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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 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 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 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 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 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 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 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
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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