEARCH & DEVELOPMENT

                                                                               Installation in a Vectron locomotive: All the interfaces between
                                                                               the engine, the diesel particulate filter and the Siemen Vectron
                                                                               locomotive were tested in advance using a trial set-up.

                                                                               motive: the 16-cylinder version is installed in the new Sie-
                                                                               mens diesel locomotive of the Vectron series, which had its
                                                                               world premiere at Innotrans. With this engine series, ac-
                                                                               cording to Breidenbach, Tognum is in an excellent positi-
              ambient conditions such as temperature or intake air hu-         on to operate in the locomotive market of the future.
              midity. A team under the guidance of team leader Philipp
              Gruber completed numerous test runs on the test stands in                                                    Words: Wolfgang Stolba
              Friedrichshafen and Detroit. For testing stationary appli-                           Pictures: Jörn Baumgarten, Robert Hack, Siemens
              cations of the new Series 4000 engine, the Detroit team led
              by Jörn Baumgarten was responsible. The team also over-
              saw field trials of the mobile engine version installed in a
              mining vehicle.

                  Presentation of the new engine at the world’s leading
              railway exhibition in Berlin highlighted its forward-
              looking technology. “We are the only manufacturer here
              showing an EU Stage III B-certified engine the size of our
              Series 4000,” said Rainer Breidenbach, member of the
              Tognum Executive Board and responsible for the Business
              Unit Engines, at the MTU booth. What surprised many vi-
              sitors was the fact that the engine is already driving a loco-

                                                                                   Transatlantic cooperation: Support for the development of
                                                                                   the new-generation Series 4000 is provided by the R&D
                                                                                   Team in Detroit headed by Jörn Baumgarten.

             “The practical experience of over 20,000 of these engines went into the
              new generation of the Series 4000. That ensures that the components
              are ultra reliable and long-lasting.”
                                                                                         Norber Veser, Head of Series 4000 Development (TKF)


                                                                                                             The new cold-
                                                                                                             test stand in
                                                                                                             Ralf Orthober
                                                                                                             (back, left) co-
                                                                                                             developed the
                                                                                                             new cold-test
                                                                                                             stand for the
                                                                                                             Series 1600
                                                                                                             (seen here with
                                                                                                             test stand ope-
                                                                                                             rator Tobias

   SERIES 1600

1600 Ratchets up the Quality
                      Productivity and quality assurance enhancements in 2010
After their initial introduction last year, Series 1600 genset engines have continued to gather momentum
throughout 2010. To keep pace with developments, Quality Assurance infrastructure at the Überlingen
plant has also been enhanced. “Our Quality concept has proved extremely effective” said project leader
Thomas Harr.

Ü   BERLINGEN. Turning out products in ever increa-
      sing numbers and safeguarding quality at the same
time represents a double challenge and in some areas MTU
                                                                 in-depth analyses are run on the threaded joints. Berthold
                                                                 Maucher is currently writing a degree dissertation on the
                                                                 subject: “We run regular and thorough random checks on
has broken new ground to meet that challenge. On pro-            the bolts on every engine using a measuring wrench and
duction start-up in 2009, for example, a leak-testing stand      we use the prevail torque measured as the basis for con-
was set up at the 18th assembly station. “This allows us to      ducting process capability analyses.” This gives crucial in-
spot quality problems at an early stage and it means we can      formation order to safeguard process reliability.
react fast,” explained team leader Jens Baumeister. In
March 2010, a semi-automatic cold-test stand was integra-                                               Words: Wolfgang Stolba
ted in the line with the same aim. On this stand, the engi-                                               Pictures: Robert Hack
nes run “cold”, i.e. are driven by a 155 kW electric motor.
                                                                                                                                  Bolt and measure:
Cold-testing takes only three minutes but that’s enough to                                                                        During Series 1600
check for leaks at a very advanced stage of assembly. And it                                                                      assembly, tightening
is long enough to test the electronics and the turbochargers                                                                      torque is measured
(at 2,100 rpm) as well as to run ultrasound checks on the                                                                         as the bolts are
                                                                                                                                  tightened up.
gear train and to test the cable harness and engine sensors.
Cold-testing provides very precise indications on the cau-
ses of engine faults and those faults can be identified faster
as a result. “And because you don’t have to wait for
the engine to cool down, the faults can be cleared
quicker,” said Ralf Orthober who worked with
the manufacturers on the development of both
the cold-test stand and the hot-test stand.
     The Series 1600 line also incorporates highly
sophisticated systems for analyzing and safeguarding the
130 (approx.) threaded joints on the unit for example, for
monitoring tightening torque at the joints. But even more


       Production in
      Datong, China:
   On 9. September,
Norinco and Tognum
   founded the joint
     venture ”Shanxi
  North MTU Diesel

                          CORPORATE DEVELOPMENT

                       Networkers                                                   Production network drawn tighter
                       Good products sell best when they are produced and marketed in close proximity to the customer. That
                       was the philosophy behind the creation this year of new production locations in Aiken, USA and Datong,
                       China. These facilities are milestones on the road to a worldwide production network and from 2011, that
                       network will be drawn tighter.

                       AIKEN/DATONG           . From Mankato and Aiken in the
                            USA via Glatten, Friedrichshafen and Istanbul to
                       Suzhou in China? Over recent years an increasingly tight-
                                                                                    production network. That step involved the production
                                                                                    of Series 2000 and 4000 engines in Friedrichshafen and
                                                                                    Detroit and, from this year, in Aiken too.
                       woven network of Tognum production locations has
                       grown up. “Along with a global sales and after-sales         Local production has many benefits
                       network, an internationally-based production capability is       According to Hans-Peter Wehrle, there is a whole raft
                       an essential prerequisite for success in the diesel engine   of significant reasons for building engine plants directly in
                       business.” So says one who should know: Hans-Peter           their home markets in Europe, America and Asia. First,
                       Wehrle, for many years head of Production in Friedrichs-     being able to avoid exchange rate fluctuations means
                       hafen and, today, head of the Global Production Network      that engines can be sold at a more favorable price and are
                       (Global Footprint).                                          therefore more competitive. Such production locations
                           In the mid-90s, Wehrle was one of those who were in-     also allow direct communication with the customer – in
                       strumental in taking the first step away from centralized    his own language. They cut down delivery times, product
                       production in Friedrichshafen toward an international        variants can be planned more quickly and payment is



                                                                                                               Profile …
                                                                              Bernd Lemkamp: The fascination of China
                                                                              The advantages of long years of experience with the com-
                                                                              pany cannot be valued too highly ? especially when it comes
                                                                              to the technical expertise and cultural competence which is
                                                                              essential for cooperation with China. In his role in the License
                                                                              Section in Friedrichshafen, Bernd Lemkamp has been closely
                                                                              involved with Asia, and with China in particular, since 1985.
                                                                              Whilst working on the formulation of license agreements
                                                                              with Norinco, he has been able to gather a wealth of experi-
                                                                              ence involving the cultural as well as the commercial and
                                                                    technical prerequisites for cooperation. It was this experience which
                                                                    enabled him to play a valuable role throughout the entire joint venture
                                                                    negotiations as an expert contact who enjoyed, and continues to enjoy,
                                                                    the confidence of his Chinese business partners.
made in the local currency. The production facility can
also utilize the local procurement market to source the
components needed.                                               in Friedrichshafen but also at MTU Turkey and in the
     With business involving the governmental sector, the-       USA.
re is another reason for creating local production facilities:       Today, there is a total of twelve locations where Tog-
in order to have any chance of winning an order from na-         num products are made: Mankato and Aiken in the USA,
tional authorities, a degree of “local content” is usually re-   plus Friedrichshafen, Überlingen, Glatten, Wolfratshau-
quired. Initially, access to governmental markets is often       sen, Augsburg, Ottobrunn, Magdeburg in Germany, Istan-
gained through licenses although the licenser has little         bul in Turkey, Suzhou and Datong in China.
opportunity to influence the operative side of the business.         And from the beginning of 2011, in parallel with the
As the example of Datong demonstrates, joint ventures            re-alignment of the sales organization, that production
provide greater possibilities for participation. In Datong,      network as it currently exists will be drawn more closely
MTU has the operative lead as well as the responsibility for     together. In future, the plant in Suzhou (China) and the
quality. The arrangement also provides an excellent              two US plants in Aiken and Mankato will be placed direct-
springboard for further market development.                      ly under the Tognum Executive Board member for Tech-
     A production network also increases production capa-        nology and Operations, Dr. Ulrich Dohle. Until now, the
city overall. In 2008, a production record of 8,000 engines      CEOs of the respective subsidiaries in Detroit and Singa-
was achieved. However, that record was also the point at         pore have been formally in charge of the facilities. “We are
which manufacturing and assembly capabilities in Fried-          on our way,” said Dr. Dohle.
richshafen reached their limit. This was why new produc-
tion capacity for major components was planned not only



          Engine production in Aiken:
             Assembly of Series 4000.
     Photo, right: William Dallas (left)
                   and Joey McGlothin.
      Photo, far right: Michael Reeder
      (left) and Brandon Bailey on the
                     series test stand.

                                            CORPORATE DEVELOPMENT

                       The new production plant in Datong                              here does not involve relocating production to countries
                                                                                       with lower labor costs – market entry is the target”, empha-
                           On 9. September 2010, the “Shanxi North MTU Diesel          sized Bernd Lemkamp, who oversaw the development of
                       Corporation” (SNMD), a joint venture created by Tognum          production in Datong and now manages it.
                       and China North Industries Group Corporation (Norin-
                       co), was formally inaugurated in the Chinese city of Da-        The latest test stand technology
                       tong. The facility will be used for assembling Series 956           Three test stands will be operating in the new facility.
                       engines as well as emergency gensets powered by Series          The size of the test stand for Series 956 gensets makes it
                       956 units for service in Chinese nuclear power plants.          unique throughout the Tognum Group. In addition to 956
                       Series 4000 engines will also be serviced and maintained        gensets, the stand, which is designed for a maximum of
                       there in the near future. Like the plant in Suzhou and the      10,000 kW, can also accommodate Series 8000 engines.
                       relocation of Headquarters to Shanghai, cooperation with        An 80-tonne crane (the largest at any Tognum production
                       Norinco forms part of Tognum’s Asia strategy which invol-       location) is available for this purpose. There is also a test
                       ves the achievement of a significant increase the Group’s       stand for Series 956 and Series 8000 engines and one for
                       Asia revenues over the coming years.                            Series 4000.
                           Together with the French nuclear power company
                       Areva, MTU and Norinco have formed a consortium to              The new production plant in Aiken
                       equip Chinese nuclear power plants with emergency
                       standby gensets in the highest security classification group.       The new production plant in Aiken in the US state of
                       This represents a major growth market as China plans to         South Carolina was set up in the record time of only eight
                       construct over 100 nuclear power plants to cover its consi-     months. The existing site was ideal with a well-preserved
                       derable energy requirement. The state-of-the-art test           factory building which MTU was able to take over in
                       stands and maintenance facilities in Datong also provide        prime condition. It has sufficient capacity for an expansion
                       solid potential for development in overhauling mine truck       of local production and, therefore, for further growth in
                       drive systems.                                                  the important American marketplace for diesel engines.
                           The plant has a workforce of around 70 and this is          The plant was able to start production so quickly because
                       expected to increase to 130 in the future. “The primary aim     the engine assembly lines were set up in Aiken exactly as


                                                                    Profile …
                                                                    Jörg Klisch: Production on both sides of
                                                                    the Big Pond
                                                                        Jörg Klisch knows exactly how MTU
                                                                    engines tick. Before he took over as head
                                                                    of MTU Production in Detroit in 2005, he
                                                                    had already acquired a thorough and de-
                                                                    tailed knowledge of their strengths and
                                                                    weaknesses – in his roles heading Engine
                                                                    Repair, Defense Engine Assembly and the Test
                                                                    Workshop. "Before I took on responsibility for pro-
                                                                    duction in Detroit, I had got used to dealing with
                                                                    engines in the condition they are sometimes in
                                                                    when they come back for repair after years of
                                                                    tough service. That provided pretty solid know-
                                                                    ledge and experience as a basis for working in pro-
they had been dismantled in Detroit. Major “lean pro-
duction” efficiency programs had already been implemen-
ted in Detroit between 2007 and 2009: “We took a good            Production from 2011
look at all our processes and optimized them – from the              Unlike the previous location in Detroit, Aiken will have
two-container system through to provision of components          both an assembly section and, from 2011, a production
in a supermarket and the introduction of a milk-run to cut       section for large components such as cylinder heads, gear-
down supply times and warehouse stocks,” said Aiken              cases and flywheel housings. This removes the logistical
factory manager Jörg Klisch.                                     complications and the cost of supplying these parts from
                                                                 Friedrichshafen. “With no series production on site, it
Flexible series test stand technology                            would take between four and seven weeks to supply the
    Two new test stands are available which are capable of       parts,” explained Wehrle. And because all the materials
taking both Series 2000 and Series 4000 engines. They are        needed will already be available on site, orders can be
designed and equipped to facilitate fast set-up routines and     completed and delivered faster. The additional production
to allow flexible capacity utilization for both engine series.   capacity available in Aiken also means that, in future,
                                                                 Aiken can relieve bottlenecks in Friedrichshafen and vice
All 29 employees relocated with their families.                  versa. A major prerequisite for that is a standardized
    For the actual assembly processes, 50 new employees          machine pool on both sides of the Atlantic.
were taken on in South Carolina. The assembly staff loaned
from DDC retuned to Detroit and all of the 29 Detroit                                                       Words: Wolfgang Stolba,
colleagues directly involved with production relocated to                         Pictures: Wolfgang Boller, Bernd Keiper, Todd Lista
Aiken, 1,300 kilometers (around 800 miles) away. “Obvio-
usly, the general situation in the labor market in Detroit
was a factor here,” said Jörg Klisch. Nevertheless, it de-
monstrates a high level of company loyalty. MTU DD pro-
vided support with the relocation process and employees
were able to choose between financial support and the ser-
vices of a moving company.




   In cattle trucks from
        Detroit to Aiken:
The Waling family made
  the 1,332-kilometer to
the south together with
         their dogs, cats,
chickens and 27 alpacas.

                             On the Road again
                                                 MTU-DD family moves to Aiken, USA, with herd of alpacas
                             When Victor Waling, Product Planning and Implementation Manager at MTU Detroit Diesel, learned that
                             his job was relocating from Michigan to South Carolina he thought, “What about the alpacas?”

                             A   IKEN/USA. Victor Waling is one of the MTU-DD
                                  co-workers who moved to Aiken as a result of the
                             relocation of production. Relocating from Howell, MI to
                                                                                             cent complete when the family arrived in early August. Mi-
                                                                                             chelle, her mother, children and dogs left first. Then Victor
                                                                                             and a friend loaded up two livestock transporters with their
                             Aiken, SC was no small feat. Together with his wife, Waling     barn cats, chickens and the alpacas. They drove all night to
                             has been raising alpacas since 1999 when the couple pur-        reduce stress on the animals and avoid the hot summer sun.
                             chased their first two. Today their farm has 27 alpacas and     They needed over 14 hours for the 1,332-kilometer journey.
                             Michelle works as a fiber artist specializing in products           “I’m happy to have it behind us and to know that all is
                             made from alpaca fleece, such as sweaters, blankets and         well,” says Michelle. The kids are settling in at school; Michel-
                             shawls. Victor placed an ad in the Aiken newspaper which        le has good opportunities to sell her handmade wares; the
                                          led them to a ranch. Next the family had to en-    alpacas have more room in the pastures to frolic; and Victor
                                           sure the land could sustain their herd. Michel-   is enjoying his 10-minute commute to work – versus the
                                           le managed the job from Michigan as workers       hour commute he had in Michigan. Now, he comes home at
                                           replaced barbed wire fencing, added power to      the end of the day, tends to the animals, and unwinds from
                                            the barn, installed water hydrants and three     his day at the office. Life is good down on the farm.
                                            automatic water systems, and built another
                                            shelter for the herd sires. They had one                                  Words: Jenifer Riley, Pictures: Victor Waling
                                             month to get the work done; it was 98 per-

     Relocation project:
            Victor’s wife
           Michelle took
     charge of preparing
      the 5-acre ranch in
         South Carolina.                                                                                            Alpaka farm:
                                                                                                                    Victor Waling and his wife Michelle have
                                                                                                                    been breeding alpacas since 1999. Today,
                                                                                                                    their farm is home to 27 animals.



    Tognum to get new Board of Management member
    FRIEDRICHSHAFEN (sw). Tognum Board of                       experience and many years of success to his
    Management member Rainer Breidenbach (55),                  credit as the Managing Director of our most im-
    who is responsible for the Business Unit Engi-              portant subsidiary who will continue the suc-
    nes, will be leaving the company on 31.12.2010              cessful management of our largest Business Unit
    at his own request. He has asked the Supervi-               Engines.” Born in Heilbronn, the mechanical
    sory Board to terminate his contract, which was             engineer joined MTU Friedrichshafen in 1989
    due to run until 31.10 2011, prematurely for per-           as a project manager for marine propulsion sys-
    sonal reasons and will then take early retire-              tems. He was involved in projects that enabled
    ment. His successor will be Peter Kneipp (52),              him to acquire experience in the Asia-Pacific re-
    who has successfully managed the Asia/Pacific               gion, where he has worked and lived since 1997.
    sales region for the Tognum Group for the last                   He began in Singapore, where he spent se-
    few years, will take over as of 1.01.2011.                  veral years working mainly in customer service
                                                                                                                          Rainer Breidenbach
        Rolf Eckrodt, Chairman of the Supervisory               and after sales. In 2000 he transferred to Austra-
    Board of Tognum AG: “We regret that Rainer                  lia, where he held the position of Managing Di-
    Breidenbach has taken this decision. Since he               rector of MTU’s subsidiary, MTU Detroit Diesel
    joined the company in 2005, his decades of ex-              Australia. Following a an interim period in the
    perience in sales and distribution have enabled             USA at MTU Detroit Diesel, Peter Kneipp has
    him to become a major force in shaping the sales            been President and CEO of the fastest growing
    approach pursued by the Tognum Group and he                 Tognum subsidiary, MTU Asia Ltd., since 2004.
    ultimately takes the credit for the success we              During this time, the revenues of the Asian sub-
    have achieved. He will nevertheless continue to             sidiary have doubled and operating profit has
    support us in an advisory capacity.”                        multiplied many times over. With the targeted
        With the appointment of Peter Kneipp as the             expansion of the production, sales and distribu-
    new member of the Tognum Board of Manage-                   tion network by setting up company-owned ma-
    ment for the Business Unit Engines, the com-                nufacturing facilities and joint ventures in Asia,
    pany is demonstrating continuity at senior ma-              Peter Kneipp has been extremely successful in
                                                                                                                             Peter Kneipp
    nagement level. Rolf Eckrodt: “With Peter                   implementing Tognum’s strategy of regional ex-
    Kneipp, we have appointed a man to the Board                pansion. Peter Kneipp is married and has three
    of Management with considerable international               adult children.


                                                                      French classification
                                                                      FRIEDRICHSHAFEN (aka). The MTU Friedrichshafen
                                                                      production site of the Tognum group recently became
                                                                      even more flexible when it comes to satisfying customer
                                                                      requirements. The subsidiary is now permitted to certi-
                                                                      fy independently engines for commercial sea vessels,
                                                                      yachts and offshore applications using the rules of the
                                                                      French classification company Bureau Veritas, who re-
                                                                      cently granted their authorization.
                                                                          The certificate of authorization was granted in Septem-
                                                                      ber on the basis of a 6-day audit conducted in Friedrichs-
                                                                      hafen. Mid-June, the entire company process was exami-
Audit in Friedrichshafen: Auditor P. Hlina (4th from left) from the   ned in detail by an auditor from the French classification
French ”Bureau Veritas” took a very close look at the Turbocharger    company. The department responsible for engine certifica-
Production section in Friedrichshafen. The audit was coordinated
                                                                      tion and classification (TQA) organized the audit and con-
by A. Kunzi, CSQ, (not pictured) and U. Gotterbarm (right) from the
”Quality Management, Engine Acceptance and Classification” sec-       ducted it in conjunction with BV and the corporate quali-
tion.                                                                 ty management department (CSQ).


     Rescue in Chile:
      On 13. October,
 the trapped Chilean
miners were brought
       to the surface.
     The rescue shaft
which was so essen-
tial to their freedom
  was drilled using a
  mobile rig powered
   by an MTU Series
         2000 engine.
        (Photos: dpa).      C&I

                         MTU drive helps save Chilean miners
                         SAN JOSE/CHILE (aka). The eyes of the world have been                  rescue shaft was powered by an MTU 12-cylinder unit
                         upon Chile in the past few days, where one of the big-                 with 567 kW output.
                         gest rescue actions in the history of mining has just                       Schramm is a manufacturer of hydraulic drill rigs for
                         been carried out. 33 miners, trapped in the San José gold              land applications based in Pennsylvania. The Schramm
                         and copper mine following a landslide, were finally pul-               drilling rig was used to widen a disused 12-cm supply shaft
                         led to safety on 13. October. Thanks to a Series 2000 en-              to turn it into a rescue shaft. Then the shaft was widened to
                         gine, the rescue operation to save the Chilean pit men                 30-cm diameter, and then drilled to almost 70-cm diame-
                         could be carried out much earlier than originally ex-                  ter. “The drill T-130XD with our S-2000 engine had an im-
                         pected.                                                                portant mission in this rescue. When our intelligence is
                             The Schramm T-130XD flat drill rig used to drill the               used along with technology even miracles can be possible”,
                                                                                                wrote Chilean Omar O. Solis, Regional Product Support,
                                                                                                Manager Latin America Office, MTU Detroit Diesel.
                                                                                                     This is not the first time that an engine built by a Tog-
                                                                                                num subsidiary has been instrumental in the rescue of
                                                                                                trapped miners. Several years ago, an MTU Detroit Diesel
                                                                                                S60 engine was used to drill a rescue shaft for miners trap-
                                                                                                ped in the Quail Creek mine in Pennsylvania.

                                                                              Joy and relief:
                          Raul Bustos (pictured right) is one of the rescued Chilean miners.
                         Top: Following the rescue, the mobile Schramm drill with its Series
                                                       2000 engine attracted keen interest.



The heart of the Puma
FRIEDRICHSHAFEN/KASSEL (sto). The Defense divi-                  „In difficult terrain and on steep
sion of Tognum subsidiary MTU Friedrichshafen has op-            inclines in particular,
timized the 10-cylinder version of the Series 890 engine         the engine reliably
to produce what is an outstanding, high-performance              delivers powerful
engine.                                                          torque,“ emphasi-
    ‘Pulsetron’ is the name of the engine designed for light     zed Knut Müller,
and medium-weight defense vehicles that was presented            head of the Defense
for the first time in September at a Symposium of the            section. “We have not
Association of the Germany Army in Kassel.                       spent this much time
    The new name highlights the engine’s role as the “pul-       and effort on any other defense
sing heart” of the vehicle with an electronic control system     engine to date in terms of calculations, design,
which guarantees optimum propulsion in all driving situa-        and the fine tuning of tests, particularly for the turbochar-   Powerful Puma:
tions. In line with the tough requirements that prevail, the     ger, combustion system and the electronic engine and            The new 10V 890 for
                                                                                                                                 the armored personnel
engine of the Puma infantry fighting vehicle now draws           drive train management system,” said Dr. Dirk Pfuderer,
                                                                                                                                 carrier produces 800 kW.
800 kW and a torque of 2,400 Nm from a total displace-           head of defense vehicle development.
ment of 11 liters.

   OIL & GAS

                                                                                                                                 Frac Packs:
                                                                                                                                 The mobile, truck-
                                                                                                                                 mounted pump
                                                                                                                                 units for oil and gas
                                                                                                                                 production are
                                                                                                                                 powered by Series
                                                                                                                                 4000 engines.

Strong demand for oil and gas system solutions
HOUSTON (sto). After the successful launch of the                pared for production during the crisis. Now they need to
“Electrical Drilling Package”, the EAP department (Ap-           be fractured before they can be used,” explained Jürgen
plication Center Oil and Gas), headed by Jürgen Blass-           Blassmann. “Secondly, new oil shale deposits containing
mann, wants to make a further step into the Oil&Gas              natural gas are currently being brought into production.
market. Therefore, EAP developed the „Frac Pack“.                Here, there will be ten to thirty frac zones per well hole.
     This is a truck mounted power train solution which is       That means that the Frac Pack fleet is in service on-site not
used to drive pumps. The pumps fracture rock formations          just for a day but a whole week”. Frac Packs are equipped
under high pressure using specialized fracturing fluids.         with the new generation of Series 4000 engines that meets
This allows the cost-effective recovery of oil & gas reserves    the latest US EPA Tier 4 interim emission regulations. This
and enhances their productivity. The most important mar-         engine stands out from the competition by virtue of their
ket is the USA, which accounts for 70 percent of the global      quality, high torque, and low fuel consumption. To date,
market. Now that the financial crisis is over, there is a high   MTU has supplied engines meeting the current EPA Tier 2
demand for new equipment. “This has two reasons. The             to OEMs who use them to build frac trucks. In future, sub-
first one is that many oil and gas wells were not fully pre-     systems including engine and transmission will be offered.


                            RESEARCH & DEVELOPMENT

                            International Development
                            PUNE (sto). Tognum subsidiary, MTU India held the            the strategic expansion of business both in India and in
                            inauguration of its new Research and Development             Asia.
                                                    Center at an official cere-
                                                    mony on 28. September                Might it not have been better to locate the 60 new
                                                    2010 in the Indian city of           posts in Friedrichshafen where there are already
                                                    Pune. The Center currently           comprehensive trial and test stand facilities?
                                                    employs approximately 30                  Dr. Wintruff: The development of R&D facilities
                                                    design and calculation en-           like this outside Friedrichshafen is essential because the
                                                    gineers and an increase to a         German labor market will not be able to provide us
                                                    total of around 60 staff is          with all the qualified engineers we need in the long
                                                    planned.                             term. CAE (Computer-Aided Engineering) is one of the
                                                                                         areas where Indian engineers are very strong and the
                                                    “Insight” interview with             university city of Pune, with its population of 5 million,
                                                    Sadish Phadke, Director              is able to offer us ideal opportunities here.
           Opening of                               MTU India, General Mana-
Development Center:         ger Operations, MTU Research and Development                 Does this not mean that work is being taken away
     From left: Satish      Center, India, Dr. Wintruff, Head of Development,            from Friedrichshafen?
     Phadke, Director,
           MTU India ;
                            Thermodynamics and Fluid Systems and Dr. Eckstein,               Dr. Eckstein: No, so far the work done in Pune was
       Yogesh Kajale,       Head of Development, Series 8000.                            never done in Friedrichshafen. Mostly, it was outsour-
  General Manager of                                                                     ced to external agencies. However, not all R&D work is
      the new Center;       How significant is the new Development Center?               suitable for outsourcing in the long term and it is this
    Dr. Ingo Wintruff,         Sadish Phadke: The opening of MTU India’s R&D             kind of work which we are now channelling into a
     head of Thermo-
      dynamic & Fluid
                            Center today marks the creation of a world-class or-         Tognum company – MTU India.
          Systems and       ganization and network. In conjunction with the new
 Dr. Michael Eckstein,      company HQ in Pune, the Center is a vital element in
 head of Series 8000

                            TRACTOR MEET

                         “Red Sea” at Lake Constance
                         FRIEDRICHSHAFEN (wob). In September, Tognum CEO
                         Volker Heuer welcomed tractor enthusiasts to the Por-
                         sche-Diesel Meet at Plant 2 in Friedrichshafen.
                             “Although tractor building doesn’t figure in the history
                         of MTU and Tognum, it has been associated with the
                         colorful past of these premises. This is where the first Zep-
                         pelin rose into the air 110 years ago and it’s where Theodor
                         Kober and Claude Dornier built their world-famous air-
                         planes”, said Heuer. It was also where the Allgaier com-
                         pany manufactured its AP 17 “Volksschlepper” tractors
                         from 1950 onwards. The tractors had been designed by
                         Ferdinand Porsche back in the 1930s, in parallel with the
                         Volkswagen. When production was discontinued, MTU’s             Porsche-Diesel Meet in Friedrichshafen, Plant 2: Red Porsche
                         predecessor took over the workforce and the buildings.          tractors and orange Algaier machines lined up once more to re-
                                                                                         form a “Red Sea” – a description dating from the days when the
                         The entire history of Friedrichshafen’s tractors is covered
                                                                                         tractors were produced in large numbers.
                         by a new book “Porsche-Diesel Tractors – Myth and Pas-
                         sion” by Manfred Krämer, Ulmer Press, € 34,90.

Building progress: The giant concrete pillars of                                                                                      News
Tognum’s new Materials Management Center
near Friedrichshafen give an indication of the
building’s dimensions.

                                                                                                 In brief …
                                                                                                 “Green” propulsion systems in demand at
                                                                                                      HAMBURG (aka). Visitors to SMM, the
                                                                                                 world’s biggest shipbuilding fair in Hamburg,
                                                                                                 could experience at the MTU booth, how ef-
                                                                                                 fectively MTU is able to dampen the noise.
                                                                                                 „Discover MTU“ at the center of the booth
                                                                                                 provided exciting on-screen insights into in-
                                                                                                 house technologies from MTU, green propul-
                                                                                                 sion solutions and offshore applications. In
                                                                                                 coming years, dynamic growth is expected in
                                                                                                 the offshore industry in terms of wind farms
                                                                                                 and oil and gas platforms.
                                                                                                 Gas-Powered Gensets for Bangladesh
MMC building growing steadily                                                                         DHAKA/BANGLADESH (aka). Interregio-
                                                                                                 nal cooperation within the Tognum Group has
                                                                                                 resulted in the successful sale of three gas-
KLUFTERN (aka). MTU Friedrichshafen’s new Materials Management Center (MMC) is
                                                                                                 powered gensets to Bangladesh. The MTU
 taking on shape with a forest of pillars pointing skyward.                                      Onsite Energy sales team from MTU Asia in
    Construction of the 46,000m2 hall began in September and the exterior shell is sche-         Singapore and the project engineering teams
duled for completion by the winter so that work on the interior can go ahead. Fall 2011 will     from Singapore and Augsburg collaborated
see the building finished and relocation is planned for the end of 2011.                         for the project which was first initiated in
                                                                                                 January 2009. Each of the three gensets ge-
                                                                                                 nerates 1.9 MW of electrical power.

                                                                                                 Genset for dairy farm
IN MEMORIAM                                                                                           MINNESOTA/USA (aka) 6,400 cows are
                                                                                                 kept at West River Dairy, a dairy farm in wes-
In memoriam: Dr. Hans Dinger                                                                     tern Minnesota (USA). Its new MTU Onsite
                                                                                                 Energy genset based on a MTU Series 2000
                                                                                                 diesel engine ensures that the milking equip-
FRIEDRICHSHAFEN (sto). The former                  lopment section                               ment and new air fans installed there keep
Chairman of the MTU Board of Manage-               at MTU Munich                                 running even if a power outage occurs.
ment, Dr. Hans Dinger, died at the end of          from 1973. Fol-
                                                                                                 Gas-powered cogeneration plant to heat
October at the age of 83.                          lowing the mur-
                                                                                                 pellet mill
    “Dr. Dinger’s entrepreneurial far-             der of Dr Ernst                                    MILAN/ITALY(aka). Highly efficient and
sightedness, which always combined deve-           Zimmermann by                                 easy on resources – those are the key featu-
lopment, sales and, primarily, market              the RAF on 1.                                 res of the natural-gas-powered cogeneration
aspects, was the key factor underlying the         February 1985, Dr Dinger was appointed        plant in the new factory operated by Italiana
                                                                                                 Pellets near Milan. The pellet manufacturer’s
success of our company at that time,” said         Chairman of the Board of Management of
                                                                                                 cogeneration plant was developed and built
Chairman of the Tognum Executive Board             MTU Munich and MTU Friedrichshafen.           by MTU Onsite Energy Gas Power Systems in
Volker Heuer in recognition of the achie-          In this capacity, he also became a member     Augsburg. A long-term maintenance contract
vements of the former MTU manager.                 of the Executive Board of Daimler-Benz        with MTU Italia ensures maximum system
“His outstanding technological and com-            AG in 1986. He retired in 1989.               availability. The cogeneration plant is equip-
                                                                                                 ped with two MTU 16V 4000 L62 gas engines.
mercial expertise, his purposefulness and              His outstanding engineering expertise
                                                                                                 It generates three megawatts of electric
his endurance were decisive in driving the         enabled Dr Dinger to achieve milestones       power and two megawatts of thermal energy.
company forward. ”                                 in technology which gave MTU Fried-
    Dr. Dinger was born in Stuttgart in            richshafen a decisive competitive edge.       Power supply in the Amazonas region
1927 and studied engineering at the Tech-          Throughout his life, both as a speaker and         MANAUS/BRAZIL (aka). 36 gensets
                                                                                                 from MTU Onsite Energy are to supplement
nical University of Stuttgart. He joined           as an honorary senator of the University of
                                                                                                 the power supply in Brazil’s Amazonas region.
Maybach Mercedes-Benz Motorenbau                   Constance, he also played an active role in   The systems are to run continuously to gene-
GmbH in Friedrichshafen in 1968 as De-             the ongoing debate on social issues such as   rate additional electric power for the local grid
puty Managing Director. In 1969 the com-           education, leadership quality and perfor-     surrounding Manaus, the 2.6 million-strong
pany became MTU Friedrichshafen with               mance. His commitment and service were        capital of the federal state of Amazonas in
                                                                                                 north-west Brazil.
Dr Dinger as Managing Director of the              recognized with the award of the Cross of
Development Division. In this position he          Merit, 1st Class and, in 1987, the Medal of
also took over responsibility for the deve-        Honor of the City of Friedrichshafen.


          Rail exhibition
          At the rail
          exhibition in
          Tognum brand
          MTU show-
          cased future-
          oriented drive
          solutions de-
          veloped for
          with Emissi-
          ons Stage
          EU III B.


        Green week with a difference
                                                               Visitors flock to MTU booth at Innotrans
        Green is not the color one would expect at an MTU trade show booth. But for some, Tognum subsidiary
        MTU’s presentation at Innotrans, the world’s most important rail industry exhibi-
        tion which took place in Berlin in September, held more than one surprise.

        B   ERLIN. Without exception, all the drive solutions on
             show – from the hybrid Powerpacks currently being
        tested in collaboration with Deutsche Bahn, to Series                                                            Hybrid Powerpack:
        1600 engines for rail applications and the completely                                                     At the exhibition, MTU
        re-worked Series 4000 engine concept – comply with the                                                  announced trials of the en-
        EU Stage III B emissions limits which will come into force                                         vironmentally-friendly drive sys-
                                                                                                           tem with “Westfrankenbahn”.
        for European trains in 2012.
            Whilst European Union emissions legislation is a
        major talking point amongst experts, there are still almost                 plained that this engine series is an excellent star-
        no 'ready-to-install' solutions available to locomotive ma-       ting point for Tognum in the locomotive market of the fu-
        nufacturers. "We are the only engine maker to build an            ture.
        engine on the scale of our Series 4000 unit which comes                The testing of a hybrid Powerpack in conjunction with
        ready with an EU Stage III B certificate," said Rainer Brei-      'Westfrankenbahn', a subsidiary of Deutsche Bahn, was a
                          denbach, member of the Tognum Execu-            major theme of Innotrans in general and especially at the
                           tive Board and responsible for the En-         MTU booth. Considerable interest was also shown by jour-
                             gines business unit. It came as a sur-       nalists during the press conference on hybrid solutions
                              prise to many visitors that this engine     given by MTU and Westfrankenbahn. "25 percent less fuel,
                               is already powering a locomotive:          meaning 25 percent less carbon dioxide – that’s quite an
                                the 16-cylinder version is installed      achievement“, said Mr Dohle. Just a day before, Peter
                                in the new Vectron series of diesel       Ramsauer, the German minister of transport, had promi-
                                 locomotives from Siemens, which          sed support for the project and given Tognum board mem-
                                 unexpectedly had its premiere at         ber Rainer Breidenbach und Deutsche Bahn CEO Rüdiger
                                  Innotrans. Mr Breidenbach ex-           Grube confirmation of 1.9 million euros in funding.
                                                                               Series 1600 engines were also in the spotlight and are
                               Twin premiere at Innotrans:                set to play a major role in the rail market from 2013. Both
                               The 16-cylinder rail version of the new-   the 1600 Powerpack engine and the version for locomotive
                               generation Series 4000 powers the new
                                                                          engines are compliant with EU Stage III B regulations.
                               Siemens Vectron series.

                                                                           Words: Wolfgang Boller, Pictures: MTU, Wolfgang Boller, Messe Berlin


           Swiss multi purpose locomotives powered by eco-friendly drives

Swiss railway companies belong by tradition to those customers presenting the very toughest operating
conditions to MTU. The latest Swiss railway order is no different.

F   RIEDRICHSHAFEN. Tognum’s ‘Engines’ business unit
     is to supply ‘Rhätische Bahn’ (Rhaetian Rail) with four
12-V Series 4000 engines with 1,800 kW output for power-
                                                                 motive comes to a halt during operation, an automatic
                                                                 start-stop mechanism switches off the main engine and
                                                                 starts up the auxiliary one. A generator then provides the
ing 4 diesel-electric multi-purpose locomotives. The loco-       locomotive with the on-board electric power it needs – for
motives are not to be used for passenger services but for        example for heating and lighting. Emissions from the
performing heavy-duty work. They showcase a highly               auxiliary drive are also cleaned in the diesel particulate fil-
cost-efficient and eco-friendly drive concept which allows       ter of the main engine.
them to perform in the tough conditions prevailing on the
Glacier and Bernina Express lines across the Bernina and             Another eco-friendly feature is the engine starter – a
Albula passes. The connection via the Bernina pass at an         maintenance-free CaPoS (Capacitor Power System) deve-
altitude of 2,250 meters is one of the highest railways in the   loped by MTU. It replaces batteries containing acid pollu-
Alps working exclusively on the adhesion i.e. non-cog and        tants and also boasts five times their service life. The elect-
pinion principle. The Schalker Eisenhütte company based          ric brake also saves energy. In contrast with the mechani-
in Gelsenkirchen is scheduled to deliver the locomotives in      cal brake, the electric brake deploys the electric traction
2012/2013. They will mainly be used in track and line            motors as power generators. As opposed to the hybrid
maintenance, railtrack construction and for snow-clearing        drive, in which electric energy is stored in accumulators,
and track servicing in the winter months. They will also         the traction motors feed power directly into the on-board
have the job of pulling stranded passenger trains.               network. The fact that the drive works without hydraulics
                                                                 or V-belts is another fuel-saving factor.
    Various technologies contribute to the outstanding                                                           Words: Wolfgang Stolba
cleanness and cost-efficiency of the drives. The Series 4000                 Pictures: Glacier Express, Illustration: Schalker Eisenhütte
engines are fitted with diesel particulate filters by Schalker
Eisenhütte. Another innovative feature is support of the
units by small 200 kW auxiliary diesel engines. If the loco-

                                                                                                                                            Locomotives for
                                                                                                                                            Four multi-purpose,
                                                                                                                                            diesel-electric loco-
                                                                                                                                            motives (see photo
                                                                                                                                            above) for service on
                                                                                                                                            routes in the Glacier
                                                                                                                                            and Bernina Passes,
                                                                                                                                            are to be fitted with
                                                                                                                                            1,800kW, 12V 4000


                   AFTER SALES

                                                                               Professional workshop services are
        Tognum Group distributors and service workshops are the              “For us, the MTU Service Units are a particularly flexible
                                                                             way of bringing MTU’s renowned service standards close
        first points of contact for our customers. As generators of
                                                                             to the customer in areas with limited infrastructure,”
          revenue, they are to be given a more pivotal role. And to          explained Hans-Peter Benz.
        provide a reliable service globally, the network of certified
                                                                                 Proximity to the customer is also the main priority of
                               service workshops is to be expanded.          the Service Center for large diesel engines in San Leandro,
                                                                             California. The center was set up in 2009 for servicing

                F  RIEDRICHSHAFEN. “Here is our heavy-duty shelv-
                     ing, and there next to the workshop area we have in-
                stalled the power supply control consoles so that they are
                                                                             Series 1163 engines in US coastguard vessels and mainly
                                                                             stores tools and components for carrying out service work
                                                                             on board. “The Service Center concept pays off, both for
                immediately accessible.” Hans-Peter Benz, team leader for    the US coastguard and MTU. Through reliable service, the
                workshop and test stand solutions in Friedrichshafen, is     swift supply of parts and the provision of support and
                describing his latest ‘baby’ – the MTU Service Unit, which   training on location we are building a basis of trust,” said
                takes the form of a mobile 40-foot container. Available      Bill Emborsky, program manager at the Service Center.
                since 2009, the containers can be taken anywhere in the      The same model proved popular in the new MTU Sales
                world. Fully air-conditioned, storm and sand-proof and       and Application Center serving the gulf coast near New
                ideally equipped with storage facilities, workshop, office   Orleans. According to Bill Emborsky, the principle might
                and power generator, they possess the small workshop in-     be applied to other locations in the east and south, since
                frastructure that customers need to have close at hand.      the number of large diesel engines in the US is increasing.
                One of these MTU Service Units is already up and running
                in the port of Muscat in Oman, exactly where 3 important         These are clear signs of the consolidation and expan-
                MTU customers – the ‘Royal Oman Police’, the ‘Royal          sion of After-Sales operations. Standard and individuali-
                Yacht’ and the ‘National Ferries Company’ – are located.     zed maintenance contracts which help sustain the value of


                                                                                                                                  Preserving value:
                                                                                                                                  In line with the Value-
                                                                                                                                  Care philosophy, the
                                                                                                                                  MTU UK workshop in
                                                                                                                                  England provides pro-
                                                                                                                                  fessional support for
                                                                                                                                  customers, particularly
                                                                                                                                  in the rail, marine and
                                                                                                                                  power generation
                                                                                                                                  Illustr., above: 3D
                                                                                                                                  image from the “Work-
                                                                                                                                  shop and Test Stand
                                                                                                                                  Solutions” team,

an indispensable part of After-Sales
   engines and systems are increasingly becoming an integral       ‘MTU ValueCare’ –
   part of purchase contracts. After-Sales work in itself and by   optimizing the value of the customer’s investment.
   virtue of its closeness to the market can help to win new           With the ‘ValueCare’ concept, the After-Sales section
   customers. In 2005, MTU’s comprehensive maintenance             has not only established a brand name reflecting its greater
   contract for Series 4000 engines in high-speed trains faci-     strategic significance but has stepped up its pledge to the
   litated its entry into Britain’s locomotive market. The first   customer. A portfolio of services and products individual-
   point of contact for engine overhauls is MTU UK, which          ly tailored to the customer’s needs provides a sustainable
                                                                                                                                  Mobile workshop:
   opened an excellently equipped workshop in East Grin-           increase in the values he has acquired. The contribution of    Model of the
   stead near London in 2008. Components and engines are           workshops is to ensure that drives perform reliably and        “MTU Service Unit” –
   sent from there to the Magdeburg location for recondi-                                                                         shown here with its
   tioning. Older MTU workshops which have the advantage                                                                          “inventors” (from
                                                                                                                                  left) Hans-Peter
   of highly experienced personnel can be geared up for the
                                                                                                                                  Benz, Martin Zöllner,
   After-Sales market with thorough modernization. One                                                                            Stefan Lanz and
   example is the German Repair Center in Duisburg. In                                                                            Thomas Moser from
   2010, floor space was extended and its processes opti-                                                                         the “Workshop and
   mized, resulting in a doubling of capacities. The                                                                              Test Stand Soluti-
                                                                                                                                  ons” team in Fried-
   center specializes in the maintenance, over-
   haul and repair of 183, 493, 652, and 396
   ‘Classic’ engines and of Series 2000 and
   4000 units. The extension has allowed
   the facility to perform additional work
   better – in particular assembly module
   maintenance jobs taken over from the
   former service center in Hamburg.


            Service in
     California, USA:
     Proximity to the
   customer was the
overriding aim of the
Large Engine Service
  Center in San Lean-
       dro, California.
The Center is located
  directly adjacent to
the vessels of the US
 Coast Guard (above).

                             AFTER SALES

                          cost-efficiently throughout their service life so that the
                          core values of the ValueCare concept – durability, reliabili-
                          ty and quality – are realized. Sustaining value also means
                          protecting resources and saving costs, which follows the
                          basic idea behind the remanufacturing concept: parts,
                          components, engines and systems are to be kept in the
                          operation/maintenance cycle for as long as possible.

                          Prudent, goal-oriented planning
                              Good service begins with the planning and equipping
                          of workshops. Efficient support means more than just

      Repair Center
        in Duisburg,
  The Service Center
   has implemented
  major optimization


                                                                                                                                    MTU Italy workshop:
                                                                                                                                    MTU Italy’s Central
                                                                                                                                    Workshop is ideally
                                                                                                                                    equipped to deal with
                                                                                                                                    engines in service
                                                                                                                                    in commercial and
                                                                                                                                    governmental appli-
                                                                                                                                    cations. The test
                                                                                                                                    stand (right) has two
                                                                                                                                    dynamometers for
                                                                                                                                    engines producing
                                                                                                                                    500 kW to 4,200 kW.

providing the right special tool. “We want to ensure that     equipment is no longer adequate for maintenance purpo-
MTU’s external service organization is capable of provi-      ses. At the same time, many workshops are unable to afford
ding MTU’s quality standards. That is why we also consi-      expensive devices such as inspection instruments for in-
der the local infrastructure when assessing external work-    jector nozzles. Whilst workshops were able to completely
shops,” emphasized Thomas Moser from the workshop             cover servicing of Series 396 engines, many components in
and test stand planning team. Which equipment, hoists,        the successor model – the Series 4000 engine – have to be
tools and machines a workshop needs depends on its ser-       overhauled by central or specialized service providers or at
vice focus. That can range from simple maintenance work       the manufacturer’s site.
and the re-conditioning of components to major engine                                                      Words: Wolfgang Stolba
overhauls with performance verification and test runs.           Pictures: Robert Hack, MTU DD, MTU Italia, MTU UK, Robert Kardas

 New technologies – new maintenance concepts
    There is no such thing as routine in a workshop. Ultra-
modern, complex engine configurations constantly pre-
sent service personnel with new challenges. To be able to
satisfy sharply tightened emissions regulations, major in-
vestments are being made in the refinement of key techno-
 logies such as turbocharging, injection and electronic
  control systems. Since these systems are subject to very
    narrow tolerances, standard testing and machining

Side glance


Clean cut
F    RIEDRICHSHAFEN (sto). A Series 1163 cylinder
     head is cut open – wanton destruction of engine parts?
No, definitely not! Test components which have been in
operation in an engine for a given period of time undergo
thorough inspection in the Test Section at Friedrichshafen
in order to identify possible changes such as internal cracks
or formation of deposits. This requires the cylinder head to
be cut open at a specific location to facilitate visual in-
spection, crack testing and geometry measurement.

                                              Pictures: Robert Hack

A look inside an open cylinder block:
Gerhard Heudorf from the “Material Mechanics/Component Tes-
ting“ section at MTU Friedrichshafen with a Series 4000 cylinder
block which has been cut open.

Side glance

Work & Social


                Online world
                           Link-up of Tognum sites would be unthinkable
                               without data communication technology.

                Information technology with its communication and work platforms has
                increased the size of the virtual world at Tognum. To help the Tognum group
                integrate further and save costs, the aim is now to achieve greater standardization of
                the group’s IT programs worldwide.

                F  RIEDRICHSHAFEN. Since the mid-90s, production
                     specialists from Friedrichshafen and Detroit (and now
                from Aiken) have held video-conferences to compare
                                                                              electronically,” concedes Bruno Hartmann
                                                                              from the IT applications service (CS1S).

                notes on the production of Series 2000 and 4000 engines.      Global standardization of processes
                In the meantime, in the field of video-communication,             More difficult to standardize on a worldwide scale than
                Internet-based solutions such as ‘round-table’ video confe-   communication are IT-based work processes such as those
                rence systems with 360° panoramic view camera devices         used in order processing, logistics or in After-Sales – expe-
                and other sophisticated software tools such as ‘Live-         cially where specifically customer-oriented business is in-
                Meeting’, ‘Sharepoint’ and ‘Communicator’ are helping to      volved. Greater uniformity is still desirable in this area, in
                make tele-conferences even more convenient to hold.           order to facilitate greater transprancy and speed as well as
                Around 860 Tognum employees worldwide make use                    more straight forward system maintenance and lower
                of these tools. However those favoring a more                             costs. “We do not want similar types of business
                reality-based approach can see the limita-                                     to be handled differently in Detroit than in,
                ions of virtual meetings: “Delicate nego-                                         say, China,” emphasized Dr. Wolfgang
                tiations must be conducted as before at                                             Heizmann, head of IT at Tognum. That
                the table since tone, gestures and facial                                            goal has at least been met in the case of
                expressions cannot be communicated                                                    a few key programs, such as the IPAS
                                                                                                      software for order configuration and
                                                                                                      processing in worldwide sales. The
                                                                                                      software allows engines, accessories
                                                                                                    and entire systems to be configured,
                                                                                                   quoted and then ordered from the re-
                                                                                                 spective production sites. “One of the
                                                                                             main reasons why IPAS is so highly develo-
                                                                                       ped is that MTU has been using and optimizing it
                                                                              for 15 years,” said Michael Feldmann, from IT Solutions
                                                                              Sales (CS1V). With the more advanced ‘IPAS Future’ ver-
                                                                              sion, it will be possible for different sites to supply engines
                                                                              and accessories for one and the same customer order. As-
                                                                              certainment and display of the order processing status will
                                                                              also be even more precise. ‘IPAS Future’ will also provide
                                                                              optimal support for standard processes in the components
                                                                              business by implementing simplified procedures.

                                                                                  Key After-Sales processes will be carried out with the
           Live-Meeting: Compared with conventional video-conferences,        help of more or less new computer programs covering pro-
           Internet-based conferences using a 360-degree camera make inter-
                                                                              duct documentation, spare parts processes, in-field service
           location conferences even more effective.
                                                                              and in-house repairs. All these processes can be located

                                                                                                                                           Work & Social

                                         Worldwide cooperation:                         1
                       Inter-location cooperation achieved global
                          dimensions long ago – especially in the
                          IT sector. A team from Friedrichshafen,             4                          7                  10
                            Singapore and Detroit is now working                                                                       8
                                 together on the “Toga” warranty                                                   2
                                                         program.                                                                      9



                                           quickly in the
                                          Business    Portal.
                                         When the programs
                                  were being compiled, great
                               value was attached to user-
                            friendliness, the ASO (After-
        Sales Object Database) program package for orde-
                                                                       The world from your desk:
     ring and managing spare parts being a case in point.              Tele-communication in the workplace. Here, a virtual meeting between two employees.
This package allows the complete propulsion system of, for
                                                                        1 Web-Cam
example, a yacht, to be displayed on-screen. If a service
technician is looking for a specific spare part, he simply              2 Live video image of the PC-user
clicks on the engine or system in question, for example, on             3 'Virtual' conference room showing documentation and presentations
the genset. A list of all components is then opened. For the
                                                                        4 Information on the meeting: who is in the virtual conference room?
engine itself, the date of delivery, emission characteristics,
certificates and the current owner are also indicated. “Our             5   Flags and comments
goal on this project was to bring together all the essential            6 Chat (only possible with more than two participants). Participants can converse
information relating to a product,” said Joachim Oeschler                 discretely during the conference.
from the IT applications service. The master data assigned              7 Signaling status: participants can state their wishes: for example: 'go more slowly'
to each engine form the core of the program, this data                    or 'I have something to say'
being available even if a vehicle is moved to another part of           8 'Communicator': provides information on the availability of contacts e.g. 'available',
the world.                                                                'absent', 'please do not disturb'
                                                                        9 List of contacts
    ‘TIM’ (Technical Information Management) is a new
content management system which standardizes the pro-                  10 Own availability status
duction of manuals and After-Sales documentation world-
wide. Not only are after-sales manuals and documents glo-
bally available, but the way they are compiled and designed         We had to go through many stages of negotiation before
has been internationally standardized. With ‘TIM’, 55 tech-         being able to reconcile the various regional requirements.”
nical writers around the world have at their fingertips huge
volumes of information on engines and components which                  Standardized IT programs for other tasks and proces-
they can use to ‘fill’ simple layouts. The system houses            ses are currently being prepared for worldwide application.
some 800 different engine configurations and versions.              One example is the TOGA warranty program (in German:
Data on new standard gensets, two-stroke engines and                Tognum-Gewährleistungsabwicklung), which is the sys-
Series 1600 engines, as well as on electronic components,           tem used at Tognum subsidiary MTU for filing and proces-
are constantly being added. The system ensures efficient            sing claims. System start-up was in October 2009 and six
working by administrating some 40,000 constantly recur-             different program versions are available so far. In future,
ring text modules. Documentation is provided in a total of          only one will be used. “That considerably saves costs, not
twelve languages, with Chinese and the Slavic languages             least for service departments,” emphasized project leader
now available. Project leader Bruno Hartmann from the IT            Hans-Peter Frohmüller.
Solutions Sales and Technology department (CS1), poin-
ted out that it had not been at all easy to find a uniform,                                                     Words: Wolfgang Stolba
workable concept: “Globalization is a complex business.                                                           Pictures: Robert Hack

Work & Social

                                            “FUTURE ACTIVE”

        “From Monday on, I’m building engines…”
                                              Most IFA-Rotorion employees have new placements

             IFA-Rotorion employees in Friedrichshafen can breathe
                     a sigh of relief: As drive shaft production is being
                                                                                F  RIEDRICHSHAFEN. The shock ran deep. When
                                                                                     the transfer of production facilities from IFA-Roto-
                                                                                rion to Haldensleben became a certainty at the start of
          transferred to the new owner in Haldensleben, the project             2009, many employees were in the dark as to their working
                                                                                future. Since then, the “Zukunft Aktiv” (Future Active)
           team “Zukunft Aktiv” (Future Active) has been seeking a
                                                                                project team has made a good deal of headway and over
               solution for every member of the workforce. And their            330 of IFA Rotorion’s 426 employees have been provided
                                                                                for. By the end of the year, 80 percent will have new place-
                 efforts have been extremely successful – most have
                                                                                ments. Most will be employed in engine-building – either
                            found a new placement in engine-building.           in production, assembly or repair, or in logistics and deve-
                                                                                lopment. Others have signed agreements for semi-retire-
                                                                                ment or for contract termination with compensation.
                                                                                     “Our ongoing aim has been to provide each and every
                                                                                employee at IFA-Rotorion with at least one prospect,” said
                                                                                head of human resources Matthias Jobmann. However
                                              “I’ve been plea-                  with just one exception, no-one was ready or able to move
                                               santly surprised”
                                              “As master craftsman, what
                                              worried me most was what             “I could have started the next
                                               was to become of my 33 per-          day’
                 ter craftsman in pro
                                         -     manent members of staff.
Thomas Enser mas            now training
peller shaft assembly, is                      They were exceptional people            “I worked in propeller shaft production for 27
                       in the Technical        who had always been ready           years, which makes it hard when all of a sudden
as a technical writer
Documentation sectio                           to put themselves out for the       nothing is like it used to
                                               company, even in difficult          be. However in my case,
                     times. The uncertainty of the situation hit many of           the turning point didn’t
                     them hard. I’m very pleased that altogether, the pla-         come at a bad time. I
                     cement initiative was a success – also as far as my           was just about to gra-
                     own future is concerned. I was a bit skeptical at first,      duate in business admi-
                     but have been pleasantly surprised. I’m now training          nistration when the bad
                     as technical writer and project manager in the Tech-          news came of the re-
                     nical Documentation section and can be there for my           location. The fact that I
                     family without the upheaval of a change of location.          had just sat the exam
                     However, that would not have been possible without            and had the back-up of
                     a certain degree of flexibility. My new job is vastly         the excellent placement      Andreas Mikusky was a pro-
                     different to my old one – instead of machines, I’m            services of the project      duction cell supervisor, but
                     now dealing with spare parts catalogues, commissio-           team opened many             is now training as a logistic
                                                                                                                specialist in the project
                     ning documentation and maintenance schedules. I’m             doors to me. I could
                                                                                                                support section for military
                     also following a related 4-month course at the Tech-          have been taken on          drive systems.
                     nical University of Esslingen.”                               straight away.”

                                                                                                                                           Work & Social

Agim Bischofberger, 37,
worked in propeller shaft
assembly and has now found
a job in Überlingen working          Transferring
on assembly of Series 1600           from assembly                       A highly motivated workforce
engines.                             to assembly
                                                                         “As a repair workshop, we are
                                “When I heard that sooner                one of the sections with more
       or later my job in propeller shaft production was                 stringent requirements when it
       going to go out the window, I panicked. I didn’t know             comes to taking on new people.
       what to do. I have a family and couldn’t just move to             The range of skills extends
       Haldensleben. Finding a new placement went surpri-                from the disassembly,
       singly smoothly, which I was really glad about. I had             cleaning, inspection, and re-
       my first talk with Mr Hanslik in mid-November 2009                working of used components
       and just two weeks later, on 1. December, I began my              to the ordering of new compo-
       job in Überlingen. I came from assembly and found                 nents and their installation
       another job in assembly, working in very clean, low-              and testing. All of the 19 Ro-
       noise conditions. My new job is actually more chal-               torion employees we took on
       lenging than my old one, but I’m being shown the                  in 2010 were actually auto-         Master craftsma
                                                                                                                             n Michael Knau
                                                                                                            fr. right) is                    s (2nd
       ropes here and have no worries about not managing                 motive specialists and there-                      head of engine
                                                                                                            in Plant 1 and
       it. The only snag is commuting from Friedrichshafen               fore qualified metalworkers.       sections taking
                                                                                                                             Plant 2 - one
                                                                                                                                           of the
       to Überlingen in the summer months. I often need an               Another six will be coming                           on Rotorion em
       hour just one-way because of the traffic jams.”                   next year. The project team
                                                                         did a fine job of organizing the placements. Our new
                                                                         colleagues are highly motivated. You can tell that
   to Haldensleben. To find a solution, four external specia-            they have found a new goal and are committed to
   lists were engaged to form a team with human resources                meeting it.”
   co-workers. Karl-Heinz Wulle, works council chairman,
   underlines that their success can ultimately be put down to
         the solidarity and flexibility of all involved – not only   tion. Unfortunately, not all companies in a similar situati-
          the employees affected, but also the co-workers in hu-     on show the same commitment to securing their employe-
          man resources, the works council and the project           es’ futures. They set up a redundancy scheme, and that’s the
          team. The same applies to the departments receiving        end of the story.” Ingo Schreck, project manager, said: “It’s
          the new co-workers as well as those areas of propeller     the first time I’ve ever seen anything like this in my time as
         shaft production giving them up. Praise also came           a placement officer. A solution could be found every time,
         from Gabriele Kreiß, head of the Ravensburg branch          so that employees who had their last working day in pro-
         of the Federal Employment Agency: “In their ap-             peller shaft production on Friday could already begin in
         proach, everyone involved at Tognum has set an              engine manufacture the following Monday.”
         example for others to follow and shown great dedica-
                                                                                           Words: Wolfgang Stolba; Pictures: Robert Hack

                                                                     Project participants: "Future Active". From left:
                                                                     Ingo Schreck, Project Leader, “Future Active”; Dagmar Metzler, “Future Active”;
                                                                     Matthias Jobmann, head of HR; Sylvia Pfadler, “Future Active”;
                                                                     Wolfgang Hanslik, Dep. Project Leader; Tanja Zerlaut, “Future Active”;
                                                                     Karl-Heinz Wulle, Chairman of the Works Council.

   Work & Social


                          Each of us is personally responsible
                                             Online compliance training for employees and management
                          From December, all employees in Germany, will receive information acquainting them more closely with
                          various aspects of “Compliance”. From 2011, the information will be passed on to employees worldwide.
                          The aim: to strengthen the “Compliance Culture” at Tognum and its subsidiaries.

                          F   RIEDRICHSHAFEN. An invitation from your hard-
                              ware supplier to a wine-tasting session; tickets to a mu-
                          sical for you and your spouse as a birthday gift from your
                                                                                               programs are to be offered worldwide to all employees in
                                                                                               2011 shows just how important the issue is for Tognum.

                          business partner; a fee for giving a conference lecture on a       The social responsibility of companies is increasingly
                          corporate theme; less favorable treatment of a co-worker           important
                          due to his age; careless use of working equipment or natu-              Numerous cases of unethical conduct by various com-
                          ral resources or even a price agreement with competitors:          panies highlighted in the media over the past two years
                          All of these situations have one thing in common – they are        have shown that illegal and unethical behavior on the part
                          not acceptable. In business-speak, they are not “compliant”.       of employees such as corruption, agreements which in-
                          They infringe the law or corporate regulations.                    fringe anti-trust laws or gross negligence in the handling of
                                                                                             natural resources or company data not only results in
                                                                                             negative personal consequences but also causes serious
                                                                                             loss of image and often involves financial loss amounting
                                                                                             to billions of euros for the companies concerned. It is gene-
                                                                                             rally recognized that corporate image is not measured
                                                                                             solely in terms of profit and that corporate social responsi-
                                                                                             bility is becoming more important and can offer competi-
                                                                                             tive advantages with respect to the labor market, the custo-
                                                                                             mer and the financial markets. Acting ethically and within
                                                                                                                  the law is not a new subject for Tognum
                                                                                                                     or its predecessor companies and has
                                                                     Definition of “compliance”:                     been practiced at Tognum for many
                                                                     “Compliance” means to follow the rules.         years now. What is new is the com-
                                                                     In business, it describes a form of be-         pliance structure that the company
                                                                     havior in which laws and directives as well
                                                                                                                     has set up. For example, a Compli-
                                                                     as corporate rules and society’s moral
The Tognum Compli-        „Such infringements are not petty                                                          ance Council has been created which
                                                                     values are observed voluntarily by com-
         ance Council:
                          offences. We take compliance very          panies                                          deals with the further development
     From left: Günter
   Leininger (head of     seriously at Tognum,“ said Tognum                                                          of compliance structures at Tognum.
 Corporate Audit and      CFO Joachim Coers. Compliance                                                             The elements involved include, for
 Risk Management),        means conducting business in a responsible manner and in example, training courses, regular reporting and the
      Georg Gösswein      accordance with the law and other rules. To achieve that, definition of minimum requirements. The Compliance
  (head of Legal Sec-
                          not only legislation but the Tognum Group’s own set of Council also makes recommendations to the Executive
   tion, Export Policy,
     Property Rights),    corporate rules, regulations and values must be observed. Board on compliance structure development. The Execu-
     Christopher Koch     These include the Integrity Code and other guidelines such tive Board has already decided that, in addition to existing
        (head of Legal    as that governing the provision of corporate data to third possibilities, confidential information on infringements
    Department, MTU       parties and the guiding principles of the Tognum Vision.           can be communicated to an external ombudsman via:
   Detroit Diesel) and
                               Right up to the Executive Board, each employee is re- The ombudsman is then
        Seow Kiak Tan
     (Senior Manager,     sponsible for observing these rules and regulations, and in required to pass the information on to the company in an
 Marketing and Sales      doing so each member of the Tognum Group contributes appropriate form in order to preserve the anonymity of the
  Control, MTU Asia).     to its success. Since September, many members of manage- informant.
                          ment have already attended one-day training sessions to
                          deal with various aspects of compliance. The remaining                                 Words: Anika Kannler, Picture/comic: Robert Hack
                          members of management and the workforce throughout
                          Germany will be involved in e-learning training programs
                          from the beginning of December. The fact that training

                                          Work & Social

Does my conduct satisfy compliance
1. Do I act in accordance with the law?
2. Do I act in accordance with the
   Integrity Code?
3. Is my conduct affected in any way
   by conflicts of interest?
4. Does my conduct protect the position
   of my company in society?
5. Would I lose face if my actions were
   reported in the newspaper?
Work & Social

        Training starts around the world:
       Apprentices are training to become
          qualified specialists at Tognum
        locations in Friedrichshafen (top),
      Magdeburg (left), Augsburg (center)
                  and South Africa (right).

                      Welcome on Board
                        Vocational training courses at German, Asian and South-African sites

       Securing a future generation of solidly qualified employees is            mechatronics. In Magdeburg, four school leavers started
                                                                                 vocational training in machining technology, mechatro-
becoming ever more vital, and in this area in-house vocational trai-
                                                                                 nics and industrial mechanics.
     ning plays a central role. In order to safeguard future standards,              At MTU South Africa in January, five new trainees
                                                                                 began learning the intricacies of engine assembly and ser-
Tognum locations such as MTU Asia and MTU South Africa are now
                                                                                 vicing. “We will use both workshop training and vocatio-
 increasingly adopting the vocational model practiced in Germany.                nal college courses to prepare our young people for their
                                                                                                              jobs as assembly technicians,”

                      F    RIEDRICHSHAFEN. Prospective candidates began
                          their training at various Tognum subsidiaries in au-
                      tumn. With a total of 83 young people in training,
                                                                                                              said Michael Baumann, Ma-
                                                                                                               naging Director of MTU
                                                                                                               South Africa. The need for
                      MTU Friedrichshafen has the lion’s share of                                              good next-generation per-
                      the next generation of employees: 60 school                                              sonnel is being covered at
                      leavers are beginning industrial training,                                                MTU Asia by 14 aspiring
                      seven young people are embarking on                                                       assembly technicians who
                      commercial training courses and a further                                                  began on 14. October. They
                      14 are undertaking integrated studies pro-                                                  will be trained as after-sales
                      grams. At L’Orange, 13 young people start-                                                  workshop technicians at
                      ed their courses and one school leaver began                                                 five MTU Asia sites.
                      a Bachelor degree. In Augsburg, three                                                                 Words: Anika Kannler
                      apprentices began a 3-year course in                                                                  Pictures: Robert Hack

                                                                                                                                         Work & Social


Express job taster
                                                              Two Apprentices on Field Assignment
A spell of work on the Canary Islands? Why not?
Prospective industrial mechanics Jasmin Klein and
Christian Hecht have spent the last three years in
Friedrichshafen getting to terms with the intrica-
cies of engine assembly.

G   RAN CANARIA. Before July this year, however, they
     had little idea about field service work or whether they
might one day want to become field service technicians.
Then, they were given the chance to spend three weeks on
a “job taster”, observing field service technicians at work
on one of the world’s biggest and most modern fast ferries,          deciding on whether to actually take up such a demanding
the “Benchijigua Express” on Tenerife. Under the watchful            and interesting career,” said Herbert Schmidtke, in charge
eye of Ralf Gruber, they were able to carry out many of the          of field service technicians in Friedrichshafen. And Jasmin
jobs on the mighty Series 8000 engines themselves. Thus,             Klein’s opinion? “The most interesting thing was being
for example, they adjusted valve clearance, changed cross-           able to see the engine as an integral part of the finished
tie bolts, overhauled the “Power Units” and checked for              vehicle in actual operation with the ferry operator and cus-
leaks. They were also able to get an idea of what certain            tomers”
procedures such as shift changeover or tool and spare part                                                     Words: Wolfgang Stolba
provision involve. “There are only a few companies which                                       Pictures: Ralf Gruber, Robert Hack, MTU
offer this type of practical vocational training. This sort of
experience is obviously extremely useful when it comes to

    Training taster on Gran Canaria:
    Whilst the fast ferry “Benchijigua Express” was laid up,
    aspiring industrial mechanics Jasmin Klein and Christian Hecht
    had the chance to watch the field service technicians at work
    and to lend a hand – as well as paying the captain a visit.

Work & Social

                          STAFF DEVELOPMENT

                      Fostering Talent
                      FRIEDRICHSHAFEN (sto). Whether they possess spe-
                      cial-ist knowledge, social skills or leadership ability –
                      employees and management personnel worldwide with
                      development potential are to be given more targeted
                      support in future.
                           To this end, Tognum’s CP division has developed the
                      global 'House of Talent' staff development concept that will
                      be implemented at all Tognum locations. “All departments,
                      locations and countries will have a standard concept desig-
                      ned to help them more accurately identify employees with
                      development potential so that they can highlight and formu-
                      late a suitably wide range of personal/professional opportu-
                      nities,” emphasized Matthias Jobmann, head of Human Re-
                      sources. The concept has four priority areas: skills and career
                      development, further education (Tognum Academy) and               Staff development at four levels: Imken Hornbostel, international
                      further development of in-house vocational training. The          staff development, introduces the four target areas of in-house
                                                                                        training Competence and Career Development, Further Training and
                      overall aim is to place even more emphasis on the process of
                                                                                        Further Development of In-house Vocational Training.
                      ongoing instruction at Tognum as a place of learning.

                                                                                        Further training on screen
     Following rules makes life easier
                                                                                        FRIEDRICHSHAFEN (sto). A system of further training
     FRIEDRICHSHAFEN (sto). The way to achieve lean production in                       that does not impose a schedule, and the freedom to
     assembly and production can be just as effective in the office.                    repeat content as often as it takes – that is the beauty of
         In Dr. Ulrich Dohle’s opinion, this is an area where a lot of dead             e-learning. MTU Detroit Diesel has been providing elec-
     weight can be eliminated – in meetings, for example. To this end, the              tronically-supported learning since 2009. This year, a
     Executive Board member responsible for Technology & Operations has                 two-man e-learning team at the Friedrichshafen site
     issued a memorandum containing binding rules for his division. These               began developing worldwide e-learning programs.
     primarily include careful planning, a clear focus on what is essential, and            “Broadening our portfolio of further training opportu-
     minutes of meetings. „My own experience is that all this will lead to              nities by adding new learning media is a future-oriented
     more effeciency,“ Dr. Dohle emphasizes. This will also result in more              initiative by our company,” explained Oliver Bittelmeyer,
     time for the family. “Fixed meeting schedules can make it easier to ar-            team leader for further training. Along with her colleague
     range plans more reliably within the family environment”, adds Silke               Stéphane Diez, Sabine Herrmann has been busy estab-
     Moll from Human Resources. None of this is really new (Procedural In-              lishing an e-learning domain at Tognum since April 2010.
     struction VA 00011 on the MTU Friedrichshafen Info-Net). The memo-                 E-learning will kick off with courses in compliance (see
     randum can be downloaded from the Info-Net at ‘Career and Family’.                 article on page 36). Many other subjects are to be added.
                                                                                        “The Sokrates project plans a learning module for sales
                                                                                           personnel in the use of the POLO portal,” reports
                                                                                                            Stéphane Diez. The POLO portal con-
                                                                                                               tains information on engine cha-
                                                                                                                racteristics and provides impor-
                                                                                                                 tant sales arguments. E-learning
                                                                                                                    programs are located on a
                                                                                                                       learning platform that can
                                                                                                                         be accessed by all em-
                                                                                                                          ployees in Intranet.

                                                                                                                             E-Learning team:
                                                                                                                             Stéphane Diez and Sabine
                                                                                                                              Herrmann prepare global
                                                                                                                               courses in Friedrichshafen.

                                                                                                                                Work & Social


                                                                                                                                 Sailing for everyone:
       Cogolin/France Cannes/France                                                                                              The 16.4 m-long
                    1  5
                           4 La Spezia/Italy                                                                                     yacht “Tognum” is
                                                                                                                                 primarily used for
                                                                3 Istanbul/Turkey
              6                                                                                                                  team-building
             Span. Riviera                                                                                                       events, further trai-
                                                                                                                                 ning and staff quali-
                                         2 Catania/Italy
                                                                                                                                 fication programs.
                                                                                                                                 It has 10 fixed bunks.
                                     M E D I T E R R A N E A N                                                                   The standard schedu-
                                                                                                                                 le is structured so
                                                                                                                                 that all members of
                                                                                                                                 the workforce can
                                                                                                                                 take part in courses
                                                                                                                                 on board – even if
                                                                                                                                 they have no previo-
                                                                                                                                 us sailing experience.

Tognum Yacht in the Mediterranean from 2011
FRIEDRICHSHAFEN/COGOLIN (sto). The Tognum yacht                French, Italian, Turkish and Spanish subsidiaries, all other
will be setting sail for new shores before the year is out.    locations are cordially invited to reserve the yacht for
The two years it spent on Lake Constance were evalua-          team-building measures or other functions. Short sailing
ted very positively by yacht manager Konstantin Panit-         trips organized in the sheltered waters around the loca-
sas.                                                           tions are suitable for anyone to take part in. More ambi-
    “Particularly in its second year in 2010, many teams       tious teams are free to join multi-leg trips over several days
and members of staff have discovered how effectively the       or longer crossings over the open sea. Details on booking
yacht can be used for team-building.” In both years, the       procedures and other possibilities for using the vessel can
yacht was in use for 210 out of a possible 240 days. Around    be found on the staff yacht Intranet pages. Yacht manager
1,400 employees have been on the yacht, of these 1,000 for     Konstantin Panitsas can be contacted on Tel. 0049-7541-
team-building measures. “Feedback from participants was        90-3614 to answer any further enquiries.
generally very positive, also with respect to the training
element, which at first was viewed more critically,” said Mr
Panitsas. The fact that participants felt their time on the
yacht – on average one or two days – to be too short was
also taken as a good sign by the yacht manager. Other yacht
events were mainly regattas, training courses and person-
nel recruitment measures.
    In autumn, the yacht was transferred to the Mediterra-
nean, and is now moored in the port of Cogolin on the
French Riviera. From there, it will sail to Istanbul, where
normal business will be resumed again in March. Up to
autumn of next year, the ‘Tognum’ will make its way west-
wards via Italy and France to Spain. Besides Tognum’s

  Work & Social

                             NOTE FROM THE EDITOR

                                                                                                  Results of a telephone survey
                         According to the latest telephone survey of readers, the format and the range of topics covered by
                         “Insight” are well-balanced and interesting and the articles are readily understandable. Nevertheless,
                         nothing is so good that it cannot be improved and most of the magazine’s readers from Friedrichshafen,
                         Detroit and Singapore who took part in the telephone survey were able to come up with useful suggestions
                         for improvement and ideas for new topics.

                         F   RIEDRICHSHAFEN. The survey confirmed the major
                             results of a questionnaire-based survey from 2008: Re-
                         ports covering technology, the company’s economic situati-
                                                                                           news items, there could be more articles based on the per-
                                                                                           sonal experience of service technicians or sales specialists;
                                                                                           instead of whole sections portraying the major locations,
                         on and articles dealing with applications and locations top       thumbnail sketches of some of the smaller locations could
                         the list of readers’ favorites. However, the telephone conver-    be included.
                         sations provided a more detailed picture in many areas –
                         including people’s reading habits. “Insight” is particularly          In order to highlight the joint identity between Tog-
                         popular, for example, because its handy format means that         num locations, suggested one reader from Detroit, there
                                                            readers can dip into it        could be more reports on the growing number of trans-
                                                            anywhere and any time          regional sales and production projects. Colleagues from
                                                            their busy work schedule       Singapore, a traditional sales and service location, also
                                                            allows. As was confirmed       expressed an interest in background reporting covering or-
                                                            by one of our Detroit col-     ders and applications as well as articles on customers.
                                                            leagues, many people take
                                                            it home for the family to          One associate from Detroit suggested that alongside
                                                            read. And another tradi-       the element of a common bond, the magazine should high-
                                                            tion still practiced in par-   light the great diversity of character, mentality and ap-
                                                            ticular by employees of        proach throughout the company. Another Detroit collea-
                                                            long-standing and illus-       gue felt that Insight still concentrates too much on Fried-
                                                            trating the close ties which   richshafen. “It is really important for the magazine to pub-
                                                            employees feel, is the habit   lish articles illustrating the different cultures. That way you
                                                            of keeping a magazine col-     can get an idea of what it is like to be a Tognum employee
                                                            lection.                       in parts of the world where culture and commerce are
                                                                                           sometimes in collision.”
   Telephone survey           As far as the function and purpose of “Insight” is con-
          of readers:    cerned, the size of the company has engendered an increa-             One of the general conclusions to come out of the sur-
Phone conversations
                         sing wish for greater closeness to the individual and for a       vey is that men and women perceive the magazine’s con-
    produced a wide-
    ranging picture –    greater emphasis on our common identity. There was, for           tent in different ways. As they said themselves, women
       even covering     example, keen interest in having a more personalized              tend to be more oriented to items with a greater depth of
respondents’ reading     approach with named photos of colleagues and manage-              emotion-based or person-based content. Men, on the
               habits.   ment staff being published. “The increasing amount of             other hand, tend to go for the latest technology. Many of
                         inter-location contact is necessarily relatively ‘de-persona-     our women readers turn first to the hobby section at the
                         lized’ because you only get to know each other by email or        back. Thus, for example, after knowing her colleague Bill
                         telephone. If you can see someone’s picture in the maga-          de Haan for eleven years, one of our female readers from
                         zine, then it makes things much more personal,” commen-           Detroit only discovered that he is an outstanding amateur
                         ted one respondent from Friedrichshafen. To achieve a             cook when she read it in the last edition of “Insight”. In her
                         more personal note, “Insight” should include more realis-         view, items like that give the articles a much more human
                         tic, real-life reports. For example, these could be about the     face: “Without those articles, the magazine would just be
                         complex problems and challenges of everyday life at work,         too full of facts and figures.”
                         but they should also include the right mixture of “heart,
                         emotions and common sense”. Instead of dry reports and                                Words: Wolfgang Stolba, Picture: Henry Schulze

                                                                                                                                 Tognum al dente

                           RECIPES FROM AROUND THE WORLD AT TOGNUM

David Stuck’s passion for potjie-cooking

CAPE TOWN             . On the third Friday of every month,
     David Stuck, a field service engineer at MTU South Africa,
removes his tie, dons an apron, and gets together with his col-
leagues to begin a ritual which has long become part of the corpo-
rate culture – a potjie party. “Potjie” is the Afrikaans word for stew, but
not just any stew. It is a South African specialty originally brought over by the white
settlers and now a favorite of the native population.

    The mouth-watering stew takes about 4 hours to make. The basic ingredients are meat,
spices, whatever vegetables are preferred and a great deal of tender loving care. To cook an aromatic
potjie, you need at least 2 kilograms of meat, the right masala spice blend and of course fresh
vegetables. The basic procedure is to lightly brown onions and then add spices, for example, cloves,
cinnamon and aniseed. The meat (which should be lean) is then added and cooked, (in the case of
an oxtail potjie, for about three hours). “Of course, there are endless variations,” explains David. His
and his wife Anneke’s definite favorite is lightly curried oxtail. A subject of endless debate among
Potjie specialists is the right choice of cooking receptacle – some swear by aluminum, while others
insist that cast-iron pots produce the tastiest results.                                                                  Ingredients for “potjie”
                                                                                                                          2 kgs meat (e.g. oxtail)
    Potjies belong to David’s earliest childhood memories. “As far back as I can remember, my                             Selected vegetables,
parents cooked a potjie meal to celebrate special occasions with guests.” David Stuck is glad that                        onions
there are always volunteers to help him organize the Potjie parties – either by setting up the grill and                  Spices (e.g. cloves, cin-
beer tables or assisting with the preparation of which However David does not sound the bell for the                      namon, aniseed …)
feast until he has tasted the potjie one last time and seasoned as required. “A potjie is always the life
and soul of the party,” he says.
                                                                Words: Wolfgang Stolba, Pictures: David Stuck

                                                                      David Stuck
                                                                      David Stuck is a service technician
                                                                      at MTU South Africa.

                                                                                                                The next culinary destination?
                                                                                                                Send your regional recipes to:
                                                                                                                The Insight editorial team will
                                                                                                                make a selection and prepare
                                                                                                                both itinerary and menu.

                                                                 Cape Town


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