forum 43 en - Wirtgen Group

FORUM
nUMbeR 43
issUe 1/12
The magazine for customers, staff and friends of the Wirtgen Group
Strong in Latin America
DOMINICAN REPUBLIC: Wirtgen Group expands highway network.
SÃO PAULO: Environmentally-friendly road rehabilitation thanks to cold recycling.
CIBER: An indispensable part of the Wirtgen Group.
ROAD AND MINERAL TECHNOLOGIES
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www.wirtgen-group.com
08.06.12 14:23
FoUR stRonG bRanDs FoR the
MininG anD ConstRUCtion inDUstRies –
FRoM a sinGle soURCe
ROAD AND MINERAL TECHNOLOGIES
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www.wirtgen-group.com
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eDitoRial | FoRUM 43
3
Dear customers,
dear staff and friends
i
t is at times of economic turbulence, such as those currently
being witnessed around the world, that our far-sighted strategies prove their worth, not only for us as manufacturers, but
also and particularly for our customers.
OUR LONG-STANDING WORKFORCE:
AN INVALUABLE RESOURCE
It is well known that nothing can replace experience. We are now
benefitting from the fact that our repeatedly reestablished market
leadership in Road Technologies and our continually expanding
position in the field of Mineral Technologies are assured by a competent workforce who are of great service to our customers in their
daily work; a workforce of exceptionally enthusiastic employees
from all around the world who work towards our joint success,
acting as once big family, regardless of their cultural backgrounds;
practice-oriented maintenance and diagnosis systems. The sales
a team which operates with the customers in mind, which under-
and service companies receive back-up from the headquarters,
stands their concerns, problems and challenges in daily working
creating a common competence which benefits Wirtgen Group
life and offers the best possible support whenever it is needed.
customers and provides them with added value.
With their in-depth knowledge of the market, the experts
at our headquarters develop products, focussing on quality and
economic efficiency. The result is a portfolio that fits the bill, not
only in terms of processes, but also in terms of regional condi-
THINK GLOBAL – ACT LOCAL:
OUR COURSE IN LATIN AMERICA
tions, catering to project- or customer-related requirements. Our
In this issue of the Wirtgen Group FORUM, we will mainly be fo-
customers have frequently inspired us to develop innovative
cussing on the Latin American market. We will be looking at local
construction, cutting, processing and rehabilitation technologies,
product development and production as well as our sales or-
consistently focussing on performance, costs and resource con-
ganization, including the dealers with whom we have long-stand-
servation. These processes have become a standard part of the
ing partnerships. The modern factories in Germany are another
rules and regulations imposed by authorities issuing invitations
focal topic in this issue. We will be taking a peek over the shoul-
to tender.
ders of the employees who advanced the latest innovations in
product development and production.
BASIS FOR THE FUTURE: A CLOSE
PARTNERSHIP WITH OUR CUSTOMERS
employees around the world, our overall position is solid and we
To ensure that we would always be close to our customers, we
tomers.
Having gained a lead thanks to the services of our trusty
will remain a reliable business partner at the service of our cus-
began organizing and qualifying our sales and service companies
accordingly at an early stage. As a result, highly experienced experts are now also available there as partners for our customers.
Our warmest wishes
This applies both to our own subsidiaries and to the authorized
dealers with whom we have been collaborating for many years –
indeed, some have been partners so long, they are now in their
second generation. The range of services encompasses everything
from applications consulting and training to workshop or job site
services and the availability of original spare parts supported by
Forum 43_en.indb 3
Jürgen Wirtgen
Stefan Wirtgen
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4
08
In the Dominican Republic, Wirtgen Group
technologies expand a
section of the island’s
most important highway.
Children from the slums of Rio are looked after at
the “Bom Samartiano” day care centre.
44
PROJECTS + PARTNERS
08 The blessing of the Caribbean
24
Highlights from the Wirtgen
Group were eye-catchers at
Intermat 2012.
24 Premieres in Paris
The Wirtgen Group presented four world premieres at this
year’s Intermat, captivating trade visitors.
Wirtgen Group companies sustainably improve the traffic
infrastructure of the Dominican Republic.
14 Recycling in the megacity
The Avenida Sapopemba in São Paulo is rehabilitated by
cold recycling, making economical use of resources.
SPECIAL FEATURE: DEVELOPMENT
28 We are the recyclers
Customer feedback is often the initial inspiration for
Wirtgen’s innovations – including the new WR 240.
SALES + SERVICE
18 A strong partner
Ciber is an indispensable part of the Wirtgen Group.
30 A new generation
Good cooperation and far-sighted planning ensured the
successful production launch of the Vögele “dash 3”-zero
series.
32 A strong team for strong compactors
Customers the world over rave about the new H-series from
EXHIBITIONS + EVENTS
22 Global presence
Hamm. Many of the advantages were developed during
construction of the prototype.
34 Never stop moving
Review and outlook: The Wirtgen Group at international
The quality of the EVO plants is the result of decades of
trade fairs.
experience and continual development work.
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Contents | FoRUM 43
5
30
A strong team: the people behind the “dash 3”
generation.
PLANTS + KNOW-HOW
36 In full swing
Wirtgen was able to sustainably optimize basic production
DIGITAL FORUM
Simply download the current issue as
a pdf or send Forum 43 to a friend using
the QR code.
www.wirtgen-group.com/forum-mobil
conditions with its new plant for special-purpose machinery.
38 High in-plant production
Vögele converted a large portion of its production facilities
to in-house manufacturing.
40 Quality concerns us all
The Hamm QA team assures the quality of purchased
parts, processes and final products.
42 Investment in the future
PUBLISHER’S DETAILS
FORUM The magazine for customers, staff and friends of the Wirtgen Group
PUBLISHED By Wirtgen Beteiligungsgesellschaft mbH, Reinhard-Wirtgen-Straße 2,
53578 Windhagen, Germany, E-Mail: forum@wirtgen.de, www.wirtgen-group.com
Commercial Register Montabaur HRB 10492, VAT No.: DE 149 525 751
A new investment has enabled Kleemann to further
BOARD OF MANAGEMENT Jürgen Wirtgen, Stefan Wirtgen, Rainer Otto
extend its position as a series manufacturer in 2011.
RESPONSIBLE FOR CONTENT Michaela Adams, Tel.: +49 2645-131 128,
Fax: +49 2645-131 499, E-Mail: forum@wirtgen.de
EDITORIAL STAFF Michaela Adams, Mario Linnemann. All rights reserved.
Reproduction only with written permission by the editorial staff.
“CHILDREN IN NEED” CHARITy
44 Hope for children in need
The children of Rio de Janeiro get a chance for a better
life in the “Bom Samaritano” children’s day care centre.
Forum 43_en.indb 5
PRODUCTION muehlhausmoers corporate communications gmbh, Cologne, Germany;
Project management: Jürgen Jehle, Jessika Knauer; Editorial staff: Christian Fuchs,
Jessika Knauer; Layout: Tobias Heinrich, Pascal Schöning, Britta Siebert
TRANSLATION interteam Übersetzungsbüro, Grünwald, Germany
PRINT Gebr. Kopp GmbH & Co.KG, Cologne, Germany
PHOTOS Forum 43: Dawin Meckel/OSTKREUZ (cover), Florian Kopp (p. 6-7), Jens Lyncker (p. 34 top,
43); Amendment Forum 42: HOCH ZWEI/picture alliance (cover, p. 11 bottom left), Roemers/laif
(p. 6-7), Jens Lyncker (p. 42-45)
08.06.12 14:24
6
THE WIRTGEN GROUP IN LATIN AMERICA
Roads of the
future
Page 8
Page 14
Page 18
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Motorway extension in the Dominican Republic
Environmental protection in São Paulo
Ciber: The Wirtgen Group’s partner in Latin America
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toPiC | FoRUM 43
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DOMINICAN REPUBLIC
The blessing of
the Caribbean
Wirtgen, Vögele, Hamm, Kleemann and Ciber technologies are sustainably
improving the traffic infrastructure in the island state.
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PRojeCts + PaRtneRs | FoRUM 43
T
9
he 223-km-long highway “Corredor Vial del Este” is the
main traffic route in the east of the Dominican Republic.
The project involved the extension of the 70-km section
known as the “Autopista Del Coral” to four lanes, each
with a width of 3.65 m, the aim being to connect the two tourist
centres La Romana and Punta Cana with their respective airports
La Romana Airport and Punta Cana International Airport. As many
as 20,000 vehicles use this important stretch of road each day.
TWENTy WIRTGEN GROUP CONSTRUCTION
MACHINES IN OPERATION ON SITE
“Faced with complex technical requirements and an ambitious
schedule, the project management organization, the consortium
Consorcio Autopista del Coral, elected to use the reliable world
market leading machines from the Wirtgen Group,” explained José
Luis Matallana from Resansil RD S.A., the Wirtgen Group dealer in
the Dominican Republic. A total of 20 Wirtgen Group machines got
to work in December 2010. Eighteen months later, the new “Autopista Del Coral” section was completed as planned.
STRONG WIRTGEN SURFACE MINERS AND
KLEEMANN IMPACT CRUSHERS
The first construction phase involved eight surface miners and
two impact crushers. Thanks to their flexible all-terrain mobility,
the surface miners were able to make maximum use of their
capacity. The four 2100 SMs and the four 2200 SMs milled off
limestone in a single pass, producing the grain size of 0 to 4”
required for its reuse for the road extension – an economical
process. For the 2200 SM mines between 150 and 200 m³ of
limestone per hour while the thickness of the cutters only drops
by 0.01 mm per cubic metre. “Not only did using the surface
miner enable us to dispense with the expensive and time-consuming drilling and blasting of larger lumps of rock, it levelled
the surface of the ground perfectly, preparing it for the following
steps, and saved resources, too,” said Matallana.
The Mobile Impact Crusher MR 130 Z EVO processed
more of the limestone, also crushing it down to the required
FACTS AND FIGURES
Dominican Republic
Area: 48,700 km²
Capital: Santo Domingo
Population: 10,088,600 (estimate for 2012)
GDP: US$ 51.6 billion (2010)
Road network: 19,705 km, asphalted portion: approx. 50%
Highways: 12,600 km, asphalted portion: approx. 50%
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1
2
3
1. The 3414 VIO Compactor with Vibration and
Oscillation was used for the earthworks. Being
able to compact in vibratory or oscillating
mode, the “VIO” drums offer the ultimate in
versatility.
2. The high-performance Super 1900-2 Paver
with Extending Screed AB 500 TP2 ensures extremely high-quality paving, right from the material feed stage: large, oscillating push-rollers
ensure residue-free feeding by the truck – a crucial factor in ensuring maximum evenness during paving.
3. The Batch Asphalt Plant UAB 18 E is used, in
particular, in large-scale projects requiring an
uninterrupted production of high-quality asphalt
mixes. It can be used as a stationary or semimobile plant and has impressive environmental
features, too.
4. Oscillating drums such as the HD O 90 V do
not waste power producing unwanted vibrations
in the vicinity, but guide it directly into the material to be compacted – exactly where it is
needed. Low vibrations guarantee a long machine service life and optimum driver comfort.
4
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PRojeCts + PaRtneRs | FoRUM 43
11
Using innovative EVO technology, the MR 130 Z EVO ensures an optimum material flow, easily achieving feed capacities of 450 m³ of limestone per hour.
grain sizes directly on site. Crushing 450 m³ of limestone per
Wirtgen soil stabilizers and Hamm earthwork rollers had already
hour, it ensured that the new base material for the further
ensured a perfectly cohesive foundation before the asphalt paving
expansion of the highway section was available in next to no time.
work commenced. In the process, the Vibratory Compactor 3520
As a result, there was no need to procure the required material
took on the work of two ordinary 11-t rollers, being able to com-
from a mine located 40 km away, avoiding high transport costs.
pact as much as 1200 m³ of uncompacted 25-cm-thick base
course. With their wide range of applications, the earthworks
TECHNOLOGIES FROM VÖGELE AND CIBER
ENSURE A PERFECT PAVED RESULT
rollers 3520 and 3414 VIO with vibration and oscillation also
The excellent preparation of the soil meant that the three Vögele
pavers could start paving the lower base course immediately.
They were supported by the Ciber Cold Mix Plant USC 50 P and
the Batch Asphalt Plant UAB 18 E. Producing between 100 and
DATA AND FACTS
140 t of mix per hour, the UAB 18 E, for instance, supplied the
Machines used
high-quality paving material without delays. The Vögele SUPER
1x
Wirtgen Soil Stabilizer WR 2400
1900-2 then got to work, performing excellently. The resultant
4x
Wirtgen Surface Miners 2200 SM
pavement had a remarkable evenness of below 2 m/km according
4x
Wirtgen Surface Miners 2100 SM
to the International Roughness Index (IRI) and a very high degree
3x
Vögele Pavers SUPER 1900-2 AB 500 TP2
of compaction of 88% on a 25-cm-thick asphalt pavement. As a
2x
Hamm Tandem Rollers HD 90 and HD O 90 V
result, the work progressed swiftly, as no further compaction
1x
Hamm Vibratory Compactor 3414 VIO
measures were required.
1x
Hamm Vibratory Compactor 3520
The 20-cm-thick lower base course and the 17-cm-thick
2x
Kleemann Impact Crusher MR 130 Z EVO
upper base course were thus quickly paved, each with a width
1x
Ciber Cold Mix Plant USC 50 P
of 6.5 m. A 4-cm binder course and a 3.5-cm wearing course
1x
Ciber Batch Asphalt Plant UAB 18 E
rounded off the pavement of the new traffic route.
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Surface miners such as
the 2200 SM cut routes
through native rock.
This route provides an
ideal sub-base for the
courses of the road.
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PRojeCts + PaRtneRs | FoRUM 43
a h a m a s
greatly reduced the amount of rollers required for the project.
Hamm Tandem Rollers HD 90 put the finishing touches to the
roadway surface – and, needless to say, they achieved ideal compaction values.
PIONEERING: WIRTGEN GROUP EXCELS
IN ALL AREAS
By constructing the “Autopista Del Coral” section and extending
the entire “Corredor Vial del Este” highway, the local authorities
achieved an important milestone in the improvement of their
national traffic infrastructure. Traffic safety has been greatly
improved, important centres have been linked and travelling
times slashed by up to 50%. This will not only benefit locals,
but also the tourism trade, the Dominican Republic’s most important industry.
amo
ba
Guantanamo
FACTS AND FIGURES
Montego Bay
CAP-HAITIEN
Santiago de
Los Caballeros
Nagua
HAITI
San Francisco de Macorís
DOMINICAN
REPUBLIC
PORT-AU-PRINCE
Baní
Barahona
Kingston
Samaná
Sabana de la Mar
Monte Plata
SANTO
DOMINGO
El Seibo
Punta
Cana
San Pedro
de Macorís
Santa
Cruz
De Bara
La Romana
P
Pon
San Cristóbal
Autovia del Este y S. Pedro – La Romana
Autopista del Coral
Boulevard del Este
Data on the project
Project management organization:
the consortuim “Consorcio
Autopista del Coral” comprising the companies
Constructora Norberto Odebrecht (CNO)
and Moya Supervisiones y Construcciones S.A
Tender issued by:
Ministry of Public Works and
Communications of the
Dominican Republic – SEUPC
Total project volume:
338.000 m³ of base course and
287,000 m³ of wearing course
Investment volume:
Personnel during the construction phase:
US$ 255 million
approx. 2,500
construction workers
Machine operators during operation:
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approx. 30
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14
ENVIRONMENTAL PROTECTION IN SÃO PAULO
Recycling in
the megacity
The Avenida Sapopemba is the busiest road in São Paulo and one of the
country’s main traffic routes. It has now been rehabilitated, making economical
use of resources. In operation: the KMA 220 and the MR 110 Z EVO.
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PRojeCts + PaRtneRs | FoRUM 43
15
The mobility and flexibility of the
plant facilitate job processing
considerably. Equipped with its
own energy-saving diesel engine,
the KMA 220 requires no external
power supply.
T
he Avenida Sapopemba is the busiest road in São
Paulo and one of the country’s main traffic routes. It
has now been rehabilitated, making economical
use of resources. In operation: the KMA 220
and the MR 110 Z EVO.
As in every large metropolis, extensive urbanization processes are under way in São Paulo, creating
up to 16,000 t of rubble daily. The road rehabilitation
programme for the 17,000-km-long road network cre-
“The project has raised
the benchmark for
road construction
in Brazil.”
Antonio Monfrinatti,
Managing Director (Reciclotec)
ates an additional 20,000 m 3 of asphalt material each
month, which has been stored in refuse dumps up to
now. The municipal authorities decided to take action
and created a legal basis for the reuse of reclaimed
asphalt pavement and construction rubble in the construction of new roads.
The cold recycling process is a particularly attractive option here, featuring the complete recycling of the reclaimed material and its cost-effective processing while saving a great deal of
time, too. The municipal administration of São Paulo also opted
to use reclaimed asphalt pavement (RAP) with foamed bitumen for
the current project to rehabilitate the 5-km stretch between the
Avenida dos Sertanistas and the Rua Bento Guelfi. “This
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16
marked a new departure in urban road rehabilitation in Brazil,
where RAP had only ever been used to construct new peripheral roads outside of cities,” explained Antonio Monfrinatti,
Managing Director of Reciclotec, the Wirtgen Group’s authorized dealer in São Paulo.
THE WIRTGEN KMA 220 AND KLEEMANN MR 110 Z EVO LAy THE BASIS
“The KMA 220 achieved
a perfect mixing
capacity and mix
quality”
Valmir Bonfim, Engineer (Fremix)
The local road construction contractor Fremix (ANE
Group) set up a recycling point in the direct vicinity of
the job site for the processing of the construction and
recycling materials as well as the RAP. This was where
the Wirtgen Group machines really came into their own.
The mobile impact crusher MR 110 Z EVO from Kleemann
crushed rubble, some of which originated from demolished buildings, into the specified grain sizes. The new material flow concept
enabled the impact crusher to process the material quickly and
reliably for further use. Fremix elected to use “in-plant” cold recycling to produce the RAP. In other words, the asphalt removed by
A PIONEERING PROJECT IN
LATIN AMERICA
a Wirtgen Cold Milling Machine W 1000 F was processed in a mo-
Thanks to the efficient cold recycling process and the perfect in-
bile plant – the Wirtgen KMA 220 – along with foamed bitumen and
teraction of the Wirtgen Group machines, the project in São Pau-
then repaved on the roadway. “The plant performed impressively,
lo was concluded swiftly and successfully and the Avenida Sap-
producing high-quality cold mix from recycled construction mate-
opemba reopened for urban traffic. The municipal administration
rials – CDW (civil demolition waste) – and achieving a high mixing
of the Brazilian metropolis has raised the bar in urban road reha-
capacity of up to 220 t/h,” concluded Valmir Bonfim, Engineer at
bilitation with this construction project, setting a shining example
Fremix. The KMA 220 was economical in every respect: time-
to other Latin American city centres.
consuming trips by trucks between the mix production site and
the job site were minimized. With an output of 200 t/h, a complete
truck load of 20 t of cold recycling mix was produced every six
minutes while simultaneously reducing CO2 emissions.
The final grain quality was outstanding: with an output of up to 350 t/h, the
MR 110 Z EVO processes quantities
that can normally only be matched by
much larger plants. A high-performance final screen creates the specified final product.
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PRojeCts + PaRtneRs | FoRUM 43
17
Clear, user-friendly
function keys
facilitate the work.
The machine operator
adjusts the pivoting
discharge belt with
millimetre precision
so that the finished
mix can be loaded
onto trucks without
a hitch.
The composition of
the mix is regularly
checked by means of
the Wirtgen Laboratory-Scale Foamed
Bitumen Plant
WLB 10 S. Mix
processed with
foamed bitumen is
particularly durable
and retains its high
quality even when
stockpiled for
months.
Wheeled loaders tip unbound input materials into the batching unit via vibrating
grates. Precise dosing is monitored by a microprocessor-based plant control system.
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CIBER EQUIPAMENTOS RODOVIÁRIOS
A strong
partner
Besides the four strong brands – Wirtgen, Vögele, Hamm and Kleemann – Ciber
is an indispensable part of the Wirtgen Group in the Latin American market.
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sales + seRviCe | FoRUM 43
C
iber Equipamentos Rodoviários is Wirtgen Groups’ local production facility for Latin America and completes
the comprehensive product range with it’s own brand.
The headquarters is located in the southern state of Rio
Grande do Sul in Brazil, in the city of Porto Alegre, and extends
over 48,000 square meters. Ciber manufactures its own brand of
hot mix asphalt plants and pavers on five production lines. Operating under licence, it also produces a model from the Wirtgen cold
milling machine line and a Hamm roller in Porto Alegre, each of
which are adapted to the requirements of the local market.
CERTIFIED MANUFACTURERS OF HOT MIX
ASPHALT PLANTS
19
“We have
invested in
the optimization of our
processes, enhanced our
product quality, trained our
dealers and forged ahead
with innovations.”
Luiz Marcelo Tegon, Ciber Vice President
Along with a logistics centre, a central warehouse, and an administrative building, the Ciber plant also boasts a training centre and
a testing ground. Last year, a special test track was created
especially for the Hamm rollers.
Ciber manufactures the Hamm 3411 under
licence using the flow assembly process.
Spick and span assembly lines: new crane systems were one of the investments made for the production of the Ciber hot mix asphalt plants.
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Everything has its place in the large warehouse,
with its 8-metre-high shelf system.
08.06.12 14:25
CUBA
20
Ciber has been certified in accordance with ISO 9001 (Interna-
MEXICO
MEXIKO
tional Organization for Standardization) since 2011 and thus
belongs to the select group of certified hot mix asphalt plant
manufacturers.
HA
HONDURAS
GUATEMALA
EL SALVADOR
NICARAGUA
The Wirtgen’s central office in Brazil (Wirtgen Brasil Sul) is
also located in the Ciber headquarters. Two further subsidiaries of
COSTA RICA
Wirtgen Brasil are located in the country: Wirtgen Brasil Centro
Oeste, located in Goiânia (in the state of Goiás) and Wirtgen Bra-
PANAMA
sil Nordeste, located in Recife (in the state of Pernambuco).
A total of 322 people work for Ciber and Wirtgen Brasil.
Nine additional authorized dealers provide excellent sales and
service support for Wirtgen Group customers in Brazil. Fifteen
further dealers in Latin America act as a point of contact for customers from Argentina to Mexico.
www.ciber.com.br
THE WIRTGEN GROUP IN LATIN AMERICA
“We can
count on the
excellent supporting team in
the manufacturing plants.
With their back-up, we can
dedicate ourselves to providing an optimum customer
service.”
CO
ECUADOR
PERU
Francisco Isaza Quintero – Fiza (Columbia)
ROAD AND MINERAL TECHNOLOGIES
“Our team is
always up to
date thanks to
regular training
and service meetings at the German
headquarters.”
Brazil
Ciber Equipamentos Rodoviários
Wirtgen Brasil
Vianmaq Equipamentos
Decker Brasil Equipamentos
Nicamaqui Equipamentos
Reciclotec Comercial
Motriz Equipamentos e Máquinas
Requimaq Equipamentos e Máquinas
Diego Lopez – Fizamaq (Ecuador)
Tratorcenter Peças e Serviços
Delta Máquinas
Deltamaq Equipamentos da Amazônia
Latin America
Argentina:
Covema S.A.C.I.F.
Bolivia:
Vezla
Chile:
Costa Rica:
Salinas y Fabres
Corporación ven Resansil de Costa Rica
Ecuador:
El Salvador, Guatemala and Honduras:
Columbia:
Nicaragua:
Mexico:
Panama:
Paraguay:
Peru:
Puerto Rico, Dominican Republic and Haiti:
Uruguay:
Venezuela:
Forum 43_en.indb 20
Fizamaq
Rensansil Guatemala
Fiza
Resansil
Construmac
Panamá Rensansil
Cimasa
Intermaq
Resansil RD
“We invest in
the structure
of our company to keep
pace with our
market success
and to develop additional
business segments.”
Felix Vezjak – Vezla (Bolivia)
Tradinter
Inversiones Resansil
08.06.12 14:25
CHI
BA
sales + seRviCe | FoRUM 43
DOMINICAN
REPUBLIC
21
PUERTO RICO
HAITI
CARIBBEAN
“Thanks to our technical service,
our warranties, and our applications expertise, our customers
see us as an extension of the
Wirtgen Group. That
makes me feel proud.”
RAGUA
VENEZUELA
AMA
COLUMBIA
Manfred Baumgartner – Inversiones Resansil,
(Venezuela)
ECUADOR
PERU
BRAZIL
BOLIVIA
PARAGUAY
“I am proud to be representing the market leader
and feel sure I am offering
customers the best
machines.”
Fernando Ferme – Tradinter (Uruguay)
URUGUAY
ARGENTINA
CHILE
“Our customers are
familiar with the tradition and the quality of
Wirtgen Group products.
That inspires confidence
in us as dealers.”
Christian Gianakis – Coverna (Argentina)
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22
REVIEW, FIRST HALF OF 2012
global presence
The Wirtgen Group is there for its customers – not only on site but also at trade
fairs throughout the world, where it presents the latest innovations in road and
mineral technologies.
BERCHTESGADEN
LAS
VEGAS
SÃO
PAULO
CHARLOTTE
LAS VEGAS, USA
World of Concrete
23–27 Jan 2012
Exhibitor: Wirtgen America
Visitors: 52,088
CHARLOTTE, USA
SÃO PAULO, BRAZIL
BERCHTESGADEN, GERMANY
World of Asphalt
M & T Expo
Deutsche Asphalttage
13–15 Feb 2012
29 May – 2 Jun 2012
8–10 Feb 2012
Exhibitor: Wirtgen America
Exhibitor: Ciber
Exhibitor: Wirtgen Group
Visitors: 6,500
Visitors: 45,000
Visitors: 1,000
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exhibitions + events | FoRUM 43
23
PREVIEW, SECOND HALF OF 2012
MAKE A NOTE!
The Wirtgen Group will also
be represented at trade fairs
throughout the world in the
second half of 2012. It’s well
worth looking in! Here is a
selection of events until the
end of the year:
PARIS
JunE
6–10 Jun 2012
ANKOMAK 2012, Istanbul, Turkey
19–21 Jun 2012
Hillhead 2012, Buxton Quarry, Derbyshire,
UK
AuguST
MOSCOW
23–25 Aug 2012
Turkmenconstruction, Ashgabat,
Turkmenistan
SEPTEMBER
16–21 Sep 2012
Capac Expo Habitat 2012, Panama City,
Panama
20–22 Sep 2012
Entreprenad Expo 2012, Knutstorp,
Sweden
24–29 Sep 2012
International Technical Fair, Plovdiv,
Bulgaria
OCTOBER
15–18 Oct 2012
ROAD 2012, Moscow, Russian Federation
16–17 Oct 2012
Deutsche Straßen- und Verkehrskongress
2012, Leipzig, Germany
17–20 Oct 2012
Baku Build 2012, AZ 1128 Baku,
Azerbaijan
24–26 Oct 2012
DorTransExpo 2012, Kazan, Russian
Federation
nOvEMBER
21–23 nov 2012
PARIS, FRANCE
MOSCOW, RUSSIAN FEDERATION
intermat
CTT
27–30 nov 2012
16–21 Apr 2012
29 May – 2 Jun 2012
bauma China 2012, Shanghai, China
Exhibitor: Wirgen France
Exhibitor: Wirtgen International
Visitors: 200,000
Visitors: 30,000
Forum 43_en.indb 23
Asphaltica 2012, Padua, Italy
www.wirtgen-group.com/fairs
08.06.12 14:25
24
INTERMAT 2012
Premieres
in Paris
They were the stars of the Intermat 2012: the Wirtgen Group’s four world
premieres. Trade visitors were truly captivated and enthused about the technical
highlights of the top exhibits.
Forum 43_en.indb 24
08.06.12 14:25
exhibitions + events | FoRUM 43
O
25
nce again, this year‘s international trade fair for con-
sector. Drawn by the four world premieres, the Wirtgen Cold Re-
struction machinery, construction materials machin-
cycler
ery and construction technology proved extremely
SUPER 2100-3i, the Hamm compactor H 20i and the mobile im-
popular, attracting some 200,000 visitors. Presenting
pact crusher MR 130 ZS EVO from Kleemann, trade fair visitors
31 road construction machines in Paris on an area of about
were given a comprehensive overview of the machines from a
2,000 m2, the Wirtgen Group showcased a cross-section of its well
total of ten product lines. Experts from the four strong brands
established product range in the road and mineral technologies
were available to offer advice and answer any questions on
and
Soil
Stabilizer
WR 240i,
the
Vögele
Paver
iT WAS ExCiTing to see the reactions of the trade
WE hAvE gREAT TRuST in the products, the service
visitors to our products. The feedback from our cus-
and the personnel of Wirtgen France. We ordered 16
tomers was very positive, confirming that we address
Wirtgen milling machines at the Intermat and our fleet
their needs and requirements on the job site and translate them
now comprises 176 of these units. Some of the new machines will
into targeted solutions in our new developments.”
also go to our new subsidiary ‘Fraisavia’.”
Benoît Etienne, President of Wirtgen Francee
Michel Chauvet, Managing Director of von Soloc
WiRTgEn AnD REPROAD maintain excellent rela-
WE PuRChASED our first Vögele paver back in 1987
tions and this also extends to our technical collabora-
and have appreciated the quality, the price-perfor-
tion. The company offers a sensational range and qual-
mance ratio and the after-sales service in Tunisia ever
ity of products in the milling and soil stabilization segments. In
since. We have extended our fleet with the purchase of an
matters of service, Wirtgen is absolutely close to its customers.”
MT 3000-2, the Super 3000-2 as well as 36 Hamm rollers.”
Michel Lötscher, Managing Director of the REPROAD Group (left) with his son
Benedikt Lötscher
Noureddine Hachicha, President of the Tunisian SOROUBAT Group
Forum 43_en.indb 25
08.06.12 14:25
26
the various technological segments. Experienced applica-
ments are certainly impressive. They offer real added value –
tions engineers provided interested trade visitors with exten-
which will mainly benefit the operators who work with the ma-
sive first hand information on current new developments, as is
chines each day on the job site. In this respect, the four world
usual in the Wirtgen Group.
premieres fit in perfectly with the Wirtgen Group‘s portfolio of
Visitors to the Wirtgen Group pavilion were unanimous
tried-and-tested solutions.
about one thing: bursting with innovative features which cater
precisely to customer requirements, the new product develop-
www.wirtgen-group.com/intermat
i BOughT My fiRST milling machine in the mid-1970s,
WE hAvE BEEn WORking very economically with
back in the early days of Wirtgen. I held many construc-
Ciber, Wirtgen and Vögele products for many years now.
tive conversations with the company founder Reinhard
I would now like to introduce the cold recycling process
Wirtgen and this was important for both parties. Wirtgen has al-
to Algeria, with the help of experts from Wirtgen. Thus we can ad-
ways forged ahead with the further development of its machines.”
vance environmentally friendly road construction in the country.”
Günter Meyer, founder and former Managing Director of
GMS Fahrbahnsanierungen
Dr. Kamel Mehsas (left), President of Rotahem and Chairman of the
Civil Engineering Association in Algeria
OnCE AgAin, the Wirtgen Group‘s trade fair presen-
ThE innOvATivE STREngTh of the Wirtgen Group
tation was impressive. I enjoy visiting the pavilion and
constantly amazes me. Often, it is the supposedly „mi-
finding out about the latest developments. We cooper-
nor“ optimizations which prove most effective in terms
ate with Vögele on a partnership basis. The SUPER 800 and the
of user-friendliness or economic efficiency. In the case of the EVO,
SUPER 1600-2 are successful machines in our range.”
I am particularly taken with the new material flow concept.”
Reinhard Roth (right), North Rhine-Westphalia Branch Manager for
HKL Baumaschinen
Damien Masson (right), TPDM
Forum 43_en.indb 26
08.06.12 14:25
exhibitions + events | FoRUM 43
27
The four world premieres from Wirtgen, Vögele,
Hamm and Kleemann were the main attraction for
visitors, alongside machines which have been
successful on the market for many years.
The principle of
oscillation –
demonstrated in
a tangible form
in the special
presentation.
Be it standard or special-purpose
milling drums – cutting technology is
Wirtgen’s core competence.
Forum 43_en.indb 27
08.06.12 14:25
28
MAKING OF: WIRTGEN WR 240i
We are the
recyclers
It sets new standards in terms of performance, user-friendliness and end product quality – as field tests have proven. But which factors shaped the development of the WR 240i? And who are the people behind it?
f
ive very different job sites, but the story always the same:
ing applications and sales aspects into account. And the develop-
the Wirtgen Soil Stabilizer and Cold Recycler WR 240i
ment of the WR 240i was no exception
glides effortlessly over the substrate, whether it is stabilizing heavy swampy soil or cold recycling a motorway.
This machine is the product of a technical development which
began with the customer before being implemented by Wirtgen
COMMUNICATION IS A CRUCIAL PART OF
THE CONCEPTUAL DESIGN
product managers, applications engineers, design engineers and
Continuous communication between all parties is decisive during
production workers.
this phase. “If the development objectives are to be met, our de-
For product managers, regular exchanges with customers
sign engineers must be provided with transparent, detailed infor-
are a key source of ideas from practical applications. Which fea-
mation,” explained Christoph Menzenbach, Applications Engineer
tures help operators in their day-to-day work? Which technical
at Wirtgen. “Once all interfaces and work sections – such as steel
details could further enhance economic efficiency? Supplemented
construction and electrical design – had been involved and the
by experience and the well-founded test results of Wirtgen’s ap-
conceptual design work completed, we could then begin with the
plications engineers, this information is pooled, sorted and vetted
construction of a prototype,” added his colleague Heiko Böhme,
for viability. An initial picture emerges at this stage. This is when
who has overall project responsibility.
the design engineers at Wirtgen GmbH come into play, collaborat-
Whether the machine meets Wirtgen’s high quality stand-
ing with the product management and applications engineering
ards in practice and can thus go into series production becomes
teams on a development project to design the new machine, tak-
clear during the test phase. The WR 240i was hence subjected to
Forum 43_en.indb 28
08.06.12 14:25
sPeCial FeatURe: DeveloPMent | FoRUM 43
29
The team who
designed and
constructed the
brand new
WR 240i.
A P P RO V E
D
WR 240/WR 240i
Working width
Working depth
Engine output
2,400 mm
0-510 mm
447 kW/433 kW
prolonged and exacting tests in a wide variety of applications.
site. And Wirtgen does its utmost to transfer its know-how to its
“External feedback is also important here, particularly responses
customers. For instance, not only are the sales and service person-
from machine operators. This soon reveals any aspects that need
nel at the headquarters familiarized with all the details, but also
further tweaking and indicates which features work and are well
the teams at Wirtgen’s 55 sales and service companies and even
received,” said Menzenbach. The WR 240i passed muster on the
the staff of the 100 authorized dealers worldwide. This enables
job site and was approved for series production. “The multi-func-
them to pass on the expertise they have gained on applications
tional joystick is a particularly big hit with machine operators, mak-
and servicing to the customers. This knowledge transfer marks the
ing their work much easier,” said Christoph Menzenbach, who is
end of the long development process for the WR 240i, from con-
overjoyed with the positive feedback.
ception to market maturity.
AFTER-SALES SERVICE ROUNDS OFF THE
NEW DEVELOPMENT
www.wirtgen.de
As always, Wirtgen’s contact with its customers does not end with
the sale of a machine. Indeed, this is just the beginning of a lasting
service partnership. Training courses are an important factor, ensuring that customers learn all the details of the machines so that
they can harness all of the advantages of the WR 240i on the job
Forum 43_en.indb 29
08.06.12 14:26
30
MAKING OF: VöGELE “DASH 3”
A new
generation
Cross-departmental collaboration, a definition of measures and far-sighted
planning: this was the recipe that ensured the successful production launch
of the “dash 3” zero series. A peek behind the scenes.
T
he new “dash 3” paver generation from Vögele is a
mix. But financial aspects aren’t the only factor, of course: the
product series bursting with innovative features. The
development aims take priority.”
development of the new SUPER 1900-3 and 2100-3
machines demanded exacting work from Project Man-
ager Thomas Schmidt and his team. “It all starts with a project
study. We set out our development aims and target costs for the
WORKING HAND IN HAND TO CREATE THE
MOST ECOLOGICAL PAVER IN THE WORLD
new product and prepare ideas for technical solutions, collaborat-
When designing new machines, the team must always take ac-
ing closely with Production Management, Sales, Service and Mar-
count of the European exhaust gas emissions standard COM 4 and
keting,” explained Schmidt. If a conceptual design fulfils the
the US standard EPA TIER 4f, too. One of the great challenges of
specifications, the project group then develops a 3D model of all
the “dash 3” project was the task of uniting engine variants in a
the individual parts using a CAD program. The entire machine is
single machine by means of a modular design in order to avoid a
created in this way, bit by bit. “The highest quality at optimized
duplication of the different model series. Another aim was to use
costs: that is the prime objective,” said Thomas Schmidt. “We
the smallest possible range of parts for the “dash 3” series to
scrutinized the main assemblies over and over, thinking of ways
simplify parts management in the factory. This makes for stream-
to further improve the drive units, traction and the conveyance of
lined procurement, storage and supply processes in assembly.
Forum 43_en.indb 30
08.06.12 14:26
sPeCial FeatURe: DeveloPMent | FoRUM 43
31
A strong team (from
the left): Hermann
Vetter, Thomas Mette
and Dieter Kolba in
front of the
SUPER 2100-3i
displayed at the
Intermat 2012.
A P P RO V E
D
SUPER 2100-3i
Nominal output
Maximum pave width
Maximum laydown rate
186 kW at 2.000 rpm
13 m
1.100 t/h
A prototype is created once the 3D drawings and parts lists are
poses. We often pass on suggestions for improvements to the
complete. Three Vögele employees play a pivotal role here: Her-
Engineering department.”
mann Vetter, Prototype Construction Manager, Dieter Kolba, De-
Thomas Mette completes the triumvirate. He is responsible
signer in the Final Assembly department and Thomas Mette, Ex-
for all tests on the prototypes. “The high temperature test is above
perimental Technician. “Our department collaborates closely with
all extremely important to us, as Vögele pavers are supposed to
the Engineering department. We discuss new features together
function perfectly at the highest temperatures and at full load,”
and test their feasibility and suitability for series production,” said
said Mette. “We aim to guarantee optimum cooling while avoiding
Hermann Vetter. The development team involves Dieter Kolba, too,
excessive fan speeds which would increase fuel consumption un-
at an early stage, as he is responsible for the smooth start of
necessarily and make the machine louder.” These tests led to the
series production. In the beginning, the SUPER 2100-3 and SU-
development of a new feature in the “dash 3” paver generation –
PER 1900-3 will be produced alongside the “dash 2” generation,
the variable-speed fan.
which is due for discontinuation. “We have to ensure that the
assembly equipment is suitable for all the models and that the
www.voegele.info
tools required are available on site,” explained Kolba. “Parts are
frequently installed and then dismantled again for testing pur-
Forum 43_en.indb 31
08.06.12 14:26
32
MAKING OF: HAMM H 20i VIBRATORY COMPACTOR
A strong team for
strong compactors
Customers the world over rave about the new H-series due to its ergonomic design,
ease of operation and high traction and compaction performance. Many of these
application advantages are developed as early as during the prototype phase.
T
he mechanical components for the H-series had long been
nesses. Determining their optimum position and length was no mean
designed with 3D-CAD and welded or bolted together “vir-
feat with the H-series, as many assemblies had been completely
tually”. What were missing were the electrical cables and
redesigned to provide the Tier 4 technology with the additional space
hydraulic hoses. Project Manager Thomas Bletscher ex-
it requires without increasing the size of the compactors. Markus
plains why: “Computer-aided design has its limitations. Prototype
Pilz, an industrial mechanic on the prototyping team, sheds light on
builders are needed for the fine-tuning and exact positioning of these
another challenge: “We aim to ensure that no hydraulic hoses collide
components.”
with other components, even during extreme manoeuvring. That was
tricky with the H-series, but we succeeded nonetheless.”
HANDS-ON MACHINE DEVELOPMENT
WITH PROTOTyPING
sequent series production process, with the chassis, engine and front
Technicians breathe life into the CAD designs. No easy task, consid-
the electrical cables. As usual, most components fitted perfectly right
ering that the H 20i consists of some 2,500 different parts in various
from the start when constructing the first H-series prototype. And if
quantities, as well as numerous hydraulic hoses and cable har-
something didn’t fit, then a creative solution was called for. “The
Forum 43_en.indb 32
The prototype development process corresponds to the subtractor unit coming first in line, followed by the hydraulic systems and
08.06.12 14:26
sPeCial FeatURe: DeveloPMent | FoRUM 43
33
The core team behind
the H-series from the
development and
design department:
designers, control
engineers and
prototype builders
A P P RO V E
D
H 20i VIBRATORy
COMPACTOR
Operating width
Operating weight with operator’s cab
Static linear load, front
2,140 mm
19.7 t
60.3 kg/cm
prototype builders are familiar with the production processes and
compactors in all situations, i.e. driving, compacting, steering, turning,
they know what is required for simple and safe assembly. They don’t
fuelling, heating and cooling, even testing the horn and cleaning the
give up until they’ve explored every avenue. That’s how innovation
machine. He tested the H 20i for well over 1,000 hours in standard and
works,” explains Thomas Bletscher, a mechanical engineer, about
extreme situations on the factory grounds, on different surfaces and
his team, which always cooperates closely with colleagues from the
on countless job sites. “Karl provides us with valuable feedback on
series production and job preparation teams.
the handling of the machine. Sometimes there are unusual noises,
other times he has an idea that could improve the ergonomics,” ex-
CLOCKING UP THE OPERATING HOURS
AND LONG-TERM TESTING
plains Thomas Bletscher. “A positive customer response is our re-
As soon as the prototype was ready, it was Karl Schleicher’s turn to
technicians are now completing additional models with a lower oper-
step in: “I’m the first person to try all new compactor models. With
ating weight, with ideas, know-how and unparalleled commitment.
ward.” However, the team is far from finished after building the H 20i
and its sister models the H 18i and H 25i. The creative engineers and
the H-series, I was amazed at the clarity of my colleagues’ design for
the 25t heavy H 25i.” And he should know, as it’s his job to test the
Forum 43_en.indb 33
www.hamm.eu
08.06.12 14:26
34
MAKING OF: MOBIREX EVO PLANTS
never stop
moving
Kleemann’s Mobirex EVO plants process a vast range of materials reliably
and efficiently. This quality is the result of decades of experience and continual
development work.
A
typical job site situation: a derelict industrial facility is
And that’s not all by a long shot: a high-performance screening
knocked down and a track-mounted impact crusher pro-
unit with two screen decks ensures the effective primary screening
cesses the demolition waste. If the material includes not
and a steady material flow. The optimized crusher infeed geometry
just the usual steel reinforcements but larger steel struc-
ensures that the material is guided perfectly into the impact range
tures, too – for instance a section of a double-T beam – an ordinary
of the rotor. The width of the conveyor system increases progres-
plant can soon get damaged, but not an EVO plant from Kleemann!
sively in the direction of material flow, making material blockages
Indeed, the company, based in Göppingen, Baden-Würt-
a thing of the past. Further winning features of the plants include
temberg, has decades of experience in the development of crush-
wear-optimized baffle plates, an economical drive concept and a
ing plants and works continually to improve them. “Our work is a
high safety factor.
challenge for every engineer,” said Thomas Kühnle, Head of the
Development department. “We give new ideas plenty of space and
tread new paths each day.” Kleemann’s engineers have come up
with countless innovations in the relatively young domain of track-
KLEEMANN’S CUSTOMERS ARE A KEy
DRIVER OF INNOVATIONS
mounted impact crushers. For instance, a system that protects the
Innovations are frequently inspired by individual customer require-
crusher from overloads: if a steel girder gets into a crusher in the
ments. For the Bernegger Group, Kleemann’s engineers developed
Mobirex MR 110 EVO series, the crushing rocker automatically
a track-mounted plant which can crush limestone without the clay
moves back to prevent damage to the rotor.
deposited on the machine impeding the material flow. The team is
Forum 43_en.indb 34
08.06.12 14:26
sPeCial FeatURe: DeveloPMent | FoRUM 43
35
Thomas Mössner
(far left), Thomas
Kühnle (far right)
and the Development
department team
work continually
to optimize the
EVO plants.
A P P RO V E
D
MOBIREX 130 ZS EVO
Output
Crusher inlet
Engine output
450 t/h
1,300 x 900 mm
384 kW
currently working for an Australian company, developing a machine
painters later on in the process. It generally takes three years for
set comprising several interlinked plants for the processing of iron
a machine to progress from the drawing board to the finished plant.
ore. Thomas Mössner, Head of the Mobile Technology department,
Thomas Kühnle sees a great deal of potential for further
recently paid a visit to the site to get an idea of the progress being
optimization of the mobile EVO plants in future. His team is set on
made. “Field work on customers’ premises is what makes my work
further improving the control and material flow while cutting pow-
exciting,” he says. “This is where I get to combine theory and prac-
er consumption.
tice perfectly.”
For us, it’s not about achieving the highest maximum shortterm plant output, emphasizes Kühnle: “The ideal EVO plant is not
CROSS-DEPARTMENTAL TEAMWORK FROM
THE IDEA TO THE IMPLEMENTATION
Apart from custom-built products, Kleemann naturally develops
a sprinter but a marathon runner. It runs at a consistently high
level, but it never stops moving.”
www.kleemann.info
series models, too. The needs of the market are the central aspect
here: how heavy can a plant be? What can it cost? At the start of
a project, Thomas Kühnle and his team hold in depth discussions
with their colleagues from Purchasing, Production and Assembly.
After all, the design has to be feasible for welders, electricians and
Forum 43_en.indb 35
08.06.12 14:26
36
WIRTGEN: NEW PLANT FOR SPECIAL-PURPOSE MACHINERY
in full swing
Since going into operation at the start of the year, production has been in full
swing in the new plant for special-purpose machinery. Countless improvements
have sustainably improved basic conditions.
W
e reported on the factory extension in
Windhagen and the extension of the
plant for special-purpose machinery in
Issue 42. Some six months down the
line, the first results speak for themselves: improved
quality, optimally coordinated processes and shorter
production times for cold recyclers, slipform pavers and
surface miners.
SURFACE MINER 4200 SM –
PRODUCTION TIME CUT
The Surface Miner 4200 SM is a prime example of the increase in
productivity: its production time has been cut by a week. “The
“The extended
production halls
provide us with
the space we
need to process
orders more flexibly and respond more
quickly.”
Norbert Lenzenbach, Foreman in the Surface Miner division
additional space available is a valuable resource for production.
Then there’s the fact that we have almost doubled the number of
employees in our division,” explained Norbert Lenzenbach, Foreman in the Special-Purpose Machinery division, which includes
the Wirtgen surface miners. “The success of the special-purpose
machines on the market means that the production plan remains
demanding, despite the increase in personnel,” said Lenzenbach,
who is looking forward to the upcoming challenges for himself and
his motivated team.
NEW CRANE AND PRE-ASSEMBLy
FACILITATE RECyCLER PRODUCTION
Klaus-Peter Brabender, Foreman in the Recycler Series Production
division, reports on optimizations in recycler assembly: “Thanks
to the new 2 x 10-t crane with two trolleys, we can move our milling drums and engines without stressing the materials and position
them absolutely precisely for installation. We used to need two
cranes for this job.” The additional room has also created more
storage space, improving the flow assembly process. According
to Brabender, “This means that we can also combine the pre-assembly of various series on site, further boosting efficiency.”
The logistics systems also benefited from important pro-
“With the
new,
flexible
crane,
we can
transport
assemblies
which used to be impossible or extremely difficult to
move.”
Klaus-Peter Brabender, Foreman in the Recycler Series
Production division
cess optimizations. “Order picking is now a great deal easier for
the entire production hall and is no longer confined to the respec-
Forum 43_en.indb 36
08.06.12 14:26
Plants + Know-how | FoRUM 43
37
More than twice the
space: the final
assembly hall for
special-purpose
machines has seven
new hall naves,
extending the total
area from 11,000 to
25,000 m 2. Surface
miner production
is one of the areas
to benefit.
tive hall nave,” explained Thomas Buchholz, Foreman
in the Slipform Paver division. “Preassembly and the
small parts store for slipform pavers have now also
been geared to the various assemblies, enabling us to
reduce transport routes, too.” Planning is even more
flexible as response times have also been reduced.
The aim of the hall extension was to equip Wirtgen’s special-purpose machinery production facilities to
meet the challenges of the future. The first six months in the
new plant for special-purpose machinery have shown that Wirtgen
is on the right track.
“The optimized
process steps
help us to assure and even
boost quality
within shorter production times.”
Thomas Buchholz, Foreman in the Slipform Paver division
Forum 43_en.indb 37
08.06.12 14:26
38
Compared with the 3-KW system
used hitherto, the two Trumpf
L3030 laser cutting systems reduce
the cutting time by about 35% in
each case.
VöGELE: INVESTMENTS IN PRODUCTION
high in-plant
production
When relocating its headquarters, Joseph Vögele AG converted various sections
of its production facilities to in-house manufacturing, by investing additionally
some € 4.5 million in new processing machines in 2012.
Forum 43_en.indb 38
08.06.12 14:26
Plants + Know-how | FoRUM 43
M
odern machines, short routes and
economical work processes: the
new factory of Joseph Vögele AG
in Ludwigshafen, Rhineland-Palat-
inate has all of these features to offer. In the past
year, the traditional brand in the Wirtgen Group
invested around €4.5 million in the improvement of
its production facilities. A Heckert HEC 1000 type
processing centre was added to each of the flexible
manufacturing systems (FFS) for the machining of welded components for screeds. Meanwhile, the optimized travelling routes
minimize the processing time per workpiece by 30%.
Two new laser cutting systems simplify the cutting of sheet
metal in the production of screed components. The machine is
39
“We currently are
planning various
replacement
investments and
will be phasing out
old, less effective
machines to make way for
modern ones.”
Siegfried Köhler, Production Manager
loaded via an integrated turntable while the laser in the interior
cuts sheets up to 25 mm thick. The sheets are transported directly from the raw materials warehouse to the machine by a chain
conveyor. Short routes like this are typical of the Vögele plant with
its ingenious layout.
processing time thanks to the higher rapid feed speed. Secondly,
over 10% of the non-productive machine time is saved by the “out
WELDING ROBOTS GUARANTEE A PERFECT
PRODUCTION CyCLE
of round turning” function, as the workpiece needs to be clamped
Vögele invested in two large stand-alone robot cells, each
IMPROVED WORKING CONDITIONS FOR THE
LUDWIGSHAFEN TEAM
equipped with four or five welding devices, in order to weld the
basic frame of the extending screeds AB 500 and AB 600 and their
less frequently, improving material flow.
extension frames even more economically. The special feature of
Vögele considered the welfare of its employees, too: many se-
the system is that it sets up and machines simultaneously. The
quences are now much simpler and the workplaces are more er-
pallets are automatically conveyed to the robot and then welded.
gonomic. The large welding robot cells bring nothing but benefits
At the same time, more pallets are being loaded in the upstream
for the workers who operate them: height-adjustable loading sta-
area so that there are no robot downtimes in the cycle. A small
tions mean that they can adapt their working environment to suit
robot cell was also procured for welding the bottom component
their statures. Vögele has also enhanced health and safety by in-
assemblies of the screed frame and for producing smaller welded
stalling an efficient smoke extractor at the rewelding station.
screed components.
And where does it go from here for the world’s most ad-
Two new CNC turning machines make for simpler handling
vanced paver factory? “We were primarily concerned with ways to
and two-fold time savings. Firstly, there is a 20% reduction in the
boost capacity in 2011. We are currently planning various replacement investments and will be phasing out old, less effective machines to make way for modern ones,” said Siegried Köhler, Production Manager.
We have already ordered a new straightening press for assemblies and a CNC turning machine for tubes. The new systems
will be up and running by the end of 2012.
www.voegele.info
Shift Supervisor Jaganjac Zicrija loading a large robot cell with frames for
the Extending Screed AB 600.
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08.06.12 14:26
40
The final check at the testing stands is the responsibility of long-standing
employees with a wealth of knowledge and experience of production.
Sum quid quiatque
sunt ut harum earum
disqui dolupit a porit
doloreped mo
magnam quibus quam
ducimus ea derum qui
si nullabo. Testions
Quality check right
behind the factory
gate: random checks
are performed on individual products in
accordance with SAP
requirements.
From the engine
temperature to the
vibration drive: a roller
has to pass some 50
individual tests before
it is given a quality test
seal.
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Plants + Know-how | FoRUM 43
41
HAMM: QUALITY MANAGEMENT
Quality concerns
us all
Ensuring the quality of purchased parts, processes and final products is the
main task of the QA team at Hamm. The staff are involved in the entire
production process, from the supervision of suppliers right up to shipment.
Q
uality begins with the development,” is the motto of
Each roller is rigorously examined during the final check in the
Wendelin Geißler, Head of Quality at Hamm, “but all
testing hall before its status is changed to “ready for dispatch”.
the other sections of the company make a major con-
The “shipping audit”, a final inspection, was introduced in 2011 to
tribution to quality, too.” An internal quality assurance
test the machines directly before shipment. QA staff conduct ran-
process covers everything, including external suppliers. This is
dom inspections on the function and appearance of the rollers. It
why Hamm has been concluding new QA contracts with strategi-
is gratifying to see that the number of defects registered at this
cally important suppliers since 2010.
stage is falling continually. Wendelin Geißler knows why: “QA
“The supplier must know how its products are going to be
used if it is to produce in the appropriate quality,” explained the
measures are now firmly established in production. The work we
have done over past few years is bearing fruit.”
QA Manager Geißler. A team formulates the intended use and the
requirements of every part for this purpose. Colleagues from
www.hamm.eu
the Quality, Purchasing and possibly Production departments conduct an audit to check that suppliers’ processes are suitable for producing the required quality and quantity. Once they’ve overcome this hurdle,
initial samples and pre-production series are
manufactured before series production starts.
Not only do individual incoming parts undergo stringent random inspections, but the quality awareness of the assembly workers is also in
“We conduct our
inspections
with customers’
interests in mind.”
demand. Supported by the QA team, all members
of staff are sensitized to specific quality features in
Michael Schedl, Shipping Audit Quality Inspector
their working environment and trained.
TARGETED QUALITy MANAGEMENT IN THE
PRODUCTION PROCESS
The quality deviation report (QAB) is an effective QA tool. This is
where employees note down any defects they notice, for instance
during assembly or the final check. Collaborating with the workers,
the QA team investigates causes, scrutinizes parts, processes and
specifications and works out measures to prevent the same defects from reoccurring in the future. At the same time, the quality
assurance staff analyse data from the SAP QM module, to pinpoint
“Quality can only be
produced if everyone involved is
committed to
achieving it.”
Wendelin Geißler, Head of Quality
trends and identify optimization potential.
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42
KLEEMANN: SUCCESSFUL SERIES PRODUCTION
investment in
the future
Effective flow assembly, flexible assembly lines, and short throughput
times. Following its plant expansion, Kleemann has greatly increased its
production since 2009. The company has thus extended its position as
a series manufacturer, thanks to new investments over the past year.
k
leemann’s investments are paying off. Alongside the
mann’s great in-house production depth allows it to respond
four new welding booths in which Kleemann trains its
quickly to new situations. Borsody can swiftly expand a production
next generation of skilled specialists, a new welding
team if there is a run on chutes, rotors, or screens.
robot has also “joined the team” in Göppingen. Since
last year, Kleemann has been using the robot to manufacture rotors
for its mobile crushing and screening plants, vastly increasing its
internal rotor production. Helge Borsody, the Head of Steel Con-
TEAM MEMBERS ENSURE PROSPEROUS
SERIES PRODUCTION
struction, is enthusiastic about the new acquisition: “The old robot
However, the success of the investments depends upon the ded-
needed 26 hours to weld a rotor. We have been able to shorten
ication of the teams on the factory floor. And this is why motivating
that time to 17 hours, using our newest robot. It’s all a question of
team members and involving them in the optimization processes
the right programming and the right know-how!” The Kleemann
is a top priority at Kleemann. “Once a month, we get together as
team is still tweaking the programming. “Only when the robot is
a team and think about how we can improve the work process. It
optimally programmed will it be able to work reliably and essen-
is often team members who work on the same assemblies day
tially unsupervised,” said Oliver Kühlkopf, Borsody’s deputy and
after day that come up with the best ideas,” said Borsody. The
Kleeman’s welding expert. The advantage is already obvious: by
successful optimizations of the past few years have proven him
speeding up internal production of its core components, Kleemann
correct.
can produce in higher quantities, without needing to depend on
suppliers.
www.kleemann.info
Kleemann, located in Göppingen, produces almost all of
the core components for its plants itself – a strategy that offers
many advantages, as Helge Borsody explains: “Our employees
know best what is important for components in assembly. The
dimensions fit virtually one hundred percent. And if, on rare occasions, this is not the case, there is no need to go through official
channels, as the teams can discuss the matter directly.” Klee-
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Plants + Know-how | FoRUM 43
Working under supervision, the apprentices
learn their craft in the
welding booths.
The use of a welding robot
shortens the time it takes to
weld a rotor by more than
nine hours.
Helge Borsody wants
to boost production
quantities this year,
too.
Forum 43_en.indb 43
43
Oliver Kühlkopf knows that
good welders are hard to find
and puts a lot of time into
training young talents.
08.06.12 14:26
44
BRAZIL
hope for children
in need
A chance for the kids of Rio de Janeiro: around 100 boys and girls are
currently benefiting from the care and education offered by the Bom
Samaritano children’s day care centre in the Ipanema district.
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“ChilDRen in neeD” ChaRitY | FoRUM 43
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45
08.06.12 14:27
46
In the deprived areas, families live in shanties,
often without electricity or water.
Preschool attendance increases the children’s
chances of graduating from school.
Health care is a top priority at Bom Samaratino.
R
Juliana and Luane are lovingly cared for in the safety of the day care centre.
io de Janeiro is a beautiful city, with enchanting beach-
addition, the favelas are ruled by drug gangs, and violence and
es, imposing mountains and modern shopping centres.
shootings are commonplace.
But Rio is not just Sugar Loaf Mountain; the favelas are
The men try to escape the harsh realities of daily life with
also just as much a part of the city. The word “favela”
drugs and alcohol. Violence directed at women and children is an
originally referred to a hill in Rio on which former mercenaries built
everyday occurrence. Many women supplement their income
an illegal shanty town in 1879. In the middle of the last century,
through prostitution. Struggling with these hardships, families of-
the city became increasingly attractive for the impoverished rural
ten lack direction and the strength to devote themselves to their
population and more and more people were forced to take up
children’s upbringing.
quarters in the makeshift dwellings of one of the over 1,000 favelas that exist today. Poor education, high unemployment and low
income affect the majority of the people who live there. Sometimes
ACHIEVING MORE TOGETHER
their meagre income is not even sufficient to pay for the staple rice
These were the issues addressed by Father Braun when he found-
and black beans, not to mention milk, fruit or medical care.
ed Bom Samaritano in 1979. He set himself the task of alleviating
Most of the families in the favelas live in shacks made from
the indescribable misery of the children as much as he could. As
wooden boards or bare brick walls. They often have to share their
he came up against difficulties with the funding of his project, he
one or two rooms with their extended families. The power and
asked Kinder in Not e.V. to provide ongoing support. The day care
water supply are poor and the sanitary conditions catastrophic. In
centre is in Ipanema, next to the deprived Cantalego district.
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“ChilDRen in neeD” ChaRitY | FoRUM 43
“We require donations for
our aid project in Ipanema
to give the children a
chance of a better future.”
47
Vilma and her staff were horrified and visited the family immediately with a food package. Together they sought solutions and
ensured that at least the most urgent bills were paid. The team did
not rest until the mother had found a permanent job. She is now
also receiving psychological therapy, and Kauan and Miguel can
smile again.
ALLEVIATE MISERy AND OFFER A FUTURE
What prospects do the children in Bom Samaratino have today?
The children from the favelas have no social skills and many are
traumatized by the violence that surrounds them. As a result, most
of them already come to grief at primary school. The newspaper
O Globo reported on 29 February 2012 that of the 171,000 children
Around 100 boys and girls from age two to six are looked after
who started school in 2010, 34,000 stopped going, and many had
there every day from 8 am to 5 pm. The smallest ones attend a
to repeat the year. Children who attend preschool have been
kindergarten group, and the older children one of the three pre-
shown to fare much better in primary school and are much less
school groups to prepare them for primary school. At least while
likely to drop out. Thanks to the work of Bom Samaratino and the
they are in the centre, they are safe from the violence and terror
support of Kinder in Not e.V. these children have better prospects
of the drug gangs and are provided with a decent shelter. They
for successful schooling and hence a more responsible, self-reliant
receive some of the things that are missing in the misery of their
life later on.
own homes: fresh drinking water and nutritious meals. A paediatrician carries out regular examinations, vaccinations and weight
Without the support of Kinder in Not e.V. the day care centre would have to close. What would become of these children?
checks, and a dentist checks and treats the children’s teeth and
instructs them in daily oral hygiene.
The importance of involving the mothers in the centre’s
work can be seen by the case of the brothers Kauan and Miguel.
They have been attending the centre for three years. Early this year
they started to become increasingly solemn and introverted. Vilma,
the director of Bom Samaratino, finally received the following let-
Yours sincerely,
ter from the mother: “I am writing this letter in desperation. I can
see no other option than to take my life. Apart from the two boys
I have an eight-month-old baby. My husband has been convicted
for drug dealing and is in prison. As his wife I am branded, and no
one will employ me. The house where I live with my children is not
only a health risk but also full of rats. Sometimes we have no food,
“Children in Need” Charity
electricity, water or soap to wash our clothes.”
Gisela Wirtgen, Chairwoman
“CHILDREN IN NEED” CHARITY
Donation accounts
The charity
Sparkasse Neuwied
Founded in 1983 on the initiative of Gisela Wirtgen
Account No. 012 022 752
Provides help and relief education on a voluntary, altruistic basis
Bank code 574 501 20
Maintains and supports relief projects in the Philippines, India, Chile,
Argentina and Brazil
Raiffeisenbank Asbach-Neustadt
Account No. 100 052 724
Bank code 570 692 38
Forum 43_en.indb 47
further information
www.kinder-in-not.de
08.06.12 14:27
CLOSE TO OUR CUSTOMERS
The Wirtgen Group stands for leading, innovative road and
mineral technology products. All of the four Wirtgen Group
brands have had a marked impact on the development of
machines and processes. Our passion for road construction
and mineral extraction and processing drives us to continue
to perfect our portfolio. Customers have always been the
central focus, which is why the Wirtgen Group not only offers
customized product solutions, but a first-class worldwide
service as well. “Close to our customers” is our pledge – one
that we not only proclaim but also put into practice.
ROAD AND MINERAL TECHNOLOGIES
Forum 43_en.indb 48
www.wirtgen-group.com
08.06.12 14:27