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K MOBIL - Kirchhoff Automotive
17th volume | issue 40 | December 2012

                                                                     K›MOBIL

                            17th volume | issue 40 | December 2012
                                                                     tHE KiRCHHOFF GROuP mAGAZiNE

  Merry Christmas
and a Happy New Year

                                                                         Eye-catcher on the KiRCHHOFF Automotive booth:
                                                                         the electric race car of the Speeding Scientists
                                                                         Siegen. the performance on the international
                                                                         Supplier Fair in Wolfsburg was a complete success!

  www.kirchhoff-group.com
K MOBIL - Kirchhoff Automotive
K›MOBIL 40 // KIRCHHOFF Group                                                                                                                                                                        KIRCHHOFF Group // 40 K› MOBIL

K›MOBIL
LIST OF CONTENTS

AUTOMOTIVE                                                    MOBILITY                                                 SCREWDRIVING TOOLS                                       DISPOSAL LOGISTICS

                      14-59                                                                  60-65                                              66-71                                                    72-107
KIRCHHOFF Group                                                                                                        KIRCHHOFF Mobility

04   Review 2012                         33     The Porsche Cayenne is          48   On course for further growth      62   REHACARE trade fair in          87   Optimising collection rounds
                                                getting a little brother                                                    Düsseldorf/Germany                   just by clicking a mouse                                                   3
08   Series: From research                                                      50   Exemplary leading
     and development                     34     Two times top grades for                                               64   Innovations for people          88   German-Czech nickel marriage
                                              outstanding quality               51   Finding and promoting potential        with disabilities
12   Dr. Kirchhoff Foundation                                                        within the Company                                                     89   Single point of contact key
                                         35     Expansion on the worldwide                                                                                       for scottish council
                                                major automotive market         52   Trend-setting training            WITTE Tools
KIRCHHOFF Automotive                                                                 programs at Van-Rob                                                    90   Warrington go for more
                                                                                                                                                                                                       Imprint
                                         36     Finalist in the Excellence in                                          68   New general                                                                K›MOBIL
16   We will insist on confidence             Production competition            53   Technology with a female touch         distributor in the UK           91   SELECTAPRESS DUO                      the KIRCHHOFF Group magazine

                                                                                                                                                                                                       Publisher: KIRCHHOFF Group,
17   Among the top 18 of 30,000          37     Supplier Quality Excellence     54   Looking for the right candidate   70   The PROTOP II series—number     92   Innovating design for Singapore       Dr.-Ing. Jochen F. Kirchhoff
                                                Award 2012 from                                                             one for safety and efficiency                                              Stefanstraße 2, D-58638 Iserlohn
                                                                                                                                                                                                       Postfach 26 26, D-58634 Iserlohn
18   Modified structures of                     General Motors                  55   Familiarization –                                                      93   AGMS is showcased at                  Tel. +49 2371 820 - 261
     leadership and organization                                                     Discovery – Experience                                                      Modern Day Marine                     Fax +49 2371 820 - 264

                                         38     The largest in the Group                                               FAUN Goup                                                                       Responsible for the content:
20   Agenda 2020                                                                56   “Career in the tent city“                                              94   Ready for take-off                    Dr.-Ing. Jochen F. Kirchhoff
                                                                                                                                                                                                       Mitarbeiter: Sabine Boehle,
                                         40     Close to customer                                                      72   Two strong brands                                                          Oliver Fries, Andreas Heine,
24   Experience more,                                                           57   We are Attendorn                                                       96   Between Chinese New Year              Claudia Schaue
     understand more                     42     Core competence                                                        76   One of the best                      and examinations
                                                                                                                                                                                                       Pictures:
                                                laser welding at Van-Rob        58   School in a different way                                                                                         Adam Opel AG, Changan Mazda
26   IZB 2012: International                                                                                           78   FAPS on the run                 98   Chinese bratwurst hire                Automobile, Porsche, VW,
                                                                                                                                                                                                       KIRCHHOFF Group, private,
     Suppliers Fair breaks all records   44     Lean Production in Romania –    59   The success story of the day                                                are hot top dogs                      Deutsche Post, Shutterstock, FAUN,
                                                a concept for success                care center “KiCoKids”            80   In the land of smiles                                                      Cosima Hanebeck
28   Premiered at the IAA                                                                                                                                   100 Impressions 2012                       Translation:
     Commercial Vehicles in              45     Optimization of                                                        82   Thank you!                                                                 Target Languages, Dossenheim
     Hanover/Germany                            shipping processes                                                                                                                                     Tongue Tied (Manchester) Ltd

                                                                                                                       84   New on the front line:          ZOELLER Group                              Design, Typesetting:
30   IAA Commercial Vehicles 2012:       46     Improved material flow                                                       Uwe Bussmann                                                               FETTE-BEUTE.com,
                                                                                                                                                                                                       Dortmund, Attendorn
     a fair with a lot of records                                                                                                                           104 Technology decides
                                         47     Worldwide on the same level                                            85   Staff from the start                                                       Printing: becker druck, Arnsberg
                                                                                                                                                            106 Special celebrations: 20 years of
                                                                                                                       86   A place of peace                     ZOELLER SYSTEMS s.r.o.
K MOBIL - Kirchhoff Automotive
K›MOBIL 40 // KIRCHHOFF Group

    Review 2012
           Industry and export orientation are the
    strong points of the economy in Germany.

    Dear customers and friends of our group of companies,
    Dear colleagues and employees,
4                                                                                                                                                                     5

    The German economy has been able           policy of “money only for restructur-       they will be handsomely rewarded for
    to weather the storms of recent years      ing measures” has generally led to a        the pleasure. Germany must exercise
    and perform well despite the recent        willingness to implement reforms.           caution not to gamble away jobs and
    euro debt crisis. This can mainly be       Additional indicators, such as unit         prosperity with the transformation of
    attributed to our strong, export-          labour costs, current account balance,      the energy landscape”, believes the
    oriented industry.                         and export activities, highlight the        German newspaper Frankfurter Allge-
                                               fact that the realignment processes are     meine Zeitung (FAZ) quite justifiably.
    However, the economy is slowing now,       in progress.
    which will lead to reduced investments                                                 It is now time that the German Federal
    and more restraint in taking on new        ECB President Draghi believes the           Government devises a plan in conjunc-
    hires.                                     budget consolidation to be “well on         tion with the Länder, in which the ex-
                                               track”. Nonetheless, this only marks        pansion of green electricity is kept in     DR.-ING. JOCHEN F. KIRCHHOFF
    The German council of economic             the beginning and the reform zeal           line with the expansion of the grid, and
    experts has forecast economic growth       must be maintained. However, the            subsidies for wind power and biomass
    of only 0.8% respectively, for this year   recent strikes and protests—which have      are curbed to prevent any impending
    and the coming year. For this reason,      shown renewed intensity—against the         overcapacity.
    it has warned the German Federal           austerity course being pursued in the
    Government that “more ambition             debtor countries in Southern Europe,        Furthermore, it is necessary to end
    should be shown to achieve fiscal          are giving cause for concern.               the prevalent German energy nation-
    consolidation and that an overall                                                      alism and harmonise the subsidisa-
    concept for transforming the energy        One particularly major challenge            tion of renewable energies across
    landscape, reforms to the health           facing Germany is the concept of            Europe. Germany’s single-handed ap-
    system and to the taxation system are      transforming the energy landscape.          proach with planned economy meas-
    lacking”.                                  “Green electricity is flowing in the         ures contravenes the market economy
                                               grid thanks to a priority feeder system     regulations of the European single
    Progress in terms of budget consolida-     with a fixed long-term, exceptionally       market and is interfering with the stabi-
    tion and competitive position has been     high remuneration. Every green-electric-    lisation of networks in our neighbouring
    made in the euro countries severely        ity provider can build as many plants and   countries by exporting subsidised surplus
    affected by the debt crisis. The crisis    supply with current as much as wanted,      quantities.
K MOBIL - Kirchhoff Automotive
K›MOBIL 40 // KIRCHHOFF Group                                                                                                                                                                                                                          KIRCHHOFF Group // 40 K› MOBIL

                                                                                                                                                             Despite waning growth figures,            globalisation strategy with the estab-     received an outstanding response. The
                                                                                                                                                             particularly in Europe, the KIRCHHOFF     lishment and approval of a wholly          company domain has now reached
                                                                                                                                                             Group was able to improve turnover        owned subsidiary for the production of     third place in terms of turnover within
                                                                                                                                                             in all four company domains and           platforms for refuse collection trucks,    our group of companies.
                                                                                                                                                             once again considerably outstrip the      sweepers, and lifters in Suzhou/China
                                                                                                                                                             good figures of the previous year.        is very encouraging; the same goes         In the global economic downturn,
                                                                                                                                                             Total turnover for 2012 amounted          for the establishment and approval         WITTE Werkzeuge has managed
                                                                                                                                                             to approximately EUR 1,490 million.       of the 50/50 joint venture between         to almost maintain figures at the
                                                                                                                                                             This equates to an increase of 10%        FAUN and its Chinese partner for the       previous year’s level despite the euro
                                                                                                                                                             compared with 2011. Global head-          assembly of platforms and lifters onto     debt crisis. A new partner with many
                                                                                                                                                             count increased to 10,600 against         chassis frames, and subsequent sale        years of experience and headquar-
                                                                                                                                                             9,200 for the previous year.              of the complete vehicle. The new col-      tered in Harlow/London has taken
                              Canada
                                                                                                                                                                                                       laboration in North America with a         over the role of general distributor for
               USA                                                                                                                                           Activities in North America have          dealer organisation from one of the        hand tools in the United Kingdom.
                                                              Ireland                                                                                        had a particularly positive impact        main US construction machinery man-
                                                                        Great
                                                                                                                                China
                                                                        Britain
                                                                                  Germany
                                                                                                      Poland
                                                                                                                                                             on KIRCHHOFF Automotive. While            ufacturers is of special significance,     My family and our employees will face
                     Mexico
                                                                                                                                                             Europe and Asia were able to increase     too.                                       these good perspectives relating to all
                                                                                                                                                             turnover by 4.6% from January to                                                     business segments with our contin-
                                                                                            Austria

                                                                                                       Hungary
                                                                                                                                                             October 2012, our majority holding        In its European production locations,      ued commitment and great pleasure.
                                                                         France                                  Romania
                                                                                                                                                             Van-Rob with 12 production locations      FAUN and ZOELLER have made consid-         We would like to thank our esteemed
                                                                                                                                                             in Canada, USA, and Mexico, was           erable headway in increasing produc-       customers for their understanding and
                                                  Portu-
                                                           Spain
                                                                                                                                                             able to boost the figure by more          tivity by systematically implementing      support, and our employees for their
                                                   gal

6                                                                                                                                                            than 20% during the same time frame.      the 5S strategy. Endeavours in devel-      loyalty and dedication.                     7
                                                                                                                                                                                                       opment to improve fuel consumption
                                                                                                                                                             We have amplified our efforts to          efficiency, to reduce fine particulate     My sons and I would like to wish you
                                                                                                                                                             strengthen our competitiveness at         and noise emissions continue to be a       and your families a merry Christmas, a
                                                The KIRCHHOFF Group: an example for the                                                                      all locations and been able to win        main focus.                                relaxing time during the festive peri-
                                                internationalization of the German economy.                                                                  numerous interesting new orders.                                                     od, and all the best—particularly good
                                                                                                                                                             Investments in new technologies           Efforts into developing electric mobil-    health—for 2013.
                                                                                                                                                             and improved productions processes        ity and other alternative powertrains
                                                                                                                                                             rose globally to EUR 90 million.          for municipal vehicles and lifters have    A cordial good luck!
                                                                                                                                                             Our executives and employees are          been intensified, too. Consequently,
                                                                                                                                                             particularly proud of the number of       FAUN is particularly pleased about be-     Yours,
                                                                                                                                                             new supplier awards we received this      ing distinguished with the TOP 100 In-
    Even the effects of the presidential        been perceptible in the automotive                                 ning of the year. Global order intake     year from our key OEMs. Presence at       novator 2012 award.
    election on the strategic position          industry, too. Domestic new registra-                              increased by 6% during the course of      trade fairs has proven again to be very
    of the United States of America are         tions from the January until October                               the year. Nonetheless, the business       successful for the Automotive Group.      KIRCHHOFF Mobility with the com-                        Dr.-Ing. Jochen F. Kirchhoff
    relevant to our group of companies.         2012 may have only fallen by 2% in                                 prospects across the world started                                                  panies REHA Group Automotive in
    The suggestion of a European-Amer-          the year-on-year comparison; how-                                  to run out of steam in this time. This    With its range of refuse collection       Hilden/Germany and Jelschen in Bad
    ican free trade zone made by the            ever, the dwindling sales particularly                             means that automotive companies           trucks, lifters, and street-sweeping      Zwischenahn/Germany, has boosted
    German Foreign Minister on con-             in the Western and Southern Euro-                                  will have to “drive by sight”, adapt      vehicles, KIRCHHOFF Ecotec was            its production and the service and sales
    gratulating Obama to his re-election        pean markets could no longer be                                    costs accordingly, and increase efforts   able to strengthen its market             network under new management,
    is a clever move. If this is indeed real-   offset by every manufacturer through                               in developing innovative products and     presence, particularly in the Eastern     and wishes to continue its expansion
    ised, it could mean a growth spurt on       higher exports to overseas countries                               processes during the coming months        European countries of Russia and          by increasing the range of products
    both sides of the Atlantic in a time of     in America and Asia. Business in                                   of 2013.                                  Poland, and—with the markets of           in the sector of vehicle conversions
    sovereign debt crisis.                      the USA remains successful for the                                                                           Germany and Western Europe—was            for elderly people and those with re-
                                                German group brands. Sales for                                                                               able to increase turnover by 5% in a      stricted mobility. The first joint trade
    The euro debt crisis as well as the         passenger cars and vans have                                                                                 fiercely contested environment. The       fair appearance for the two companies
    global economic slowdown have               increased by 20% since the begin-                                                                            continued implementation of the           at REHACARE in Düsseldorf/Germany
K MOBIL - Kirchhoff Automotive
K›MOBIL 40 // KIRCHHOFF Group                                                                                                                                                                                                                     KIRCHHOFF Group // 40 K› MOBIL

                                                                                                                                   What are organic sheets?                         materials are used—polypropylene                        usually consist of glass, as well as
                                                                                                                                                                                    (PP), as well as technical thermoplastic                carbon, aramid, or natural fibres.

    Series: from research
                                                                                                                                   One variant of FRP are continuous                materials such as polyamide (PA), or                    Typically, the fibres account for 50%
                                                                                                                                   fibre-reinforced thermoplastic materi-           temperature-resistant materials such                    of the mix. The semi-finished product
                                                                                                                                   als. The term “organic sheet” for the            as polyphenylene sulphide (PPS), are                    arising from this process is completely
                                                                                                                                   semi-finished product is derived from            predominantly used in the automo-                       consolidated and can be directly

    and development
                                                                                                                                   the organic matrix and its property              tive industry. Various types of fabrics                 processed by the user.
                                                                                                                                   of being formed in a manner akin to              or unidirectional bonded composites
                                                                                                                                   sheet metal. Various thermoplastic               are embedded in this matrix. These

                                                                                                                                   Material properties

            This year again, the KIRCHHOFF Group can look back on many new developments and                                        Due to the relative distribution of the
    research projects. One example originated from FAUN, who developed a new energy-saving                                         fibres, organic sheets have a heavily
                                                                                                                                   anisotropic behaviour. This means that
    and environmentally friendly drive concept fitted in the first waste collection vehicle with diesel-                           the material’s properties vary consid-
    electric hybrid drive. WITTE Tools, the screwdriving tool specialist, devised a new compact bit                                erably depending on direction. The
    box, the “Ratchdrive”, in which a powerful ratchet mechanism is integrated. Furthermore,                                       standard fabric ratio is 4:1—i.e. 80%
                                                                                                                                   of the fibres are woven in one direc-
    KIRCHHOFF Mobility as the umbrella brand for the companies REHA and Jelschen presented no

                                                                                                                                                                                  Spec. strength
                                                                                                                                   tion, 20% in the other direction—or 1:1.

                                                                                                                                                                                                                                                                                  Spec. rigidity
    less than three new specially adapted vehicles for people with limited mobility at the REHACARE
    trade fair in Düsseldorf/Germany. In this edition, we would like to focus on the latest fi ndings                              As part of the definition of material
                                                                                                                                   properties, various organic sheets avail-
    from the material research department at KIRCHHOFF Automotive.                                                                 able on the market were analysed us-
8                                                                                                                                  ing experimental testing while exposed                                                                                                                          9
                                                                                                                                   to single- and multi-axial loads, and
                                                                                                                                   the material properties were validated
                                                                                                                                   as a function of the loading angle.                                                   Materials from structural design
                                                                                                                                   These characteristic values obtained
                                                                                                                                                                                                                         Spec. strengths       Spec. rigidities
                                                                                                                                   from the process are used as input pa-
                                                                                                                                   rameters for the existing FEA-material                          Fig.2: Comparison of the density-specific mechanical
                                                                                                                                   cards for composite material models.                                      properties in structural materials

    Organic sheet—a material for light-      not just the environment that benefits   magnesium, continuous fibre-rein-
    weight automotive construction           from this. Vehicle manufacturers who     forced plastics (FRP) with their excel-                                       Fig.3: Material behaviour as a function of fibre direction
                                             exceed EU regulations must expect to     lent mechanical properties in rela-
    Apart from the optimisation of the       face penalties in the future.            tion to density are increasingly being
    powertrain, lightweight construction                                              utilised.
    play a crucial role. This is because     Apart from high-strength and ultra-
    lighter vehicles consume less fuel and   high-strength steels and light alloys
    cause fewer CO2 emissions. And it is     using metals such as aluminium or

                                                                                                                                                                 Unidirectional                    Bidirectional                           Quasi isotropic

                                                                                                                                                            Fig.4: Mechanical properties according to the classical lamination theory

                                                                          Fig.1: Organic sheet structure:
                                                                          Thermoplastic material + fibre fabrics = organic sheet                                                                       Stiffness
                                                                                                                                                                                                       Young s modulus
K MOBIL - Kirchhoff Automotive
K›MOBIL 40 // KIRCHHOFF Group                                                                                                                                                                      KIRCHHOFF Group // 40 K› MOBIL

     Design concepts

     The use of analytical approaches has
     made it possible to assess the suitabil-
     ity of organic sheets for various com-
     ponent geometries using the material
     characteristics acquired.

     Thanks to this fundamental testing, a
     high level of rigidity can be achieved       Fig.5: FEA result from                                                                                                                         Fig.8: Joined demonstrator
     with reduced material for layered and        the demonstrator component                                                                                                                     component with steel structure
     shell-like components. In this context,
     a layered demonstrator component
     modelled on an existing steel seat shell                                                                                                                                                    Fig.7: Bonded hybrid samples with sub-
     was analysed. Under normal circum-           Fig.6: Trimming of finished component was made by                                                                                              strate failure (right) and hybrid sample with
     stances, it is not advisable to substitute   3D laser trimming. Demonstrator component after                                                                                                semi-hollow punch rivet shorn off (left)
     metallic materials with fibre-reinforced     thermoforming and 3D laser trimming.
     plastics. However, as the objective was
     to integrate the GFR component in an                                                             6                                                                                          7
     existing steel structure, all of the seat
10   shell’s mounting surfaces were left un-
     changed and the remaining geometry
     was adapted in terms of design and
     production taking the existing installa-
     tion space into consideration.

     Forming of organic sheet

     Following the analytical and theo-
     retical observations, prototypes were
     manufactured by thermoforming at
     KIRCHHOFF Automotive’s Tec Centre
     in Attendorn.

     First, the organic sheet is melted, as                                                               Joining technologies                        ing elements and processes, and the        lightweight structures depends on
     the material is stiff and brittle in its                                                                                                         subsequent construction of the dem-        two factors: fibre-reinforced plastics
     condition at time of supply. The heat-             Info                                              Joining technology is particularly criti-   onstrator component of a hybrid            being available at density-specific,
     ing temperature required depends on                                                                  cal when applied to hybrid designs.         underbody, as seen in Figure 8.            competitive prices, and cost-efficient
     the respective matrix available. Once                                                                Particularly in the case of metal/                                                     series production processes.
     heated, the organic sheet is fed as                                                                  plastic combinations, the use of ad-        Both the fundamental analytical in-
     quickly as possible into a mould and                                                                 hesive bonding in combination with          vestigations and the actual develop-       But even then, the principle for hybrid
     formed. Hence, this is a hot forming               Weight comparison of the seat                     mechanical joining processes, such as       ment of the hybrid structure indicate      solutions will remain applicable: the
     process similar to press hardening.                pan—steel vs. organic sheet                       semi-hollow punch rivets, blind riv-        the considerable lightweight con-          right material in the right location!
                                                                                                          ets, RIVTAC technology, etc. becomes        struction potential fibre-reinforced
                                                        It was possible to reduce the weight of           more and more common.                       plastics. Whether these materials                  Rolf Schwarzer, Stefan Szabo,
                                                        the seat shell by 40% by using glass-                                                         will be increasingly used in the body                       Christoph Wagener
                                                        fibre-reinforced organic sheet with com-          Fundamental analyses initially involved     in the future, depends especially on
                                                        parable mechanical properties to the series       the practicality of several selected        the associated costs. The feasibility of
                                                        production equivalent made of steel.              adhesives as well as a variety of join-     using such materials in series, hybrid
K MOBIL - Kirchhoff Automotive
K›MOBIL 40 // KIRCHHOFF Group                                                                                                                            KIRCHHOFF Group // 40 K› MOBIL

    Dr. Kirchhoff Foundation
                                                                                                       4                             5

             Once again, the Dr. Kirchhoff Foundation has been involved in a large number of
    activities for the region in 2012. Overall EUR 30,000 was gifted to activities, and various
    charitable projects in the areas of education, culture, sports, and social causes were supported
    in the long run.                                                                                       1. ERG Iserlohn                            4. Classical Guitar
                                                                                                                                                      Festival/culture symposium M
                                                                                                           The ladies’ team was first established
                                                                                                           in 2011 and has been incredibly suc-       Meanwhile this event is known as
                                                                                                           cessful. In the German national roller     one of the most famous and largest
                                                                                                           hockey league, the young team is           symposiums in this vein in Europe.
                                                                                                           currently unbeaten in 12 matches           For the 21st time in a row more than
                                                                                                           and could win this year the German         300 participants from 49 countries in
2                                                                     3
                                                                                                           Championship and Cup.                      Europe, Asia as well as North- and
                                                                                                                                                      South America came from August
                                                                                                           2. Circus project at                       12th to 19th, 2012, to Iserlohn and
                                                                                                           Bleichstraße primary school                Schwerte in Germany. More than
                                                                                                                                                      4.500 visitors enjoyed the vespertine
                                                                                                           An educational circus project, uncou-      concerts.
                                                                                                           pled from the context of school, to in-                                              13
                                                                                                           crease the sense of self-worth in every    5. With the Bach cantatas
                                                                                                           child. The urban primary school was
                                                                                                           transformed into a circus for one week,    “Wachet! Betet! Betet! Wachet!”
                                                                                                           with teachers, parents, and pupils be-     (Watch! Pray! Pray! Watch!), “Herz
                                                                                                           ing the artists and stars of the ring.     und Mund und Tat und Leben” (Heart
                                                                                                                                                      and Mouth and Deed and Life), and
                                                                                                           3. Handball district                       “Erschallet, ihr Lieder” (Resound,
                                                                                                           Iserlohn-Arnsberg/Germany                  Ye Songs), the Märkische Motetten-
                                                                                                                                                      kreis choir conducted by Dr. Wolfgang
                                                                                                           Fifty children aged between 11 and         Besler entertained listeners in the
1                                                                                                          14 spent one week at a training camp       fully packed Johanneskirche church in
                                                                                                           on the island of Borkum/Germany            Iserlohn to mark the 85th birthday of
                                                                                                           together with the district team. An        Dr.-Ing. Jochen F. Kirchhoff.
                                                                                                           unforgettable event for everyone
                                                                                                           involved.

                                                                                                           Safeguarding the Iserlohn
                                                                                                           European volunteer service in 2012         Chameleon Caritas Group, Iserlohn

                                                                                                           This is a project for teenagers and        Once again in 2012, we supported the
                                                                                                           young adults, which enables them           drop-in centre in Iserlohn for children
                                                                                                           to undertake voluntary work abroad         and young people living in families
                                                                                                           thanks to a so-called dispatch plat-       afflicted by addiction.
                                                                                                           form. The European volunteer service
                                                                                                           has been available in Iserlohn for three
                                                                                                           years now. During this time, much has
                                                                                                           been achieved for the project’s on-
                                                                                                           going development.                                             Kerstin Garmatter
K MOBIL - Kirchhoff Automotive
14                                    15

     Innovations.Worldwide.   14-59
K MOBIL - Kirchhoff Automotive
K›MOBIL 40 // KIRCHHOFF Automotive                                                                                                                                                                                              KIRCHHOFF Automotive // 40 K› MOBIL

     We will not
     lose confidence
            Despite a harsh wind blowing through the automotive industry,
     the global market for passenger cars is still growing.

     The global market grew by 6% in 2011,        and new automotive, aircraft, and           We must continue to improve produc-
     4% in 2012, and will grow by 2% next         medical technologies ensure success         tivity within the KIRCHHOFF Compa-
     year too, although we must prepare           on the global markets.                      nies. We provide outstanding solutions                                              left: Awards for the best. VW Group Award 2012 award ceremony in Copenhagen,
     ourselves for unprecedented volatility in                                                for our customers with innovations in                                               from left to right: Dr. Francisco Javier Garcia Sanz, Arndt G. Kirchhoff, Prof. Dr. Martin
     market trends. While America and Asia        As suppliers, our future growth will        the field of lightweight automotive                                                 Winterkorn, right: Only eighteen of over 30,000 Volkswagen Group suppliers were
     continue to enjoy vigorous growth, we        rely on our unique ability to generate      construction in particular and with                                                 distinguished as premium partners with the VW Group Award 2012
     are seeing difficulties in the compact car   and implement innovative performance        good delivery and service quality. We
     segment, especially in Western Europe.       combined with excellent processes and       are learning to improve the culture of
     This is linked to the lack of confi dence    products. We will only become more          responsibility and performance thanks
     in Europe’s economic stability, in par-      able to weather critical phases than        to numerous training activities and
     ticular to the turbulent fi nancial mar-     others by means of a strong founda-         transparent communication.
16   kets here and to the declining industrial    tion on industrial added value; this will                                                                                                                                                                                    17

                                                                                                                                       Among the top 18 of 30,000
     added value in most European Union           underpin our prosperity.                                        Arndt G. Kirchhoff
     countries. The sole exceptions thus far
     are Germany and its neighbouring Cen-
     tral Eastern European countries. The
     only way to calm the financial markets
     is by implementing structural reforms
     so as to decrease unit labour costs as
     an expression of competitiveness. In                                                                                                      With the VW Group Award, the Volkswagen Group honours KIRCHHOFF Automotive
     order to increase industrial added value
     again as a stepping stone for growth in
                                                                                                                                       as a premium partner for the first time.
     the countries, the Vice President and
     Industry Commissioner of the EU Com-
     mission, Antonio Tajani, reformulated
     the objectives of the industrial policy                                                                                           KIRCHHOFF Automotive was one                  award, Winterkorn stressed, “As one of       continue to be fulfilled worldwide in
     in October. The industrial share should                                                                                           of only eighteen companies in the             our most important business partners,        the future. With all its brands, the VW
     increase from currently 16% to 20%                                                                                                world to receive the VW Group                 it is an honour for us to give you the       Group is one of the most important
     again.                                                                                                                            Award 2012.                                   Volkswagen Group Award 2012. We              and largest automobile manufacturers
                                                                                                                                                                                     would like to use this distinction to pay    in the world, and is thus a significant
     In order to achieve this, however, the                                                                                            Each year, the Volkswagen Group               tribute to your company’s exceptional        growth customer for our Company.
     trend towards deindustrialisation must                                                                                            honours the best of its 30,000 suppliers      performance, which stands out thanks         Winning this award is therefore par-
     be reversed and clear priority given to                                                                                           with the distinction of premium partner       to outstanding reliability and a lasting     ticularly important for the future and
     industrial growth ahead of climate and                                                                                            for their innovative strength, product        partnership with Volkswagen AG.”             for the development of KIRCHHOFF
     consumer protection objectives. The                                                                                               quality, development expertise, and                                                        Automotive with Volkswagen.
     sustainable, sparing use of resources                                                                                             reliable project management.                  The VW Group particularly appreciates
     in the development and production of                                                                                                                                            the wholehearted, successful commit-                            Dr. Thorsten Gaitzsch
     environmentally friendly products, re-                                                                                            Managing partner Arndt G. Kirchhoff           ment to new technologies, such as
     newable energy, network expansion,                                                                                                was presented with this year’s VW             hot forming as well as KIRCHHOFF
     increased use of secondary raw materi-                                                                                            Group Award by VW Chief Executive             Automotive’s global presence. These
     als thanks to higher rates of recycling,                                                                                          Officer, Prof. Dr. Martin Winterkorn          factors help to ensure that the high
                                                                                                                                       in Copenhagen. Speaking about the             quality requirements of the VW Group
K MOBIL - Kirchhoff Automotive
KIRCHHOFF Automotive // 40 K› MOBIL

                                                                                                                                                                            KIRCHHOFF Automotive Holding GmbH & Co. KG
                                                                                                                                               A. G. Kirchhoff (CEO)                         J. W. Kirchhoff (COO)                                  R. Spindeldreher (CFO)

                                                                                                                                                                                       KIRCHHOFF Automotive GmbH                                                 Van-Rob
                                                                                                                                      Global Business Functions
                                                                                                                                                                                                   Europe / Asia                                                     Nafta
                                                                                                                                                                        S. Leitzgen (COO), A. Haase (CFO), T. Gaitzsch (CTO), J. Sobon (CSO)              D. Berry (CEO), N.N. (COO)

                                                                                                                                              Finance                                                Finance                                                      Finance

                                                                                                                                             Controlling                                           Controlling                                                  Controlling

                                                                                                                                                 S                                                       S                                                            S

                                                                                                                                                 TD                                                     TD                                                           TD

                                                                                                                                                CME                                                    CME                                                          CME

                                                                                                                                                 HR                                                     HR                                                           HR

                                                                                                                                             Purchasing                                            Purchasing                                                   Purchasing

                                                                                J. Wolfgang Kirchhoff and Arndt G. Kirchhoff
                                                                                                                                                 IT                                                     IT                                                           IT
                                                                                during the interview in Aurora, Toronto/Canada

     Changed management and                                                                                                      of KIRCHHOFF Automotive, which has
                                                                                                                                 thus far been successful. In the future,
                                                                                                                                 we will envisage additional central
                                                                                                                                                                             J. W. Kirchhoff: The introduction of
                                                                                                                                                                             the central manufacturing engineering
                                                                                                                                                                             function will definitely be something
                                                                                                                                                                                                                                           capacities can be balanced despite
                                                                                                                                                                                                                                           the varying numbers of ramp-ups
                                                                                                                                                                                                                                           each year. The introduction of central

     organisational structures                                                                                                   functions so as to achieve global
                                                                                                                                 co-ordination and standardisation
                                                                                                                                 wherever it is needed. In principle the
                                                                                                                                                                             new in America. It is basically the in-
                                                                                                                                                                             dustrialisation of processes. For years,
                                                                                                                                                                             it has been put into practice very suc-
                                                                                                                                                                                                                                           manufacturing engineering in North
                                                                                                                                                                                                                                           America will thus be helpful, particu-
                                                                                                                                                                                                                                           larly for demanding new projects.
18                                                                                                                               new structure is different in that we       cessfully by our team in Germany, and                                                                     19
                                                                                                                                 are now more flexible both locally and      subsequently implemented in Europe                            The interview was performed by
                                                                                                                                 in the regions.                             and Asia. As a result, we are achiev-                         Andreas Heine, Director Communi-
           On 1 January 2013, the organisational structure of the Executive Board of KIRCHHOFF                                                                               ing the required productivity signifi-                        cation & Marketing.
     Automotive will change. In addition, the distribution of tasks and responsibilities between the                             A. Heine: Why do tasks and responsi-        cantly faster with new ramp-ups, and
                                                                                                                                 bilities have to be realigned between       new processes or commissioning new
     headquarters in Germany and the individual locations in Europe and Asia will be restructured.
                                                                                                                                 the headquarters in Germany and the         machines pose fewer surprises for us.
                                                                                                                                 foreign locations?                          Currently, things are still organised on
                                                                                                                                                                             a more local basis in the plants here
                                                                                                                                 A. G. Kirchhoff: When a company             in North America, and therefore with
                                                                                                                                 grows in different countries and con-       varying degrees of success. Thanks
                                                                                                                                 sequently in different cultures too,        to a central organisation in North
     Besides their tasks in the KIRCHHOFF   (Chief Operating Officer) und Janusz      order to control the complexity of cor-    then it is all the more necessary not       America, a standardised process and
     Group, shareholders Arndt G. Kirch-    Sóbon (Chief Strategy Officer). The       porate development. This is achieved       to take away people’s responsibility        defined workflow can be ensured, and
     hoff und J. Wolfgang Kirchhoff will    spokesman for the Executive Board         by means of organisational changes,        if possible, but rather to try to give
     concentrate more and more on           will be Stefan Leitzgen. The new          where departments and also organisa-       them more responsibility. Indeed, as
     the overall strategy of KIRCHHOFF      Executive Board will be responsible       tional units are constantly streamlined.   a family-owned Company it is typical
     Automotive und Van-Rob. Particular     for all KIRCHHOFF Automotive de-          We now have a global presence and          for us to have confidence in our
     emphasis will be placed on the man-    partments in Europe and Asia.             must adapt so that we do not make          colleagues and employees. And this is
     agement of KIRCHHOFF Automotive                                                  our daily work too complicated.            what we are now doing in every coun-
     Holding and the steering committee     Questions to Arndt G. and                                                            try. In addition, we hand over respon-
     for the entire KIRCHHOFF Automotive    Wolfgang Kirchhoff:                       A. Heine: By doing this, will the or-      sibility to individuals who are closest
     and Van-Rob Company, the GET                                                     ganisational structure of KIRCHHOFF        to what has to be done, namely in the
     (Global Executive Team). A newly       A. Heine: What benefits do you antici-    Automotive have definitively adapted       plants, in the countries, or even in a
     formed Executive Board will take       pate from the changes to the manage-      to its role as a global player, or will    customer base. Our objective is to as-
     over the operational business of       ment structures?                          there be further changes in the future?    sign more responsibility to the region,
     KIRCHHOFF Automotive:                                                                                                       to the countries, to the local company.
                                            A. G. Kirchhoff: Well, whenever a         J. W. Kirchhoff: No, the process is not
     Andreas Haase (Chief Financial Of-     company grows, as we have been do-        complete. For the time being, we have      A. Heine: Can you give an example of
     ficer), Dr. Thorsten Gaitzsch (Chief   ing over the past twenty years, adjust-   given ourselves a global structure in      how this type of realignment would
     Technology Officer), Stefan Leitzgen   ments must continually be made in         keeping with the matrix organisation       look?                                                             New Executive Board of KIRCHHOFF Automotive (from left to right):
                                                                                                                                                                                                   Stefan Leitzgen (Chief Operating Officer and spokesman for the Executive
                                                                                                                                                                                                   Board), Andreas Haase (Chief Financial Officer), Dr. Thorsten Gaitzsch
                                                                                                                                                                                                   (Chief Technology Officer) and Janusz Sóbon (Chief Strategy Officer)
KIRCHHOFF Automotive // 40 K› MOBIL

                             Agenda 2020

                                     The challenges of the years ahead require a sustainable strategy with long-lasting
                             effectiveness—Interview with Dr. Thorsten Gaitzsch.

20                                                                                                                                                              21

                             Agenda 2020. Under this heading,          into a comprehensive, sustainable            material continue to be sustainable in
                             KIRCHHOFF Automotive is currently         strategy. Dr. Thorsten Gaitzsch is Man-      the future?
                             developing a comprehensive strat-         aging Director Sales and Technical De-
                             egy with which the Company can            velopment at KIRCHHOFF Automotive            Dr. T. Gaitzsch: In my opinion, steel
                             adapt to the challenges of the com-       and is organising the strategy process.      will remain the most important ma-
                             ing years in the best possible way.                                                    terial for the foreseeable future, par-
                                                                       A. Heine: Agenda 2020. Did this              ticularly in relation to high-volume ve-
                             From sales and technical develop-         agenda originate from the fear of an         hicles. Naturally, we are aware of the
                             ment through to human resources,          impending economic crisis? Does this         discussion about weight and CO2 re-
                             all departments within the Company        form the backdrop?                           duction, which will also have a major
                             will be involved. Initially, a workshop                                                influence on the development of new
     DR. THORSTEN GAITZSCH   with the shareholders and KIRCHHOFF       Dr. T. Gaitzsch: I believe that it would     vehicles in the future. Certainly, the
                             Automotive’s Executive Board took         be utterly wrong to talk about an            required reduction in weight will only
                             place. This is where the individual key   economic crisis at the moment. In my         be realised in the long term when al-
                             topics were established; these are now    opinion, the current situation, particu-     ternative materials will become used.
                             being developed in conjunction with the   larly in southern Europe, has less to do     This is why I believe that hybrid struc-
                             executives of the various departments     with a crisis and much more to do with       tures will be more widely used in the
                                                                       market volatility and therefore with         future, i.e. steel-based combinations
                                                                       market fluctuation. This condition will      with other materials, such as alumin-
                                                                       shape our industry for the next five,        ium, plastics, and of course, glass fibre
                             ABOUT THE PERSON                          ten, or even fifteen years. It applies       or carbon fibre reinforced plastics.
                                                                       not only to end-consumer demand for
                             Dr. Thorsten Gaitzsch has been            vehicles, but also, for example, to the      A. Heine: One of the items in Agenda
                             Managing Director of KIRCHHOFF            field of vehicle design. With Agenda         2020 concerns our customers. Why
                             Automotive Deutschland GmbH               2020 we will adapt in a targeted and         do changes need to be made in this
                             and Executive Vice President              timely manner to these changes.              respect?
                             Sales & Technical Development
                             of KIRCHHOFF Automotive GmbH              A. Heine: At the moment, our main            Dr. T. Gaitzsch: One of our strengths
                             since November 2008.                      field of activity remains steel. Will this   during the 2008/2009 crisis was the
K›MOBIL 40 // KIRCHHOFF Automotive                                                                                                                                                                                   KIRCHHOFF Automotive // 40 K› MOBIL

     fact that we were already quite di-        Agenda 2020—all plants, all depart-        is based on strong plants, such as         be more supportive to smaller loca-      Dr. T. Gaitzsch: On the one hand we      across our large customer base, with a
     versified with regard to brands and        ments, and in the end all employees.       those in Germany and Poland, and           tions such as Spain and Ireland. If      will have continued to establish our-    distinctly more harmonious customer
     products. However, we know that this                                                  this will continue to be the case in the   customer-related fluctuations occur      selves as one of the large global sup-   share.
     is another area with room for improve-     A. Heine: What are the markets in          future. This is where we achieve the       at these sites, there are, for exam-     pliers. I am sure that the gap to our
     ment, which is why we are now con-         which KIRCHHOFF Automotive will            financial potential to develop other       ple, considerations about transferring   large competitors has shrunk, and that   A. Heine: Dr. Gaitzsch, many thanks
     centrating on analysing our custom-        operate in 2020?                           locations.                                 to such locations certain production     we have grown more strongly than         for the interview.
     ers’ presence and scope of activities                                                                                            ranges, which we currently manufac-      our competition. On the other hand I
     in the global market; we then want to      Dr. T. Gaitzsch: That is a difficult       A. Heine: Will Agenda 2020 have a          ture at other Group locations or which   believe that we have further expanded    The interview was performed by
     evaluate the extent of our operations      question. At the moment we have            positive impact on really small loca-      we purchase from external suppliers.     our development know-how, in par-        Andreas Heine, Director Communi-
     with them—with whom, where, and            numerous       options.     Fortunately    tions such as Spain or Ireland? Or                                                  ticular towards becoming a systems       cation and Marketing.
     how extensively we collaborate. This       our customers require us at many           might these locations be disconnected      A. Heine: Imagine that it is now 2020.   developer and systems supplier. And
     is where we can identify one or the        locations worldwide, which is of           from the general development of the        What is the status of KIRCHHOFF          last but not least, I believe that our
     other area in which we can become          course to our credit, and which once       whole Company on account of their          Automotive?                              entire business is spread more evenly
     even stronger.                             again highlights our significance on       size.
                                                the global market. At the moment,
     A. Heine: Agenda 2020 is to have an        though, it is not really possible to say   Dr. T. Gaitzsch: I don’t see this as a
     impact on the entire Company. What         where we will ultimately be present in     risk. Agenda 2020 will also provide
     does this mean for our employees?          2020. I can only perhaps say that if,      new ideas in relation to how we can
                                                from our present perspective, we are
     Dr. T. Gaitzsch: Our employees are the     considering some locations in con-
     basis for our success. Due to demo-        crete terms, these would more likely
     graphic development, it is, however,       include projects in Brazil and Russia
     increasingly difficult to find qualified   than in India or Thailand.
     employees. However, I am sure that
     we will overcome this situation thanks     A. Heine: Will the importance of
22   to the various programmes, which we        what I would term “old” loca-                                                                Strategies & strategy champions                                                                                     23
     have already implemented, such as          tions in Europe suffer as a result
     “Learn to Lead” for our managers, as       of this development?
     well as many other programmes. This
     is because we will need to look after      Dr. T. Gaitzsch: Absolutely not.
     new employees much better than be-         In my opinion, new locations
     fore, as it is the only way that we will   may even contribute to the ca-                                                                                   Specific customer                                 New market
     be able to recruit the best employees      pacity utilization of established                                                                                growth strategy                           development strategy
     for our Company.                           locations. Overall, the suc-
                                                cess of our Company
     A. Heine: At the end of the day,
     Agenda 2020 should be driven by all                                                                                                               Lean transformation                                                Product portfolio
     employees. How can we go about it?                                                                                                                strategy (KAPS)                                                            strategy

     Dr. T. Gaitzsch: Agenda 2020, and
     thus a strategy for the next eight
     years, cannot be an instrument which
     is only driven by shareholders or the
                                                                                                                                              Manufacturing /                            Strategies                                           Global
                                                                                                                                              Investment strategy                                                                        HR strategy
     Executive Board; it must be lived, so to
     speak, by the entire Company. I there-                                                                                                                                             Agenda
     fore feel it is completely natural and
     obvious for everyone to work together                                                                                                                                               2020
     on this topic, so that everyone is com-                                                                                                           Risk management                                                Sales controlling and
     mitted to all the targets arising from                                                                                                            strategy                                                     administration strategy

                                                                                                                                                                 Supplier selection
                                                                                                                                                                 strategy                                        Finance strategy
K›MOBIL 40 // KIRCHHOFF Automotive                                                                                                                                                                            KIRCHHOFF Automotive // 40 K› MOBIL

     Experience more,                                                                                                        country. This is because the writers
                                                                                                                             for the relevant location section all
                                                                                                                             come from the country in which the
                                                                                                                                                                       was not just very successful, but this
                                                                                                                                                                       common event for our international
                                                                                                                                                                       Company really helped us form a
                                                                                                                                                                                                                 additional media. Videos will also be
                                                                                                                                                                                                                 available of, for example, trade fairs,
                                                                                                                                                                                                                 new machines, or country-specific

     understand more                                                                                                         section appears. Overall, there will
                                                                                                                             be eleven different location sections,
                                                                                                                             so that all employees can learn about
                                                                                                                                                                       bond, and we all had great fun, too.”

                                                                                                                                                                       In the future, Andreas Heine and
                                                                                                                                                                                                                 family celebrations for employees. It
                                                                                                                                                                                                                 will be possible to click on these videos
                                                                                                                                                                                                                 in the new intranet or to view them on
                                                                                                                             items of importance for their plants.     his four colleagues will act as the       new large screens in the production
                                                                                                                             Although English is our corporate         hub for international corporate           department. In order to achieve this,
                                                                                                                             language across all levels at every       information. Colleagues located in        a new global intranet will be created,
             KIRCHHOFF Automotive continues to expand its internal corporate communication.                                  location, K>NEWS will, however,           the countries will write for their        which will start off as a pilot project
                                                                                                                             appear throughout in the relevant         location using a predefined layout and    in Germany in 2013 and will there-
                                                                                                                             national language to enable better        send their articles to Germany. The       after be gradually set up and installed
                                                                                                                             understanding.                            articles are combined with informa-       in all locations. All plants, in turn,
                                                                                                                                                                       tion from the headquarters and from       will then be equipped with large
     More information for everyone at the   agement or on the welding machine,    employees. Its content is international.   “We are particularly pleased that         the Executive Board, then return to       information screens
     same time. This is the objective of    from December, all employees will     One section of the magazine reports        we have been able to combine lo-          the individual locations as a global
     the new internal communication. Re-    be informed about the latest Com-     on the developments and goals of           cal and international information in      magazine, where, translated into                                   Andreas Heine
     gardless of where the around 8,000     pany developments at the same time.   the entire Company and contains            one employee magazine. To do this,        the various languages, it will be
     employees at KIRCHHOFF Automotive      The new edition of the K>NEWS         interesting articles from all locations    we put together a fantastic team of       distributed to all employees.
     are working, whether in Germany,       employee magazine will be the first   across the world. The second sec-          colleagues from all the countries in
     Canada, or China; independent of       new medium. In the future, it will    tion deals in an authentic way with        which we operate. The first joint work-   From 2013/14, the corporate commu-
     whether they are working in man-       be sent four times a year to all      the particularities of the respective      shop in Germany held in November          nication will then be supplemented by

24                                                                                                                                                                                                                                                                  25

                                                                                                                                                                   left: participants of international communication workshop for internal communication; centre:
                                                                                                                                                                   our photographs from two continents from left to right: Eduardo Cay (Spain), Veronica Gao
                                                                                                                                                                   (China), Aneta Furgal (Poland); right: homepage of the new KIRCHHOFF Automotive intranet
K›MOBIL 40 // KIRCHHOFF Automotive                                                                                                                                                                                          KIRCHHOFF Automotive // 40 K› MOBIL

     IZB 2012: International
     Suppliers Fair breaks all records
             The International Suppliers Fair (IZB) in Wolfsburg/Germany, which was held on 10–12
     October 2012, is regarded as Europe’s leading trade fair for the automotive supply industry. This
     year’s edition exceeded all expectations with 776 exhibitors and 49,000 professional visitors and
     was a complete success for KIRCHHOFF Automotive, too, after six years of absence.

     WE.MOVE.FUTURE. True to this               stand product samples. “This is hands-     High-calibre delegations from busi-
     motto, the international develop-          on technology”, summed up one of the       ness, politics, and trade association
     ment supplier presented its product        visitors.                                  attended the trade fair. Europe’s
     innovations and technologies for the                                                  leading trade fair for the automotive
     automotive lightweight construction of     However, the new electrically powered      supplier industry came to a close with
     tomorrow. Hybrid structures made of        S3-12e racing car, developed by the        these positive results. “After 2010,
     metal-plastic and steel-aluminium com-     student team of Speeding Scientists        the significance of the exhibited
26   posites attracted considerable attention   Siegen/Germany with the support of         products and international character                                                                                                                                          27
     from the numerous visitors. Other core     KIRCHHOFF Automotive proved to be          of the exhibitors and visitors increased
     competencies such as research & devel-     an eye-catcher and an attraction for the   considerably this year”, summa-
     opment as well as cold and hot forming     visitors.                                  rised Thomas Krause, Member of the
     were explained using easy-to-under-                                                   Management Board at Wolfsburg AG

                                                                                                                                                                          An eye-catcher on the KIRCHHOFF Automotive booth: the electrically powered S3-12e
                                                                                                                                                                          racing car; proudly presented by Arndt G. Kirchhoff, CEO KIRCHHOFF Automotive, and
                                                                                                                                                                          Götz Poenaru, team member of the student team Speeding Scientists Siegen/Germany.

                                                                                                                                        in his review of the trade fair, and thus   mercial Vehicles were cultivated or        ness and we have been very positively
                                                                                                                                        highlighted the great proportion of         re-established. This included Jens         surprised. The basis for a continued
                                                                                                                                        decision-makers from across the world       Wenzlau, Head of Metal Procurement         successful co-operation with the VW
                                                                                                                                        who were encountered at supplier            at Volkswagen, who was welcomed            Group has been further strengthened
                                                                                                                                        stands or as visitors.                      by Arndt G. Kirchhoff, and showed          by our presence at this year’s IZB, and
                                                                                                                                                                                    great interest in the Company’s inno-      promises to continue growing in the
                                                                                                                                        This was also the case at the               vations and range of products.             future.”
                                                                                                                                        KIRCHHOFF Automotive stand, where
                                                                                                                                        contacts to high-ranking representa-        Dr. Thomas Steinhaus, Director Sales       The date for the next IZB in autumn
                                                                                                                                        tives from technology and procure-          Europe, summarised, “After our ex-         2014 has been duly noted.
                                                                                                                                        ment of customers such as VW,               perience in 2006, we approached
                                                                                                                                        Audi, Skoda, Porsche, und VW Com-           this trade fair with a certain cautious-                    Dr. Thomas Steinhaus

                                                             Left: The KIRCHHOFF Automotive stand on the International Suppliers
                                                             Fair; right: Arndt G. Kirchhoff (on the left) shares his happiness about
                                                             the VW Group Award with Jens Wenzlau, Head of Metal Shell Moulds
                                                             Procurement and Chassis Components at Volkswagen.
K›MOBIL 40 // KIRCHHOFF Automotive

     This is how it might look like,
     the new Post minivan

     Premiered at the IAA Commercial
     Vehicles in Hanover/Germany
                                                                                                                                        The electric minivan from StreetScooter GmbH was presented to the public at the IAA Commercial Vehicles in Hanover.
28                                                                                                                                      From left to right: Prof. Dr. Achim Kampker (Managing Director, StreetScooter GmbH), Christoph Wagener (Head of Research &   29
                                                                                                                                        Development KIRCHHOFF Automotive), Arndt G. Kirchhoff (CEO KIRCHHOFF Automotive)
               KIRCHHOFF Automotive involved in the development of an electric van.

     An electrically powered minivan           The main benefits of this model can be        cept, there is additional interest in      ThyssenKrupp Steel, the Attendorn-
     was one of 350 premieres at the IAA       found in its ergonomically perfected          further vehicles. Apart from climate       based, family-owned Company forms
     Commercial Vehicles in Hanover. A         and optimised equipment: an extend-           protection—assuming         regenerative   the lead engineering group for the                                          Info
     premiere not to be missed: it has a       ed wheelbase and power output of              energy is used—the vehicle also of-        body of the vehicle—which was devel-
     loading volume of approximately           30/45 kW—generated from a lithium-            fers competitive advantages in terms       oped in line with the purpose design.
     four cubic metres with a top speed        ion battery and an asynchronous mo-           of acquisition and running costs for       In contrast to conversion design, this
     of 85 km/h, and the electric drive        tor—ensure the vehicle is a genuine           short-distance fleets against conven-      process does not modify a vehicle with
     has a range of 120 km.                    “urban delivery vehicle”. Its particular      tional diesel vehicles. This opens up a    conventional powertrain: rather, it                                         StreetScooter GmbH was established
                                               features make the vehicle an interest-        comparatively large potential market       designs one specifically for the                                            in 2010; the project is regarded as one
     Furthermore, it looks just like the big   ing prospect for energy suppliers, car        in the sector of electric minivans. The    electric drive.                                                             of the most innovative in the field of
     brother of StreetScooter, the electric    rental companies, car-sharing opera-          van will be based on the longitudinally                                                                                electric mobility. The objective was
     car that was rapturously welcomed at      tors, tradesmen and service providers         scalable StreetScooter body in order to    This allows a body in white to be cre-                                      to develop an electric vehicle suitable
     its launch in 2011 at the IAA in Frank-   alike. Deutsche Post DHL is planning          comply with the relevant safety regu-      ated specifically tailored to satisfy the                                   for everyday use without any involve-
     furt am Main/Germany.                     to use the electric van for delivering        lations, and to benefit from economies     requirements of an electric vehicle,                                        ment from OEMs. The shareholders
                                               letters and parcels.                          of scale.                                  i.e. the usual package of battery and                                       of StreetScooter GmbH are more
     The two-seater van was developed                                                                                                   powertrain. This is particularly advan-                                     than 20 industry partners under the
     jointly by research and industry part-    To coincide with the trade fair,              Since 2011, KIRCHHOFF Automotive           tageous for the load curve develop-                                         guidance of the university RWTH
     ners on the basis of the StreetScooter,   Deutsche Post DHL announced an                has been heavily involved in the de-       ment during accidents at high speed.                                        Aachen/Germany. They have joined
     and is primarily intended as an urban     order for 50 prototypes intended for          velopment of the vehicle frame for         Consequently, the vehicle battery can                                       together to form the nine lead engi-
     delivery vehicle. After collaborating     first fleet trials, which will initially be   the StreetScooter project, particularly    be accommodated in a sandwich floor,                                        neering groups (LEGs) Body, Exterior,
     on the StreetScooter electric car pro-    based on a tubular space frame. As            in the development of high-strength        instead of crumple zones such as front                                      Interior, Chassis and Safety, Power-
     ject, KIRCHHOFF Automotive is also        the global logistics service provider         rolled profiles and deep-drawn and         or rear end; this provides additional                                       train, Battery, Thermal Management,
     involved in the development of this       has set itself the goal to improve its        hot-formed components for the front        safety reserves in the event of an                                          Electronics, and Closures, to bundle
     prototype.                                CO2 efficiency by 30% compared with           end and structure. Together with           accident.                                                                   their research and development
                                               2007 as part of its “GoGreen” con-            Gebrüder Dingerkus GmbH and                                           Marco Toeller                                    expertise and design this electric
                                                                                                                                                                                                                    vehicle together.
K›MOBIL 40 // KIRCHHOFF Automotive

     IAA Commercial Vehicles 2012:
     a fair with a lot of records

           “Commercial vehicles—driving the future”—this was the theme of the 64th IAA, where
     KIRCHHOFF Automotive presented its latest innovations for commercial vehicle construction.

30   Never before has an IAA been as ex-     KIRCHHOFF Automotive was present             as frame components made of high-                                                                                          31
     citing as this one! Never before were   with a 140 m2 stand. Under the theme         strength steel.
     there as many new commercial vehi-      “WE.MOVE.FUTURE.”, the Company
     cles—vans, heavy-duty trucks, buse—     presented the latest technologies and        High-ranking     guests    from     the
     to be seen as there were at this one.   processes in the areas of metal form-        worlds of politics and business were
     The 64th IAA was true to its theme      ing as well as product innovations for       amongst the numerous visitors to the
     “Commercial vehicles—driving the        lightweight body construction, such          KIRCHHOFF       Automotive       stand.
     future” and demonstrated                                                                      Amongst them was the
     that the commercial vehicle                                                                   German Transport Minister
     sets technological trends.                                                                    Dr. Peter Ramsauer, who
     This sector is the pioneer for                                                                commented: “The best of
     environmental technology,                                                                     the best are congregated
     efficiency, alternative pow-
     ertrains, and the optimisa-
                                             Info                                                  at this trade fair. I am im-
                                                                                                   pressed by the quantum
     tion of the diesel engine.                                                                    leaps in efficiency, econo-
     The topic of lightweight                                                                      my, end ecology presented
     construction is also being                                                                    here particularly for trucks.”
     regarded as an increasingly             The IAA Commercial Vehicles is the                    After his opening speech
     important strategic aspect.             world’s largest trade fair for mobility,              for the IAA Commercial
                                             transport, and logistics solutions, and is            Vehicles, Peter Ramsauer
     The IAA is the only place               a window to the innovative power of                   also visited the stand of
     where the entire commercial             the entire sector. With 354 world pre-                KIRCHHOFF         Automotive.
     vehicle sector can be seen              mieres—more than two thirds of which                  There, he was particularly
     and experienced alongside               from suppliers—there was a new record                 interested in the front un-
     the entire value chain of               level of innovations. The number of                   derride protection for the
     suppliers. As a leading de-             exhibitors—1,904 exhibitors from 46                   MAN TGX and TGS, which
     velopment partner of the                countries—is 9% higher than in 2010;                  is produced at our main
     international    automotive             the exhibition area has increased by                  location in Iserlohn/Germany     above: view to the IAA booth; centre, picture on the left: VDA Manager Klaus
     industry for complex metal              11%. A total of 260,000 visitors attend-              using a brand new, fully         Bräunig (left) informs himself about the rear axle housing; centre, picture on
     and hybrid structures for the           ed the IAA: this represents a growth of               automated welding unit.          the right: the IAA booth team; bottom: Federal Minister of Transport, Building
     body in white and chassis,              9% in comparison with 2010.                                                            and Urban Development, Dr. Peter Ramsauer (left) and VDA President Matthias
                                                                                                                                    Wissmann (right) visited the KIRCHHOFF Automotive stand.
K›MOBIL 40 // KIRCHHOFF Automotive                                                                                                                                                                                  KIRCHHOFF Automotive // 40 K› MOBIL

     Due to the changed requirements           the many possibilities of starting a
     for installation space resulting from     career with the Company and about
     the implementation of the EURO 6          the extensive range of internships,
     emissions      standard,   KIRCHHOFF      trainee programmes, and study
     Automotive in conjunction with MAN        research projects. At the end of the
     has completely redesigned the front       day, everyone agreed: this event has
     underride protection. Commercial          to be repeated!
     vehicles must meet the EURO 6
     standards for commercial vehicles         In conclusion, this edition of the IAA
     from 31 December 2013—for new             Commercial Vehicles was a complete
     vehicle types the date is 31 December     success thanks to more world pre-
     2012.                                     mieres, more exhibitors, more space,
                                               and more visitors! And—when one
     For the second time, KIRCHHOFF            IAA closes its doors, the doors of the
     Automotive organised a day for            next one are about to open: in just
     school pupils and students from the       under a year, the 65th IAA Cars
     region of Iserlohn and Attendorn as       (12–22 September 2013) will start in
     part of the initiative to promote young   Frankfurt/Main, and we hope to see
     talent and to provide orientation         you there again.                                                                                                                                              Design sketch of Porsche Macan, source: Porsche
     when choosing a career. Following

                                                                                                                                The Porsche Cayenne
     the theme of “Technology to touch”,       We are looking forward to it!
     the Company had invited them to
     immerse themselves in the exciting        Sabine Boehle

                                                                                                                                is getting a little brother
     working world of the automotive
     industry. After a tour of the stand
32   and hearing the insights into a day                                                                                                                                                                                                                            33
     in the life of an engineer, the young
     visitors explored the IAA exhibi-
     tion centre. On their return to the
     KIRCHHOFF Automotive stand, many                            The front underrun protection for the MAN TGX and TGS, a                KIRCHHOFF Automotive receives orders for the new Porsche Macan.
     took the opportunity to ask on-the-spot                     product that KIRCHHOFF Automotive is in charge of during
     questions about personal career plan-                       all phases of the product life cycle, from design and devel-
     ning and informed themselves about                          opment through prototyping to series production.
                                                                                                                                An off-road vehicle from Porsche?           fully-fledged production location with     time, they make a contribution to
                                                                                                                                The idea of the Stuttgart-based             body shop and paint shop for this new      reducing the weight of the body
                                                                                                                                sports car manufacturer, that               SUV.                                       in white—an aspect that is vitally
                                                                                                                                caused many a motorist to shake                                                        important in the SUV segment.
                                                                                                                                his head in disbelief 15 years ago,         Currently, KIRCHHOFF Automotive is
                                                                                                                                has evolved into a success story.           already represented at Porsche with        We received a further indicator of the
                                                                                                                                The Cayenne is now successfully             innovative and sophisticated products,     positive collaboration with Porsche,
                                                                                                                                established on the market in its            such as the transmission mounting          which came in the form of the
                                                                                                                                second model generation.                    for the Cayenne, and rear-axle cross       order for a structure component in
     TECHNOLOGY TO TOUCH                                                                                                                                                    members, which were developed              the Macan’s front compartment in
                                                                                                                                Together with its Group brothers built      in-house and can be found in the           summer. Developed as two variants
     Under this theme the students for                                                                                          on the same platform—the VW Touareg         911 series and Boxster/Cayman.             for different engine types, this
     mechanical engineering from the                                                                                            and Audi Q7—the target production                                                      welded assembly with subsequent
     university of applied science of                                                                                           figures for the vehicle have been clearly   This made our joy even greater when        CDP surface treatment will be manu-
     Southwestphalia in Iserlohn could                                                                                          exceeded for the last few years. What       we were awarded the order for a pack-      factured at our plant in Iserlohn/Germany.
     see and discover a lot at the IAA.                                                                                         seemed more obvious than to develop         age of thermoformed structural body
     On the picture with deanship                                                                                               a little brother for the Cayenne? The       components for the new Macan in            These new orders will significantly
     assistant Rainer Witt (centre) and                                                                                         new, fifth series from Porsche will be      spring this year. Made of ultra-high-      boost sales with our customer Porsche.
     human resources specialist Tatjana                                                                                         called “Macan”, derived from the            strength steel on the thermoforming
     Schutte (right) who presented                                                                                              Indonesian word for “tiger”. Production     lines of the KIRCHHOFF plant in                                         Jens Römer
     career opportunities at KIRCHHOFF                                                                                          of the Macan will start at the end of       Esztergom/Hungary, our components
     Automotive to the students                                                                                                 2013 in Leipzig. The Porsche plant          play an important role in satisfying the
                                                                                                                                there will be expanded to become a          high crash requirements. At the same
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