Deutz Inside 3 2012 en Verlinkt

8/19/2019 Deutz Inside 3 2012 en Verlinkt

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DEUTZINSIDEThe magazine of DEUTZ AG Edition 3 I 2012

INNOVATION & TECHNOLOGY Innovative, efficient,

progressive

PEOPLE & MARKETSIdeally integrated,

socially committed

Protect resources;

create value from stock

Sustainability as a part of the company philosophy

S u s t a i n

a b i l i t y


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CONTENTS

2 DEUTZINSIDE 3 I 2012

TITLEProtect resourcesSustainability as a part of the DEUTZ company philosophy

IMPRINTDEUTZ INSIDE Edition 3/2012Published by: DEUTZ AG, Ottostraße 1,51149 Köln (Porz-Eil)Person responsible: Janina Decker,Public RelationsDirector: Janina Decker,Phone: +49 (0)221 822 24 93,

Telefax: +49 (0)221 822 15 24 93,E-Mail: [email protected] team: Janina Decker (DEUTZ AG),Jan Dimog/Markus Fischer(Diamond media GmbH)Design: Diamond media GmbH,Miria de VogtPrinting: Druckpartner, EssenPicture credits: Caesars EntertainmentCorporation, Janina Decker, DEUTZ AG,dreamstime, Forschungszentrum für Verbren-nungsmotoren und Thermodynamik Rostock,fotolia, istockphoto, Iveco Magirus Brand-schutztechnik, privat, SAME DEUTZ-FAHR,Wikimedia Commons/MeikeChristoph

SPECIAL

MOVING MOMENTSWinners of the DEUTZ INSIDEphoto competition ........................ p28

TEAM & CHANCES

Ideas management goes mobilePrototype test withDEUTZ ideas management ........... p29

“They look after us!” A year with DEUTZ:report from trainees ...................... p30

FASCINATION & VISION

When the fire brigadelearnt to drive

From the DEUTZ history ............... p32

NEWS IN BRIEF

AnniversariesDEUTZ staff celebrateanniversary ................................... p34

Did you know that...... DEUTZ has been called DEUTZfor precisely 140 years? .................p34

NEWS

Reports and informationabout DEUTZ ................................p4

The power of the Tiger SAME celebratesits 70th year .....................................p6

TITLE

Protecting resourcesSustainability as a part of theDEUTZ company philosophy .......... p8

INNOVATION & TECHNOLOGY

Innovative, effective, progressiveIntroduced ten years ago:

The DEUTZ environmental

management system .................... p12

„It must be possible to operateDEUTZ engines anywhere in theworld and with all qualities of fuel“Interview with Dr Ralf Marquardand Prof. Dr Horst Harndorf .......... p14

Only in Vegas The biggest Ferris wheel in theworld is being built in Las Vegas –with power packs from DEUTZ ..... p16

PEOPLE & MARKETS

Ideally integrated, sociallycommittedDEUTZ DIESEL POWER:Responsibility for disabledpeople ..........................................p18

“¡De Madrid al cielo!”Business etiquette in Spain ........... p20

Madrid makes it possible The new Madrid Service Centre

(SCM) from DEUTZ DITER ...........p22

SAFETY & QUALITY

In Cologne, 4,500 metresabove sea levelHeight simulationat DEUTZ site ............................... p23

Diagnostics for Tier 4i CRT enginesCRT system for exhaustgas after-treatmentDEUTZ employees explain ............ p24

Streamlining the processesDEUTZ realises One-Piece Flowin packaging production ............... p26

3

Only in Vegas The biggest Ferris Wheel in the world is being builtin Las Vegas

p8

p16

p20

EDITORIAL

Dear Readers,

Welcome to the new edition of ourmagazine DEUTZ INSIDE. We haverecently submitted our business fig-ures for the third quarter of this year,and we would like to explain themto you at this point.

Characterised by the continuingsluggishness of the economic cli-mate, the demand for our engines has fallen in particular during the summer months dueto seasonal effects. Hence sales revenue in the first nine months of 2012 amounted to€969.4 million, about 14 per cent lower than the good figures of the previous year. In thisnine-month period, new orders amounted to €960.5 million, almost 18 per cent less thanin the comparison period. At €24.6 million, operating earnings (EBIT) only attained a third ofthe figure of the previous year. In addition to the reduced business volume, this is primarilydue to lower profit contributions from our joint ventures, production start-ups of new en-gines and negative one-off effects in previous quarters. For this reason we have introducedmeasures for the reduction of costs and improvement in earnings, and in doing so we are

also re-examining established structures. In the last few months we have taken importantoperative and strategic steps for the further successful development of our company. Inparticular, we have continued our product offensive with the introduction of the TCD 3.6,the TCD 2.9 will follow by the end of the year.

Dear Readers, what can you expect from DEUTZ? Quite simply, the most robust andeconomic engines that are available to meet each individually desired purpose. This is thetask that the competition presents us with, and that we pursue with a passion. In order tomeet our objective, we have taken on a company mission statement that is based uponthe five principles of innovation, quality, success, trust and responsibility. We have placedthe latter at the top of this edition of our magazine as a guiding theme, because we wantto show you from a number of different perspectives how we live responsibility and whatthat means to you.

We take responsibility for our decisions and actions in the same way as we do for ourproducts and services. We bear responsibility with respect to our customers and investors,our environment and our society. For this reason, DEUTZ AG introduced an environmentalmanagement system over ten years ago; we would like to inform you about this on pages12/13. Sustainability is not just an ecological theme that you read about, but somethingthat strengthens our, and above all our customers‘, position among the competition. Inorder to keep it that way, we at DEUTZ do not just rely on what we know, we also bring theexpertise of scientists from academia to the table in the field of research & development.

This means that you can be sure that our engines not only meet all of today’s requirements,you can also expect future-orientated solutions from us. On this subject, you can read ahighly interesting discussion with Prof. Dr. Horst Harndorf from the University of Rostock on

pages 14 and 15. Sustainability and responsibility are not restricted to making sure that weare always aware of the latest and upcoming emissions legislation in engine development.Sustainable market development is also a part of this. Hence it is good to have an inter-national presence with subsidiaries, sales offices and distribution partners. As an exampleof this, we present our new service centre in Madrid (page 22). If you, dear Reader, havebusiness in Spain in the near future, we recommend that you read our short business cul-tural guide on pages 20/21. You’ll find lots of useful tips.

We wish you and your families a peaceful Christmas and a successful New Year!

With best wishes,

Dr Helmut Leube Dr Margarete Haase

Ideally integrated, socially committedDEUTZ DIESEL POWER: Responsibility for disabled people

You can find DEUTZINSIDE online here.


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NEWS

DEUTZ, Bosch and Eberspächer reorganise collaboration

AB Volvo is a new major

shareholder at DEUTZ

DEUTZ AG, Robert Bosch GmbH and J. Eberspächer GmbH & Co. KG have reachedan agreement to reorganise their collaboration in the field of exhaust gas aftertreat-ment. To this end, DEUTZ and Eberspächer are selling their shares in Bosch EmissionSystem GmbH (BESG) to the majority shareholder Bosch. In future, the cooperationbetween DEUTZ and Bosch will be continued and expanded in the form of an innova-tion partnership in the fields of exhaust gas aftertreatment, diesel injection technologyand electronics. The goal of this more intensive collaboration is to attain greater systemintegration in drive technology for mobile processing machinery. In future, BESG willalso deliver systems for exhaust gas aftertreatment to DEUTZ. Since its formation in2010, BESG offers a modular production concept for diesel exhaust gas aftertreat-ment systems for construction & agricultural engines right up to commercial vehiclessuch as heavy goods vehicles and buses, and employs about 180 staff at three loca-tions in Germany.

The Swedish commercial vehicle and con-struction machinery manufacturer AB Vol-vo has increased its shares in DEUTZ AGfrom 6.7 per cent to just over 25 per cent.

As announced in June 2012, AB Volvohas acquired 22,117,693 shares from thelongstanding majority shareholder SAMEDEUTZ-FAHR for about 130 million Euros.With this transaction, the company hasbecome the largest shareholder in DEUTZ

AG with 25 percent plus one share. TheItalian agricultural machinery manufactur-er SAME DEUTZ-FAHR retains a sharein DEUTZ of about 8.4 per cent, and willcontinue its successful customer andsupplier relationship and also its strategic

partnership with DEUTZ. Early this year,DEUTZ and Volvo signed a declaration ofintent with the aim of examining the possi-bility of expanding the longstanding coop-eration between the two companies withthe joint development of a next generationof medium-duty engines for industrial ap-plications. The declaration of intent alsoplans to analyse the conditions for estab-lishment of a majority DEUTZ-owned jointventure in China.

On 1st September 2012, the green light was given to the new trainees at DEUTZ. Onthis day, 43 young men and women started their vocational training with DEUTZ AGand were welcomed to the DEUTZ technical college by Board member Dr MargareteHaase. “I’m very pleased that they have decided to do their apprenticeship at DEUTZ.Our company has a long history of training, and we would like to provide these young

people with the best basis for their professional career. In particular, I am pleased thatfour women will be training towards a technical-commercial profession again this year.We as a company are also taking a further successful step with a new generation oftrainees since we can only prepare junior staff for the challenges of tomorrow if we pro-vide thorough training today”, says Dr Margarete Haase in welcoming the youths to thetraditional introduction week. In the introduction week, which is organised by the train-ers and the second-year trainees, the newcomers are prepared for their time in trainingand are familiarised with the fields of activity and company divisions.

DEUTZ offers the candidates a wide spectrum of professional occupations in the tech-nical-commercial sector: production mechanics, industrial mechanics, machining me-chanics, electronic engineers, warehouse staff, and in Cologne for the first time thisyear, training as a mechatronics technician. “The proportion of mechatronic compo-nents and systems in production is continuously growing. With the introduction of theprofessional occupation of mechatronics technician, we want to cover the interfacebetween electronics and mechanics and train qualified personnel for this technicallychallenging sector”, explains Martin Strecker, head of Human Resources at DEUTZ.Since 1st September 2012, four trainees are being trained as industrial mechanics ineach of the DEUTZ factories in Ulm and Übersee. Two youths have started their train-ing as machining mechanics in the DEUTZ factory at Herschbach. Overall, DEUTZ AGcurrently employs 156 trainees in Germany. Last year, the DEUTZ training centre waspresented with the award “The Best” by the Cologne Chamber of Industry & Commercefor its excellent performance. At the same time, the very good examination results ofDEUTZ trainees were also praised; these frequently lie above the Chamber’s average.

DEUTZ welcomes 43 new trainees

NEWS

An open ear for students

On 21st September 2012, the DEUTZcomponent works in Herschbach pre-sented itself at the 3rd vocational informa-tion fair at Oberwaldschule Selters. Theevent gave students from ages 12 to 15the opportunity for vocational orientationand informed them of possible profes-sional occupations and career prospects.

Andreas Epp (production planning), Mu-rat Karasu (production and youth repre-

sentative), Dennis Löcher (trainee) andJan Marth (trainee) advised the interestedyouths about the various training opportu-nities at DEUTZ AG and were available toanswer their questions relating to applica-tions and aptitude tests.

Training at DEUTZ – outstanding!

DEUTZ training can be pleased with its double Chamber of Industry& Commerce award. This year, the Cologne Chamber of Industry &Commerce again presented the DEUTZ AG training centre with theaccolade “The Best” in acknowledgement of i ts outstanding perfor-mance. At the same time, the Chamber of Industry & Commercepraised the very good examination results of DEUTZ trainees,which were frequently well above the Chamber’s average. “It isimportant to us to give our trainees the best possible start for asuccessful future, and we are committed to achieving this. The

award from the Chamber of Industry & Commerce and the very goodresults of our candidates confirms that we are doing the right thing”, says Frank

Opitz, head of training at DEUTZ in Cologne, delighted with the award. The trainingat the DEUTZ component works in Herschbach was also honoured by the KoblenzChamber of Industry & Commerce for its excellent work and great commitment. Cur-rently, 8 trainees are being trained in Herschbach in a technical-commercial profession.“We are very pleased that our training has received awards from Chambers of Industry& Commerce in both Cologne and in Herschbach. Last year, our training centre was

awarded the accolade “The Best” by the Cologne Chamber of Industry & Commerce;the fact that we have again received an award this year shows that we have not onlyunderstood that this award contains a responsibility, we have also taken this on board”,explains DEUTZ Board member Dr Margarete Haase.

DEUTZ in the running

The sound of two cities: Beijing and Cologne in concert

“Nessun dorma” – the world-renowned Puccini composition was on the programme atthe concert matinée of the DEUTZ Choir of Cologne, which took place at the event ofthe 25th anniversary of the town twinning between Cologne and Beijing. The popularChinese tenors Dai Yuqiang, Wei Song and Warren Mok also enthralled the audience atthe well-attended Kölner Philharmonie with further Puccini arias and with the rousing mel-odies of Chinese folk songs that brought the sound of China to the venue. The audienceappreciated the grandiose performance with standing ovations. These were also directedtowards the renowned Beijing Symphony Orchestra with its committed members and itschief conductor Maestro Tan Lihua – both invited by the DEUTZ Choir of Cologne.

Together with Jürgen Roters, the Lord Mayor of thecity of Cologne, Choir President Johannes Schiff-gen welcomed prominent guests to this concert.Guests included the Finance Minister of the Stateof North Rhine-Westphalia Norbert Walter-Bor-

jans, the German ambassador in Beijing Dr Mi-

chael Schaefer, the Chinese ambassador in BerlinShi Mingde, the Chinese consul general ZhenshunWen, senior officials of the Beijing municipal gov-ernment, Board member of DEUTZ AG Dr Marga-

rete Haase and Zhou Meng, the economic ambassador of the city of Col ogne for China.Under the baton of composer and head of DEUTZ Choir Heinz Walter Florin, the BeijingSymphony Orchestra played “Symphonie in Kölsch”, a sensitive homage to the city ofCologne. Choir, orchestra and the two soloists, the Australian tenor Darren Williamswith his rousing voice and the Cologne rocker Michael Hirsch, were in top form andharmonised beautifully with one another, forming an impressive musical sound.

Following the suc-cessful participationof DEUTZ AG lastyear with numerousrunners in the HRSBusiness Run Co-logne, the companyagain paid the entry fee

this year for its participating staff mem-bers. More than 150 DEUTZ staff mem-bers got together to take part in the race.

This not only meant a full 50 per centmore participants than last year, at thesame time DEUTZ also attained 5th placein the most strongly represented compa-nies in the Business Run 2012. In mid-June 2012, the runners showed their ca-pabilities on a 5 kilometre course throughthe Kölner Stadtwald to the RheinEner-gieStadion. Donning DEUTZ caps andrunning vests, they sprinted in their teamcolours towards the finish line and, evenfrom a distance, were easy for their wait-ing fans to recognise due to their uniformappearance. The sportsmen and womenwere treated to an after-event party, andthey only had praise for the race. Aboveall, they agreed that it was a good way tomake contacts in other departments andto get to know colleagues better fromother sectors. For DEUTZ AG, support forstaff members participating in the Busi-ness Run is a further successful measure

in preventative health management, alongwith influenza vaccination and cardiovas-cular screening.

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NEWS

6 DEUTZINSIDE 3 I 2012 7

The power of the

NEWS

“SAME DA” and “SAMETTO”: thesewere the names of the agricultural andvinicultural tractors in post-war Italy.Since then, the brand SAME has con-tributed towards modernisation of agri-culture with countless technical innova-tions. This is confirmed by the assertionof the company’s co-founder FrancescoCassani: “...SAME was founded to pro-mote the establishment of an industryin Italy that produces high-quality trac-tors and combustion engines.” Over the years, the company has acquired an

outstanding reputation as a specialistin agricultural technology whose equip-ment was, and is, efficient, robust, safeand reliable. Today, SAME DEUTZ-FAHRS.p.A. (SDF), based in Treviglio, a smalltown between Bergamo and Milan, isa successful internationally-active andmodern company with strong traditions.

DEUTZ and SAME DEUTZ-FAHR: aclose and successful partnership

The SDF Group is a longstanding cus-tomer and partner of DEUTZ AG andwas for a long time the largest singleshareholder, occasionally with a stakeof more than 40 per cent. However, inSeptember 2012 the Swedish AB Vol-vo Group expanded its stake in DEUTZ

AG from 6.7 per cent to just over 25 percent and is now the largest sharehold-er of DEUTZ. The SDF Group retains ashare of approximately 8.4 per cent andcontinues to be an important strategicbusiness partner.

Business relations between the twocompanies began in 1995 when the SDFGroup purchased the DEUTZ-FAHR ac-tivities from DEUTZ, at that time calledKHD AG. Since then the collaborationhas been intensified, such as in autumn2003 when DEUTZ became the main

supplier of diesel engines for SDF’s ag-ricultural machinery. Since September2012, DEUTZ engines of type TCD 3.6,

AGRI model, provide power at the pow-er take-off shafts and strong propulsionfor the new Silver3 range of SAME trac-tors. The Silver3 tractors are character-ised by their reliability, high performanceand versatility – characteristics thatwere, and are, of elemental importanceto SDF since the start of their successstory.

Foundation of SAME in 1942

It all began with the brothers Frances-co and Eugenio Cassani, who formed

SAME in 1942. On 12th October 2012,the 70th birthday of the brand was cel-ebrated with a great anniversary partyin Treviglio, where the merits of the twofounders Francesco and Eugenio Cas-sani were remembered. At the sametime, the way towards a successful fu-ture was presented: new investments,new models, expansion of the dealer

network and the development of newmarkets form the strategic focal pointsof the coming years.

The Tiger and the Virtus

Over 500 guests from Italy and abroadattended the ceremony. In addition torepresentatives from politics and gov-ernment, customers and journalists aswell as many dealers and importers.Lodovico Bussolati, Chairman of theBoard of the SDF Group and DeputyPresidents Aldo Carozza and Fran-cesco Carozza gave a comprehensiveoverview of the future strategies of theGroup. The high point of the event wasintroduction of the new SAME tractor,

Virtus. This model range is avail able inthree product types from 99 to 122hpand sets the standard with its innovativeequipment. A great deal of emphasiswas also placed on the design of thenew vehicle. The cabin and bodyworkwere styled by the world-famous studio

Italdesign Giugiaro. The same compa-ny was also responsible for redesigningthe characteristic tiger logo, which nowhas an expressive and powerful appear-ance. Presentation of the new logo wasalso part of the festivities, at the end ofwhich dinner was served in the exhibi-tion hall of the SAME DEUTZ-FAHR mu-seum. On the following day, over 2,500visitors were able to take a lookat the production linesand the historicalarchive during anopen day.

Profile of the SAME DEUTZ-FAHRS.p.A (SDF) Group

The company: SAME DEUTZ-FAHR isone of the world’s leading manufacturersof tractors, harvesters and agriculturalmachines and engines.The philosophy: SDF has gained an ex-cellent reputation with farmers as a reli-able, innovative and safe manufacturer ofagricultural machines that underpins thecompany again and again with innova-tions and modernisation.The product range: The range of trac-tors covers performance classes from23 to 270hp, in the sector of harvestersthe performance range extends from 100to 395hp. The products are developed,produced and sold worldwide underthe brand names SAME, DEUTZ-FAHR,

Lamborghini, Lamborghini Green Pro,Hürlimann and Grégoire.The sites, personnel and figures: Inits sites in Germany, Italy, Croatia, In-dia, China, Russia and Turkey, the SDFGroup employs more than 2,850 staffand in 2011 generated a turnover of 1.12billion Euros. The German headquar-ters of SDF is in Lauingen, Bavaria, andemploys about 700 staff. This is whereall high-performance tractors from SDFabove 120hp are produced. Lauingen isalso the site of the Group’s centralisedglobal spare parts warehouse. TheLauingen site is also home to a moderncustomer centre with exhibition hall andtest track as well as the SDF academy inwhich the company offers training cours-es and advanced training to partners andtheir employees.

Chronicle of SAME and the SDF Group

1942: Founding of the company Società Accomandita Motori Endotermici, inshort SAME, by the brothers Francesco

and Eugenio Cassani in Treviglio (Berga-mo), Italy1947: Three-wheeled mowing machinewith reversible steering wheel and seat1948: the 10hp Universale small tractor isawarded a gold medal by the Turin agricul-tural academy.1951: SAME designs new modular en-gines1952: the first tractor with all-wheel driveis produced1956: construction of a new factory asdemand for SAME tractors increas-es rapidly. The factory extends over anarea of 80,000 m², a unique 250 metrelong workshop with three completelyequipped assembly lines (engines, paintshop, tractor assembly)1957: 3,000 tractors are produced1961: “Puledro” and “Samecar” are devel-oped1965: expansion of the product rangewith “Centauro”, Leone70” and “Minitau-ro55”1972-1973: “Drago” with 100hp 6-cyl-

inder inline engine and “Panther” with5-cylinder engine are produced1980s: production of “Laser” and “Ex-plorer” with the innovative 3-shaft man-ual transmission1995: SAME DEUTZ-FAHR (SDF) Groupis formed2003: SDF has a 29.9 per cent sharein DEUTZ AG and in the following yearsbecomes the majority shareholder of theworld’s oldest engine manufacturer2012, September: SAME DEUTZ-FAHRreduces its share in DEUTZ to 8.4 percent2012, October: 70th anniversary ofSAME and introduction of the new SAMEtractor Virtus

7

Congratulations, SAME! Thisyear, the brand of the SAMEDEUTZ-FAHR Group (SDF)with the eye-catching tigerlogo from Treviglio in north-ern Italy is celebrating its 70-year existence and appearsstrong in innovation and fu-ture-orientated


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TITLETITLE

9

Protect resources;create value from stockSustainability as a part of the company philosophy

Everyone is talking about sustainability and the need for companies to con-duct business in a sustainable manner. The idea is to reinvigorate the principleof sustainability. DEUTZ AG does this by anchoring sustainability in environ-mental management, in compliance management and within the framework ofits product policy. The engines produced by DEUTZ are developed with seri-ous consideration for environmental aspects and support DEUTZ customersin their sustainability activities. They are “enablers”, so to speak, in matters ofenvironment and climate protection.

In a word: sustainability

The term sustainability is not a post-modern coinage from the economic environmentof the 21st Century – it was actually originally used in forestry, as far back as the 18thCentury. In this regard, sustainability meant that each year, only at most as much woodcould be felled as could grow back within the same period. This guaranteed that thesupply of resources was also ensured for the following year. And for the year after that,and ultimately for the next generation.

This definition of sustainability from dealing with the raw material of wood can be trans-ferred to the use of any resource. It is not possible to economise without using resourc-es. But an economic system is only sustainable if raw materials are used in such a waythat a sensible, usable basis of raw materials also remains for coming generations.Companies that pay attention to their energy efficiency for example, or make productsthat help customers to reduce CO2 emissions, make a contribution towards this. Inci-dentally, the statement about maintenance of the resources base does not only apply tothat classic raw material, crude oil. Even human manpower is a resource, an extremelyvaluable one – and not only in the so-called high-wage countries. In this regard, sus-tainable conduct of business from a company perspective is expressed by a viableconcept of training and further education, ideas management such as at DEUTZ AG orby mechanisms that ensure the know-how of experienced staff members is not simplylost to the company when they retire, for example.

So sustainability and environmental protection are not synonyms. However, it’s not dis-puted that ecological activity forms those aspects within the complex of sustainabilitywhere commercial enterprises can and must make a particularly valuable contributionto society as a whole.


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TITLE


understand compliance as exclusivelymeaning something that should in anycase be self-evident: observance of thelaw. In contrast, valuable compliancemeans that a company also fulfils so-cial expectations and primarily upholdsthe regulations it has imposed on itself.DEUTZ does this, for example, within theframework of the environmental man-agement system, introduced on a volun-tary basis in 2003, because the compa-ny is conscious of its great responsibilitywith regard to environmental and climateprotection (see contribution on page10 / 11) At this point – with regard toenvironmental protection – the secondterm, sustainability, now comes into play.

A matter of global concern

Sustainability and environmental pro-tection are not the same thing (see box

The company mission statement ofDEUTZ AG is based on five importanttenets: innovations, quality, success,trust and responsibility. The last of thesemeans: DEUTZ takes responsibility forits decisions and its actions, for its prod-ucts and services, responsibility with re-

spect to its customers and investors, aswell as with respect to our environmentand the society in which we live. “Tak-ing responsibility means that everybodyin the company must carefully assessthe consequences of their own actions,conserve resources and comply withlaws and guidelines”, stresses Dr HelmutLeube, Chairman of the Board of DEUTZ

AG. A pair of terms can be heard in theseprinciples that many companies writeon their banner but that have to be re-invigorated on a daily basis so that theydo not just become a mere slogan: sus-tainability and compliance. Many people

for explanation of terms). But environ-mental protection and attempts to avoidclimate-damaging emissions are quiterightly placed as important demandson companies in connection with sus-tainable economic management. UNEP– United Nations Environmental Pro-

gramme, based in Nairobi – functionsas a kind of global authority for environ-mental protection. Even today, the studyconducted by this UN organisation in2010 on global environmental aware-ness serves as an expressive warningof where we stand. In summary, theExecutive Director of UNEP, the Ger-man Achim Steiner, gives this warningin an interview with the Süddeutsche-Zeitung. “The world’s natural capital isbeing destroyed on a grand scale.” Thiscriticism from the United Nations andits senior environmentalist Steiner wasthen aimed primarily at the global play-

ers, and not without reason: the studywas published in the same year that theecological responsibility of the corpora-tions created a particularly big stir. Thebackground was a disastrous oil spill inthe Gulf of Mexico, caused by an explo-sion on a deep-sea oil drilling platform.

The legal process in this case is ongoing;damages payments to aggrieved coastaldwellers and companies that run into themillions have beeninitiated. Economi-cally speaking, a lothas been achieved.But recovery of thedamaged ecosys-tems can only beassisted to a limited

degree with cash payments. For in thesame way that business dealings mustbe characterised by the principle of sus-tainability, environmental damage, gen-erally speaking, has a sustainable andhence long-term – in the worst caseseven irreversible – character once it hasoccurred. From the perspective of disas-trous damage to the environment, thequestion poses itself as to whether wehave to experience catastrophes in orderto learn from them. Or is it not so thatevery company must understand howsustainability can look in their own field ofbusiness, even without the same impactin terms of business activity or forbear-ance as that of an oil giant? In any event,DEUTZ AG understands the principle ofsustainability.

Sustainable activity in your own fieldof business

Carbon dioxide emissions that resultfrom the activities of DEUTZ AG are re-

corded and evaluated at regular inter-vals. In 2011, the proportion of dieselfuel consumption per compactengine at the Cologne-Porzworks was reduced byabout three per cent incomparison with theprevious year with anunchanged mix in theengine range. Conse-quently, CO

2 emissions

also fell. This declinein fuel consumption isprimarily due to the opti-misation of test runs on diesel

engines over time and is favoured bythe ever-decreasing emissions of thelow-emission DEUTZ products. This issupplemented by advanced exhaustgas retention concepts in the area ofplant technology. The permitted limitvalue for organic dust has been set at10 mg/m³ for the operation of enginetest fields in the works. During the lastmeasurement by a recognised monitor-

ing agency, a valueof less than 1 mg/m³was recorded in thecompact enginesarea. These verifiedresource savingson the one hand,and emissions re-

duction on the other hand have a globaleffect for their own part: DEUTZ enginesare used in large numbers all aroundthe world. They support customers withtheir sustainable economic manage-ment – whether in Europe or China, inthe USA or Australia.

Figures testify to success in the mat-ter of sustainability

To have your finger on the pulse withregard to emissions protection and tohave a future-proof portfolio is morethan just a matter that soothes yourecological conscience. It is also anoperational necessity. Based on Tier 4interim, the specified emissions lim-it values are being reduced more andmore. For example, in the current lateststage, from 2014 nitrogen oxide emis-sions must be reduced by 95.7 per centand soot particulate emissions mustbe reduced by 96.5 per cent in com-parison with the first threshold level

from 1999. In addition, the latest gen-eration of DEUTZ engines require five

to ten percent less fuel thanthe respective predecessor

model, which conservesresources and leads tolower CO

2 emissions.

Furthermore, evennoise emissions willbe recuced – in thecase of the 4 to 8-litre

Tier 4 engines by morethan 25 dB (A).

“Taking responsibility means that

everybody in the company must

carefully assess the consequences

of their own actions, conserve

resources and comply with laws and

guidelines”Dr Helmut Leube

To have your finger on the pulse with

regard to emissions protection and to

have a future-proof portfolio is more

than just a matter that soothes your

ecological conscience.

TITLE


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Committed goals and continuous im-provements distinguish DEUTZ AG’senvironmental management system.

The three environmental goals – waterpollution control, air purity and the con-tinuous reduction in the quantity of re-fuse – have been successfully put intopractice in production and manufac-turing for more than ten years and arebeing pursued with great ambition. In2003, DEUTZ introduced an environ-mental management system on a volun-tary basis. In 2011, environmental certi-fication in accordance with ISO 14001was confirmed by the renowned DQSGmbH. Customer wishes, such as dis-pensing with environmentally-harmfulmaterials in production, are taken intoaccount and are also factored into therenewed evaluation. Since introduction

INNOVATION & TECHNOLOGYINNOVATION & TECHNOLOGY

DEUTZ AG introduced the environmental management system more thanten years ago. A résumé of sustainability in practice and continuous im-provements

Innovative, efficient,progressive

of the environmental management sys-tem, Volker Neumann has been the en-vironmental management representativeand hence the first point of contact forall environmental issues and aspects ofthe company. His duties include all as-pects of occupational safety measures,operational safety and regular trainingthat is offered to staff members to keepthem up to date with the latest devel-opments.

“The sustainability of our measuresmakes the difference”

Permanent improvements distinguishthe environmental management system,ensuring that legal requirements are ful-filled and often exceeded. “The sustain-ability of our measures makes the differ-

ence because other comparable com-panies are not yet so advanced”, ex-plains Volker Neumann. Test stationshave been modernised and the enginetest processes have been optimisedto reduce throughput times. This hasa positive effect on both energy con-sumption and emissions in the develop-ment area.

With regard to packaging, disposablepackaging has been replaced wherev-er possible with reusable packaging.

The replacement of disposable packag-ing with reusable containers has beeninvestigated again. The results wereworth it, as DEUTZ invested a total ofmore than three million Euros in reus-able packaging in 2011. By avoidingwaste, DEUTZ simultaneously fulfilledan important requirement of waste leg-islation. Neumann wants to take furthercommitted steps in this direction in thefuture, but investment in building ren-ovation could also be made to reduce

overall costs.

New development building as a model

The new building for engine develop-ment in Cologne-Porz is a striking exam-ple of our committed actions. The officebuilding comprises more than 100 mod-ules, which allows a great deal of timeto be saved during construction. Afteronly a few months’ construction time,the three-storey building with 5,000 m³gross floor area will be ready for occu-pation at the end of the year. 350 staffmembers will be moving into the build-ing, which is distinguished by its envi-

progress in these areas over the last fewyears. Good for customers, better forthe environment.

The proportion of highly-modern regen-erative supply units was expanded con-siderably in 2011 and the engine teststations continuously improved so thatengines can be developed in a more en-ergy-efficient manner. Generator brakesconvert the kinetic energy generated atthe test stations into electrical energy.

The reclaimed energy is then fed backinto the power grid of DEUTZ AG. Theproportion of reclaimed electric energyhas risen significantly. In addition, theoperation of regenerative supply unitsalso allows the use of low-tax fuels inthe Research and Development sector.

These two effects resulted in savings ofmore than half a million Euros each.

The latest engine generation fromDEUTZ meets the highest global ex-

haust gas and environmental standardsand corresponds with emissions legis-lation Tier 4 interim. It emits less nitro-gen oxides and other toxic gases intothe environment than previous genera-tions. With this principle, DEUTZ makesa substantial contribution to the protec-tion of environment and climate, trueto the principle “as much technologyas necessary and as little as possible.”DEUTZ customers – and the environ-ment – benefit from the increase in effi-ciency due to lower consumption, low-er emissions and improved engine per-formance.

ronmental efficiency and resource con-servation. Thomas P. Boll, qualified en-gineer and architect responsible, refersto “the implementation of energy-effi-ciency standards that lie at least 15 percent below the requirements of the En-ergy Saving Ordinance (EnEV 2009).”

Energy costs are also saved with thetriple-glazed insulating windows. Win-dows with triple glazing have excellentinsulation values. The benefit: in win-ter the heat is kept in the building, andin summer the windows allow less heatinto the building from outside, so it re-mains pleasantly cool even in hot tem-peratures. In combination with the un-der-floor heating and the ceiling cool-ing system, the interior climate in the in-dividual parts of the building is regulat-ed in an optimum manner. The fact thatstaff members have been provided witha pleasant environment is also shownby “the maximum flexibility with respect

to future user requirements such as in-dividual and collective offices, team-ori-entated project workspaces, openspace offices”, says Thomas P. Boll.

All level s are accessible and the build-ing has a wheelchair-accessible lift sys-tem. The highly modern and future-ori-entated EDP connection and communi-cation as a whole being improved by in-tegrated and open social areas are fur-ther highlights.

These are factors that have a positiveeffect on engine development and en-vironmental protection, especially asDEUTZ has documented substantial

13

The new R&D building in Cologne-Porz


8/19




to find young experts that have alreadyworked on industrial applications andhave been able to gain experience inthis area. Ultimately, DEUTZ places all ofthe aforementioned benefits in the ser-

vice of its customers. This is becauseour competitive angle is to pursue theobjective of providing the most robustand reasonably-priced solutions thatalways generate substantially less thanthe permitted emissions values in therespective markets.

DEUTZ INSIDE: Professor Harndorf,the subject of emissions that you have

just addressed is the driving force for

industry behind effo rts in engine devel-

opment. Does this also apply to your

research work at the uni versity?

Prof Dr Horst Harndorf: It certainlydoes! SCR catalytic converters – ‘selec-tive catalytic reduction’, diesel particu-late filters and the way that both of thesecan be most efficiently applied in engineconstruction is an absolutely “hot” topic.Furthermore, we are working under the

DEUTZ INSIDE: Dr Marquard, the co-operation with the University of Rostock

involves external experts i n DEUTZ AG’s

own R&D activities. What is the purpose

of this?

Dr Ralf Marquard: The university co-operation has a whole range of positiveeffects. On the one hand, we benefitfrom the technological expertise of Prof.Dr Harndorf’s team and from the latestresearch findings that are being devel-oped here. Furthermore, it is importantfor us to obtain a second opinion whenit comes to certain conceptual deci-sions. This has to come from an objec-tive viewpoint, and it is all the better ifthe second opinion comes from out-side the company. Willingness to take aself-critical stance with respect to yourown development results is importantif you are to assess what technology touse for series production. And finally, thecooperation with the university is natu-rally also interesting to us because wehave the opportunity to discover talentamongst the graduates there. We want

umbrella of the Forschungsvereinigung Verbrennunskraftmaschinen e.V. [com-bustion engine research association]– FVV for short – in which DEUTZ is in-volved within the framework of pre-com-

petitive, multi-manufacturer research.One current project that I should care tomention is the testing of so-called bio-fuel blends. Here, fossil EN590 die-sel fuel is supplemented with bio-

genic components such as rape seedoil methylester or esterified vegetableoil, otherwise known as biodiesel, andthe compatibility of this blend with thecombustion engines available nowa-days is then tested. In doing this, wecollect knowledge about the effects onexhaust gas post-processing, the injec-tion system, interactions with lubricantsand much more. The objective is clear:we want to gauge options for resourceconservation with the finite fossil energysources. A further challenge in our re-search work, particularly with respect toexhaust gas post-processing and emis-sions management: if we test an engineat our site in Rostock, at the same timewe must keep in the back of our mindsthat the same diesel engine might be

operated with a different fuel in anotherpart of the world, the composition andquality of which might more or less de-viate from what is put into the tank inthis country.

DEUTZ INSIDE: What does that meanfor an engine developer and for the ex-

haust gas regulations that have to be

factored into the development process?

Dr Ralf Marquard: At DEUTZ, we pur-sue a very simple, and for this very rea-son challenging, concept: it must bepossible for every customer to use ourengines with any available fuel quality.For this reason we orientate ourselveson all globally-applicable exhaust gasregulations. In cases of doubt the moststringent standards are authoritative,and these generally come from Eu-rope and North America; the keywordis Tier 4 final. In addition, we take aforward-looking approach. With this inmind, we have already developed testapparatus to satisfy the upcoming re-quirement for verification of so-calledin-use compliance. In short, this meansthat the behaviour of an engine is mea-sured under its typical operating con-ditions – in the field rather than in thelaboratory, as it were.

DEUTZ INSIDE: And what does thecombustion engine of the future look

like?

Prof Dr Horst Harndorf: Even with-out gazing into a crystal ball, which weknow doesn’t exist, we have to under-stand that the era of crude oil as a mainenergy source that can be extractedeconomically will end at some point.

The coverage, that is, the period forwhich resources will remain available,is a great deal larger for natural gas. Iconsider hydrogen as an energy sourceto be a distant vision of the future. Gaspropulsion and hybrid solutions will defi-nitely become more important in themedium term.

Since 2010, Dr Ralf Marquard has been head of Research and De-

velopment at DEUTZ AG. After studying Engineering with a focuson Design and Internal Combustion Engines at RWTH Aachen, heworked as a scientific employee with Prof. Franz Pischinger at FEVMotorentechnik GmbH, also in Aachen, where Ralf Marquard re-ceived his doctoral degree in 1992. This was followed with seniorpositions at Meta Motoren- und Energietechnik in Herzogenrath andwith the engine constructor AVL Liste in Graz / Austria. From 2004to 2008, Dr Marquard was in charge of the development of medium

speed engines at MAN SE in Augsburg. Directly before he joined DEUTZ AG, hemanaged the Research and Preliminary Development sector of MAN Nutzfahrzeuge

AG in Nuremberg. What Dr Marquard finds particularly pleasing about his career path:“I have got to know the birthplace of both the diesel engine and the petrol enginereally well with my activities in Augsburg and Cologne. Together with my team, I havethe fantastic opportunity of taking this historically exceptional and also unabatedlyfuture-orientated technology to the next level.”

Since 2006, Prof. Dr Horst Harndorf has held the Chair of Piston andInternal Combustion Engines at the University of Rostock. Enginesand motors not only accompanied him on his academic career path,but also in various posts in the industry: following his degree in En-gineering, Horst Harndorf completed his training as a machine fitter.

As a young engineer, he found his way to Kraftwerk-Union AG (KWU)in Offenbach. From 1984 to 1989, Horst Harndorf was a scientificemployee at Darmstadt Technical College, where he graduated. Hethen worked at Forschungsvereinigung Verbrennungskraftmaschi-

nen (FVV) and in the central area of Research and Preliminary Development at RobertBosch GmbH. In addition to his position as Professor, Prof. Harndorf is a partnerin FVTR GmbH (Forschungszentrum für Verbrennungsmotoren und ThermodynamikRostock [research centre for internal combustion engines and thermodynamics]), aspin-off development of the university. He succinctly summarises the objective of thiscompany: “Within the synergy field of research, university operation and industry, wedevelop technological solutions that provide practical benefits to all involved parties.”

Interview on the issues of engine development and emissions protection

regulations with Dr Ralf Marquard and Prof. Dr Horst Harndorf

“It must be possible to operateDEUTZ engines anywhere in theworld and with all qualities of fuel”

What do engine developers haveto do to satisfy the current andcoming exhaust emission stan-dards? And is it possible today toventure a glimpse at the combus-tion engines of the future? It wasquestions such as these that DrRalf Marquard, R&D manager atDEUTZ and Prof. Dr Horst Harn-dorf at the University of Rostockaddressed.

Dr RalfMarquard

Prof. Dr HorstHarndorf


9/19


17

The door closes. Spellbound, the pas-sengers stand at the floor-length win-dows and wait with bated breath. The

journey begins. The gondola rises.

Higher and higher, until it finally reach-es a height of more than 160 metres.

The view is breathtaki ng, thanks largelyto the 360° glazing of the cabin allows

passengers a unique panoramic view ofSin City.

Las Vegas: city of glamour and money,wedding chapels and casinos. The Strip,the Hotel Mirage or Caesar’s Palace areworld famous – and the Las Vegas HighRoller is a construction that fits in with itssurroundings and is already creating a stir.With a height of 167 metres, bigger thanthe London Eye or the Singapore Flyer,

the biggest Ferris wheel in the world is setto start turning at the end of 2013.

Ferris wheel with DEUTZ technology

The gigantic Hi gh Roller will be built di-rectly on the Strip, opposite Caesar’sPalace. This means that the skyline ofLas Vegas will be permanently changed.

This new construction will not go unno-ticed, as can be seen in the statisticsfor the most important road in the city,the Strip: every day, almost 70,000 carsand more than 50,000 pedestrians passalong this road. Las Vegas attracts 40million tourists each year. Such figurespresent an incentive and a challenge tothe operators of this construction.

The operators have to be able to counton the technology that goes into the con-struction of the installation – especiallywhen you take the climatic conditionsof the location into consideration. In thewinter months from December to Feb-ruary the temperature rarely exceeds 15degrees Celsius, and temperatures droptowards freezing point at night. Whereasin the summer months, peak values ofup to 45 degrees are reached. Sudden

Only in Vegas



In the gambling town of Las Vegas, the biggest Ferris wheel in the world willstart turning from 2013, altering the skyline of “Sin City”. Power packs fromDEUTZ AG will be used for the emergency power system.

History of the Ferris wheel

The oldest recorded appearance of the idea of a Ferris wheel comes from Bulgaria. In1620, English traveller Peter Mundy saw some children that had attached small seatsaround the circumference of a large wheel so they could enjoy themselves as the wheelturned. Similar contraptions were also seen in England later in the 17 th century. The firstmodern Ferris wheel in the world was built by George Washington Gale Ferris, Jr., rail-way and bridging engineer from Pittsburgh, on the occasion of the World Exhibition inChicago in 1893. The event organisers were looking for something original and uniqueto overshadow the Eiffel tower, erected for the 1889 World Exhibition in Paris. TheFerris wheel had a height of 80.5 metres and 36 gondolas, each offering space for 60persons. Ferris took inspiration from the storage principle of penny farthing bicycles. Hisdesign comprised a wheel that was attached to the hub with 6 cm thick steel spokes.

The Ferris wheel was opened to the public on 21st June 1893 and became a particularattraction at the World Exhibition. Ferris wheels were also erected in other cities in fol-lowing years, setting new height records. The name “Ferris wheel” became used as ageneral designation for big wheels in English.

The biggest Ferris wheels in the world A selection

Las Vegas High Roller Las Vegas, USA Completed: End of 2013 (planned)Height: 167 m

Singapore Flyer SingaporeCompleted: 2008Height: 165 m

Star of NanchangNanchang, ChinaCompleted: 2006Height: 160 m

Skyvue Las Vegas Super WheelLas Vegas, USA Completed: Summer 2013 (planned)Height: 152 m

London EyeLondon, EnglandCompleted: 2000Height: 135 m

The Southern Star Melbourne, AustraliaCompleted: 2008Height: 120 m

desert storms whip through the region athigh speed – a challenge for every build-ing in Las Vegas, especially if it turns andhas many glazed gondolas hanging fromit. Therefore provisions have to be madefor every eventuality.

Engineers from the Dutch company En-erpac, who are responsible for the hy-draulic drive system, are using DEUTZtechnology for the emergency powersystem. Two TCD 6.1 L6 power packsthat drive the hydraulic emergency pow-

er system will be installed. If thereis a power cut, the emergencypower system is activated to

continue turning the Fer-ris wheel, allowing

all passengers to

safely exit thegondolas. Forthe Ferris wheel,

the robust 6-cyl-inder inline engine

with turbocharger andintercooler will impress with its

long engine service life, excellent effi-ciency and long service intervals – char-acteristics that are important for a Ferriswheel almost 170 metres high under thehot sun of the State of Nevada.

30 minutes’ ride time

The Ferris wheel is part, and indeed thecentrepiece, of a shopping, gastronomyand entertainment paradise – called “TheLINQ” – with a total surface area of justunder 20,000 square metres. The Ferriswheel itself has 28 gondolas, each offeringspace for 40 persons. The ride lasts justunder half an hour. 30 minutes for a rideabove the City of Sin, in which it appearsthere is nothing that cannot be achieved.


10/19


At DDP, service is paramount – just likethe continuous support of staff mem-bers. This is how the programme thatcommenced in September 2011 on theinitiative of the DDP Supervisory Boardcan be described. The objective of theinitiative “Learnership for disabled peo-ple” is to involve disabled people in workprocesses and to improve the employ-ment chances of disabled people inthe economy. The programme lasts fortwelve months, and the course coversthe subjects of IT, EDP, personnel andadministration. After completion, partic-ipants receive a qualification certificate

recognised by the South African econ-omy. This concept fits in with the DDPvision that intends to support staff mem-bers sustainably in the long term. Fromnumerous applications, four participantswere taken into the programme. With184 employees, this amounts to morethan two per cent. A proud figure thatcan be compared to German enterprisesof similar size. The programme was verywell accepted within the company. Fourinternal mentors were commissioned tosupervise and look after the programme.

The mentors were also responsible forchecking the portfolio submitted by the

“At the heart of society”Facts on the participation of disabled people in working life

The access of disabled people to healthcare, training and employment is a human right

in accordance with the UN Disability Rights Convention of 2006. The central idea: “Rightfrom the start, people with disabilities belong at the heart of society.” It is also enshrined inthe constitution of the Federal Republic of Germany that nobody is to be disadvantageddue to their disability. The Equal Opportunities for People with Disabilities Act (BGG), theGeneral Equal Treatment Act (AGG) and the United Nations Convention on the Rights ofPersons with Disability form the framework for this policy at a national and internationallevel.

Access to the employment market: is of decisive importance for the social integrationof disabled people. However, serious disability still has a significant effect on unemploy-ment. But the world of employment has changed a lot in recent years. Subjects such aseducation, life-long learning and vocational adjustment become more and more import-ant in times of a globalised world of employment. The demographic change also hasan effect on the structure of the employment markets and the participation of disabledpeople. Individual, bespoke solutions that focus on the employability of the individual arenecessary. Numerous measures and support structures help disabled people in findingand taking up employment, and in keeping their job. In line with this, the Disabilities Rep-resentative, for example, will campaign within the commercial world for the employmentof persons with disabilities throughout Germany in the coming 15 months under the title“Unternehmen inklusive Arbeit [Businesses for inclusive jobs]”. According to the GermanFederal Employment Agency (BA), in 2012 there are more than 3.2 million seriously dis-abled persons of employable age. About 900,000 seriously disabled persons were em-ployed in August 2012, of which 300,000 were employed in disabled workshops. Therewere also 177,000 unemployed persons.

ISO 26000: was published on November 1 st 2012 and is a guideline for social respon-sibility and sustainability in organisations, companies and institutions. It tries to create aglobally uniform line with respect to the different interpretations of sustainability and socialresponsibility. Stakeholders from approx. 100 countries were involved in its drafting, in-cluding representatives from industry, employers, consumers, government officials andnon-governmental organisations.

Corporate Citizenship: with this term, DEUTZ AG describes its social responsibility asa global operator. This is why the Group has for so long been committed to social is-sues, culture, education, sport and the environment. DEUTZ is also making a mark in theintegration of disabled persons. The company has been working together with NostraGmbH, one of the largest and oldest integration companies in Germany, for more than20 years – and it has been working with GWK (Gemeinnützige Werkstätten Köln GmbH)for more than 40 years. With both of these operations, DEUTZ is cooperating in the sec-tors of stock receipt, packaging and component manufacturing. To this is added globalcommitment, such as the “Learnership for disabled people” programme from the South

African DEUTZ DIESELPOWER (DDP).

trainees. These were examined and thenassessed in detail.

Assuming social responsibility

At present, the DDPmanagement team isworking on integratingISO 26000 into the ex-isting ISO certification.ISO 26000 is an indi-cator of the social en-

gagement and a guideline that providesorientation and recommendations as tohow organisations, companies and in-stitutions should behave in order to beseen as socially responsible. Applicationof the guideline published in November2011 is voluntary and is not a certifiablemanagement system standard like ISO

9001 or ISO 14001. The company islooking into options for incorporating thenew standard into work processes. Evenat this point, they are convinced that thenew standard will not only improve via-bility in the future, but will also improvethe economic, social and environmentalsustainability of the products.

DEUTZ DIESELPOWERhas been selling DEUTZengines in South Africaand the regional mar-ket for more than threedecades. Formed in1981, the investment

company has excelled again and againin the course of the company history withexcellent customer service, proactivestaff management and innovations. Thedemand for new designs in mining hasopened further markets to DDP’s enginerange. This demand extends across theentire range of compact air and liquidcooled engines for use in a variety of dif-

ferent applications.

DDP employs 184 staff members in allof its offices in South Africa. The servicepartner concept is utilised in regionswhere DDP does not have its own offic-es, such as Lesotho, Swaziland, Namib-ia, Botswana, Zimbabwe, and Zambia.

19

PEOPLE & MARKETSPEOPLE & MARKETS

DEUTZ DIESELPOWER (DDP) inSouth Africa supports people withdisabilities and offers them one-year advanced training courses. Inthis way, DDP is assuming socialresponsibility and also wants toincorporate the new standard ISO26000.

Ideally integrated,

socially committed


11/19


Africa and Europe shapethe face of Spain andhave given it a charac-teristic peculiarity thatis without comparison.Basically, Spain is dif-ferent in a positive way– it won’t take busi-ness travellers long tonotice this.

The working day usu-ally starts late in Spain,around 9.30 am. Thenat 11.30, Spaniards liketo have breakfast in theso-called “bar”. So if you arein a meeting at this time, youshouldn’t necessarily insist that itcontinues.

Then between 1.30 and 3.30 pm it iscommon to have the so-called sies-ta, an extended lunch break – this is a

Spanish cultural asset that foreign busi-ness travellers should definitely takeinto account in their planning. For thisreason, try not to arrange meetings inthis lunchtime rest period. Spaniardstend to be relaxed in meetings, too.Frequent coffee breaks are welcome,and promote a relaxed atmosphere. Buttake care – in spite of the relaxed at-mosphere, you should avoid discussingbusiness or swearing whilst sharing acommunal meal, as both of these areconsidered extremely rude in Spain.On the other hand, you can gather pluspoints by guiding the conversation ontothe subject of family, as Spaniards are

just as open on this subject as with

conversationtopics such assport, art and archi-tecture. But you shoulddefinitely avoid criticalsubjects such as the CatholicChurch, World War II or any criti-cism of bull-fighting.

You shouldn’t rely too much on Mediter-ranean placidity in Spain, though, be-cause along with a dislike of being re-duced to common clichés, Spaniards

valuep u n c -

t u a l i t yand courte-

sy. People thatspeak good Spanish

also have a clear advan-tage. If you haven’t mas-

tered the Spanish language itmight be a good idea to engage

the services of an interpreter, sinceEnglish is not the traditional businesslanguage in Spain.

You should also take note o f formal ityin the choice of your clothing. Ladies

and gentlemen are alwayswell-dressed in dark,conservative businesssuits. Even when thetemperature is high,men should not wearshort-sleeved shirtsand women shouldnot show too muchskin. In addition to the

correct clothes, thecorrect form of address

should also be used. Menare addressed as “señor”.

The form “señorita” (Miss)is used for women, “señora”

is used to denote somewhatolder women. Furthermore, the

addressee’s position e.g. President,Director or a title such as Ingeniero or

Professor should be used. You shouldalso take care with apparently all-too-fa-miliar behaviour.

In general, the familiar form is quick-ly used in Spain, although this is not asure sign of clear affection. There arealso great differences from a regionalperspective: whilst a handshake is allthat one receives in Catalonia, womenin Madrid give each other a kiss on thecheek. Men only do this if they are verygood friends. If this is the case, you canalso hug one another, and good busi-ness partners can also slap each otheron the back.

*“Only heaven is more beautiful than Madrid!”

Spain – Germany’s favourite holi-day destination is pure Mediterra-nean temperament. In an area of504,000 km², the devout southernEuropeans cultivate international-ly-renowned traditions such as fla-menco, tapas and the productionof olive oil. But the Iberian penin-sula has much more to offer thancommon clichés might lead you tobelieve.

PEOPLE & MARKETSPEOPLE & MARKETS

P a r t 6 S p a i n

The “thumbs up” sign that is so popularhere is considered vulgar in Spain andshould be avoided at all costs.

Do not buy chrysanthemums as presents. These are only used for mourning.

When driving, keep to the speed limit.Exceeding the limit by as little as 20 km/hcosts about 90 Euros, speeds of 200 km/hcan earn a punishment of community ser-vice or even imprisonment.

In bars and restaurants, five to ten percent of the bill amount is simply left on thetable as a tip. It is impolite to leave smallcoins such as two or five cent pieces.

Bizarre: Black animals or plots of land nearcemeteries are not popular.

It isn’t Friday 13th, but rather Tuesday 13 th that is considered unlucky in Spain andLatin America. ““En martes y trece, ni tecases ni te embarques.” Do not marry ortravel on Tuesday 13th.”

Spaniards do not enjoy fun at the expenseof others on 1st April , but rather on 28th December, the Feast of the Innocents.

You should not lend money or sign a con-tract on this day because you might becheated.

EL GORDO: the traditional Christmas lot-tery where wooden balls are drawn is anational spectacle in Spain. About 98% ofall Spaniards buy a ticket or a tenth sharein a ticket.

In Spain, most apartment name platesdo not contain a name but rather a vague

combination of numbers and letters. These represent the storey and the po-sition of the apartment – on the right orleft-hand side

Every Spaniard has two surnames (apel-lidos), in each case the first of the fatherand the mother. Married people retain theirown surnames. Children receive in eachcase the first surname of each parent.

Business cultures¿CÓMO?

„¡De Madrid al cielo!“*


12/19


SAFETY & QUALITY

DEUTZ engines are used in extremeenvironments. Not only do they haveto work reliably in hot and dry areas,but also at great height and at lowtemperatures. And that must be guar-anteed all around the globe: for exam-ple, American legislation also requirescompliance with emissions limit valuesin applications at heights of up to 1,650metres. “In order to ensure all of this,

up to now we have had the option ofeither carrying out field tests – that is,the engines were tested on site at theactual altitude in question – or we couldhire special test stations externally”, re-flects Dr Michael Röbel, team leader inthe Development sector of DEUTZ andresponsible for test station technologyand construction. The construction ofan in-house height simulation plant atthe DEUTZ development centre in Co-logne-Porz was initiated to make thecompany independent of these cost-in-tensive and logistically-complex tests.During planning, it rapidly became clearthat the available space there was in-

Almost 4,000 m² of space is available inthe highly-modern, newly-opened Ser-vice Center Madrid (SCM). The SCM inthe east of the Spanish capital presentsitself as a new business unit and is fur-thermore an engine competence centreof DEUTZ DITER. The SCM is sub-divid-ed into several areas. There is the wingwith the office rooms and the shop, theworkshop with 500 m² and the logisticsarea with more than 1,000 m². The of-fice building, clinker-clad in business-like,restrained colours, also serves as recep-

tion since customers and visitors arereceived in the open-plan rooms on theground floor of the building. Care wastaken that the office workspaces havean attractive and open design. Trans-parency and style in the interior fittings isdesigned to give employees a pleasantworking environment. The training roomis located on the first floor; this can beused for training courses, OEM trainingand sales presentations.

Latest technology, coordinated design

The workshop has four areas, alongwith which a fifth part is to be explicitlyused for repairs to engines. There are

sufficient. A decision was made to builda new technology building as a bridgebetween the existing wings C and D.Construction of the building started assoon as planning permission had beenreceived. Work progressed rapidly, andthe main equipment was brought onsite by a heavy crane. The centrepieceof the plant, a Roots reciprocating com-pressor, weighs just under 6 tonnes

and has dimensions of 3.7 x 2.5 x 2.7metres. Using this compressor, the airin the plant can be regulated down to575 millibar, which represents the natu-

also two rooms for special activities;these are to be used for testing, elec-trical installations, cabling andmuch more. The technicalequipment includes thecompressor systemthat can supply allwork stations withcompressed airin parallel andwashing andcleansing ma-chines that ap-

propriately andproperly clean allproducts, includingcrankcases and largerengines. A 5-tonne over-head crane that can reach all rele-vant positions and work stations in themain hall rounds off the equipment. Ad-ditionally, there are four fully-equippedtransporters with which the mechanicscan carry out on-site repairs.

Dynamics and efficiency

The logistics have been split: one sec-tion is provided for paletted productsand goods. The racking system is de-

23

ral pressure at 4,500 metres above sealevel. The mechanical installation of theplant commenced in early 2012.

Siberia and the Sahara lie close toone another

Tuning of the height simulation plantusing an engine of type TDC 12.0 V6commenced at the start of June. Allconditions that can be simulated by theplant were tested using this engine. It isprobably the first engine that has everbeen used in winter-time Siberia at atemperature of -40 °C, followed by theSahara at +60 °C without having left theground in Cologne. Within a few min-utes, the simulation rises up from low-ly-ing Cologne up to the 1,650 metres re-quired by the American legislator, thenup to the 2,500 metres of the Gross-glockner High Alpine Road and finallyup to the extreme 4,500 metres. In suchtests, the engine is exposed to the lowpressure at both the inlet and exhaustside. This means that in future, the en-gines can be optimally tuned directly inthe development works by program-ming the control electronics in terms of

the engine function and the exhaust gaspost-treatment for all operating heightsand temperature ranges.

signed so that the different weights ofthe engines can be stored in a stable

manner and so that the loadingand unloading process is

guaranteed to be safeand fast. To this

end, the systemhas been provid-ed with a mas-sive base andcompact crossbraces. Never-theless, fork lift

truck drivers canreach the relevant

areas without prob-lem when manoeuvring

and driving. The other sec-tion is set up for smaller goods

and spare parts. This section of logisticsis equipped with modern and automatedstorage technology, in a similar way tothe racking system. An integrated mate-rial flow system provides a problem-free,dynamic process which means that ef-ficiency, rapidity and hence productivityare also guaranteed here.

PEOPLE & MARKETS

How to reach 4,500 metresabove sea level in Cologne

Madrid makes it possible

Height simulation at DEUTZ site

Cologne is about 50 metres above sea level. Under certain circumstanc-es, the engines that are built there by DEUTZ are used at heights of sev-eral thousand metres. Even in such conditions, they have to work reliablyand deliver their power with reduced emissions. In order to ensure this,DEUTZ has commissioned a height simulation plant.

Service Center Madrid (SCM) of DEUTZ DITER in the Spanish capital impresses with its attractive design andhigh-tech in its logistics and workshops.

Address:

DEUTZ DITER, S.A.

División Motores CompactosC/ Picos de Europa, Nº 4 - B28830 San Fernando de HenaresMadrid, Spain

Technical data and capabilities

Diesel engines are subjected to extreme conditions in tests on the DEUTZ AG heighttest station. This not only occurs by reducing the air pressure (the actual height simu-lation), but also via temperature and air humidity.

Height that can be simulated up to 4,500 m above sea levelPossible temperature range of combustion air -40 °C to +60 °CQuantity of combustion air suppliedto the test engine at 20 °C 3,900 kg / h.

Air humidity that can be realised at 20 °C 5% to 95% relative air humidity


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operating mode on a securely disabledengine.

The complex functi ons that all ow oper-ation of the CRT system were predom-inantly developed by DEUTZ. The dras-tically-increased complexity in terms ofengine operation, calibration and diag-nosis due to the apparently straight-forward CRT system (large DOC-DPFcombination, 3 sensors) is reflectedmassively in system development (op-erating concept incl. software solution)and in the greatly-increased parametri-sation requirements of the engines (3operating modes).

Precise knowledge of the soot loadingof the DPF is indispensable to the CRTsystem. To determine this information, itis necessary to map the engine emis-sions behaviour with regard to soot andNOx. Furthermore, both NO

2 forma-

tion by the DOC and soot burn-off inthe DPF must be mapped in softwaremodels. Both models together then al-low calculation of the DPF soot loading.In addition, the best possible operatinglogic must be developed that combines

best engine performance and prob-lem-free CRT system function.

Such a complex system requires thedevelopment of adapted diagnosticsfunctions since in this case conventionaldiagnostics processes are no longer ad-equate. In addition to the requirementsfor ensuring hazard-free operation, di-agnostics must also support reliableand rapid fault-finding by DEUTZ Ser-vice. Since the introduction of electronicengine control units (ECUs) and varioussensors and actuators, every enginecontrol unit has sensor or actuator di-agnostics that are based on 3 standardprocesses:• Electrical diagnostics of sensor / actu-

ator, e.g. voltage OK, resistance OK.• Plausibility diagnostics of a sensor

signal, e.g. value > minimum, value< maximum

• Reaction diagnostics of an actuator,

e.g. 50 % valve opening required =>feedback of actuator position = 50 %

This allows a multitude of faults to bedetected. If a fault occurs, it is stored

“by name” and, as appropriate, triggersfault-specific reactions that guaranteesafety and inform the operator. The cor-relations between sensor or actuatorfaults and necessary fault reactions areexamined and evaluated in the develop-ment phase within the framework of anFMEA (Failure Mode and Effects Anal-ysis). 85% of the diagnostics functionsare derived from this. However, thereare limits to the process of an FMEA:only the failure of one sensor is everconsidered, not the simultaneous failureof e.g. two sensors. Furthermore, somefaults can only be detected by observingcomplex relationships over longer peri-

ods of time. In both cases, conventionaldiagnostics cannot ascertain a fault.

In order to support DEUTZ Service inthe best possible way in spite of the in-creased complexity, but also to obtainmore information on the reasons forequipment failure, system diagnosticsare utilised for the first time at DEUTZwith the introduction of exhaust gasstage 3B < 130 kW. This goes beyondthe classical diagnostics approach inthat it stores selected secondary infor-mation if a certain event occurs, for ex-ample.

An exampl e o f this is the fault “Dieselparticulate filter overloaded with soot”.Reasons for the fault include e.g.1. a defective differential pressure sen-

sor (to be diagnosed),2. an exhaust recirculation valve stuck in

the ‘open’ position (to be diagnosed),or

3. a dripping injector (could not be diag-nosed up to now)

4. and also user ignorance about thestandstill requirement (could not bediagnosed

up to now). If one of the faults that areto be diagnosed is present, the causecan be remedied directly by the Ser-vice team. In case 3 or 4, however, thecause remains unclear. Case 3 can onlybe detected if one knows the intervalsin which heat mode or standstill arerequired, and what trigger source (seefigure A) has requested the modes. Fur-thermore, the operator cannot be ex-cluded as a “reason for the fault” (case4); however, incorrect operation cannotbe detected by the control unit.

Such faults require system diagnostics,which are split into two groups:

1. complex fault detection process1.1. simultaneous failure of several

sensors1.2. observation of characteristic val-

ues of a component over a lon-ger period to detect ageing ordrift effects

2. storage of specified values at specificpoints in time (regeneration statistics)2.1. When changing engine operat-

ing modes (heat mode, stand-still), extensive information isstored with regard to engineoperation and the CRT system:temperatures, pressures, engineoperating hours, loading of the

particulate filter, present faults,etc. In this way, a large amountof secondary information is avail-able that describes the circum-stances in which a heat modeor standstill regeneration wouldhave been requested.

If the complex fault detection process-es essentially represent an expansion ofknown methods, the regeneration sta-tistics are a complete innovation. Stor-age takes place in a ring memory witha fixed number of (n) storage spaces. Itworks in accordance with the so-calledFIFO principle (First In, First Out). Thismeans that if there is a new require-ment for storage space when all stor-age spaces are filled, all stored imagesmove up one place. This creates space

for the new stored image and the oldestis deleted. In this way, the last n stored

Figure B This information and its evaluation allows DEUTZ to discover insidious or complex faultsand also incorrect operation, where applicable. In this way, by comparing the point intime of the standstill request with the point in time that the standstill process is carriedout by the operator, it can be ascertained as to how long the request has been ignored.Furthermore, using this data DEUTZ can gain knowledge for the first time about the cir-cumstances under which the system has functioned or fail ed. Up to now, this has oftenbeen a problem with development equipment, as the precise circumstances of a fieldtest equipment failure usually remain unknown or putatively unimportant information isnot communicated. Since this data is generated by every engine, it provides a moreextensive picture than could be supplied by the largest test equipment fleet. Further-more, in part, it renders even complex data logger installations superfluous. Continuousproduct improvement is permitted by feeding t his knowledge back into development.In this way, the series production experience with engines of emissions stage Tier 4istage B can supply valuable knowledge for system development of emissions stage

Tier 4 final.

images are always visible. In doing this,the information is stored as compactlyas possible. Each stored image requires

just 22 bytes in the permanent memo-ry of the engine control unit (EEPROM).Overall, for both the heat mode and thestandstill regeneration, n stored imagesare recorded in the control unit and areread by the service program (SERDIA).Figure A gives an overview of what in-formation is stored, or which informationcan be directly or indirectly inferred withknowledge of the data availability, in theevent of standstill regeneration.

A CRT system removes HC, NO andparticulates (soot) from the engine ex-haust gas to meet the legally stipulat-

ed NOx threshold value using in-enginemethods. The latter takes place in bothengines via external, cooled exhaustgas recirculation. For trouble-free op-eration of the diesel particulate filter, itis necessary for all engines to exhibitthe same emissions behaviour. In addi-tion, the emissions behaviour must notchange throughout the service life of theengine. Furthermore, the mean exhaustgas temperature should be above 250°C during at least 60 per cent of the en-gine operating period. If this cannot beguaranteed, the temperature level in theexhaust system must be raised depen-dent on the soot loading level of theDPF. This takes place by activat ion of analternative engine operating mode, theheat mode, in which the engine provideshigher exhaust gas temperatures at theexpense of higher fuel consumption. Ifthis operating mode cannot reduce thequantity of soot in the DPF either, stand-still regeneration must be carried out.Here, the DPF is regenerated up to 95%

within 30 minutes in a special engine

SAFETY & QUALITY

A CRT system denotes the combination of a diesel oxidation catalytic converter (DOC) with a downstream dieselparticulate filter (DPF), wherein regeneration of the collected soot takes place using NO 2 (CRT effect). For the firsttime, CRT systems for exhaust gas treatment will be used by DEUTZ with engine model series TCD4.1 and TCD6.1in the power range greater than 56 kW and less than 130 kW. DEUTZ employees AbderrahimQriqra, Jens Weyersand Holger Zimmermann explain the process.

SAFETY & QUALITY

S o o t l o a d D P F

1st Stand still

100 h 200 h 260 h 320 h1xx h 2xx h 3xx h

D a t a a b o u t l o a d i n g p h a s e

D a t a a t H M s

t a r t

260.5 h

Engine Operation hours[h]

2nd

3rd

Figure B clarifies the function of the FIFOs for storing the statisticalvalues.


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Increased efficiency in processes, flexi-bility and cost reduction: these are justsome of the results of the conversionfrom unit-based to requirements-basedproduction of engine frames. From theparent plant in Cologne-Porz, 300,000finished engines are delivered each yearto customers in Europe, North Ameri-ca and Asia. To guarantee safe trans-portation, the joinery in Porz producestransportation frames. These comprisea wooden palette as a base with a su-perstructure of squared timber in which

the finished engine can be placed, bolt-ed down and then shipped. How canan engine, with its irregular corners,edges and surfaces, be safely trans-ported around the world? This is a jobfor the DEUTZ “Transport PackagingManagement & Customs” department.

They plan and produce the transporta-tion frames, whereas the service pro-vider Stute Logistics is responsible forthe operative production. “The effectsof customer-specific engine productionare also reflected in a great demand for

flexibility in framework production bythe joinery”, said Claus Rausch, headof Transport Packaging Management.However, the system that existed upuntil now was no longer able to providethis flexibility. The storage of great quan-tities of raw materials, the high expen-diture in production and transportationand the deficiencies in safety (in theproduction area and HGV unloading onthe approach road) meant that a changewas absolutely necessary. In the end,2,000 m³ of free space at the centre

of the Porz production site was need-ed for the immense demand for woodand framework storage alone. “Natural-ly, this imposed severe restrictions onworks traffic”, commented Rausch. Anoverall solution needed to be found.

DEUTZ and the University of Colognetravel new, innovative paths

The existing cooperation with the Uni-versity of Cologne helped and was in-tensified. The head of the seminar forcompany management and logistics, Di-rector Prof. Dr. Dr. h. c. Werner Delfmannadvertised the project for reorganisa-tion of packaging production amongsthis students and assigned it to Tobias

Schmitz, who managed it on behalf ofDEUTZ AG within the framework of his

Master’s thesis. The project commencedin January 2012. “We firstly carried outan analysis of the starting situation sothat we could discuss and work out theproblems and adaptation options”, com-mented Schmitz. He explained further:“Up until now, the wooden frames weremass-produced in the stores so that re-quired quantities and the diversity of vari-ants could be rapidly and securely met.Naturally, this involved enormous stocks,high requirements of space and ultimate-ly costs.”

Clear direction: new and better pro-cesses

The objectives were clearly defined,primarily: to increase efficiency, con-centration on core activities, reductionin material wastage, optimisation ofprocurement and delivery cycles andproduction after orders. “Ultimately, aholistic approach was found where-by suppliers were involved and a newproduction process and a new trans-portation concept could be implement-ed” said project manager Schmitz, de-scribing the outcome. Central to thereorganisation was realignment of theproduction process. The productionof frameworks should be configured

flexibly, so that, analogously to engineproduction, only the required frames are

produced at a time in a two-hour pro-cess. It was possible to attain the OnePiece Flow concept first and foremostby means of a new task assignmentsystem between wood commissioningand framework assembly. The minimumbatch size was reduced to piece pro-duction. “Thanks to the conversion, wewere able to avoid the lengthy transpor-tation routes between the wood storagearea and the assembly hall, as now allmaterials are available in the hall. Thisalso made the production steps easier

for our staff members”, explains RomanSchanofski, head of Material Flow Man-agement at Stute Logistics.

Plans implemented and project objec-tive attained

“After a two-week implementationphase, we were able to start the newconcept of procurement, productionand delivery in mid-August. With this, wehave already been able to substantiallyreduce material and framework stocksand realise unit-based production anddelivery”, summarises project managerSchmitz. “In addition, we were able todispense with a large proportion of theplant inventory: operation of our own

sawing centre including side loaders aswell as automatic separators and indi-

vidual production benches, for example.Overall, the project was a success andwe were able to achieve our objectives.With this collaboration with suppliersand service providers, we have achievedadded value for ourselves, for the joineryand ultimately for our customers”, saidtransportation manager Claus Rausch,happily. Following this success, he wouldlike to increase the collaboration with theUniversity of Cologne. “There are”, saidRausch, “assuredly more fields that wecan optimise, for example in logistics.”

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SAFETY & QUALITYSAFETY & QUALITY

Streamlining

the processes

Within the framework of the existing cooperation with the University ofCologne, DEUTZ AG has implemented One Piece Flow in packaging pro-duction. The outcome of the several-month planning and implementationphase is economic and productive manufacture.

Reorganising the joinery

n Key task: production of frameworksand crates for the transportation offinished engines

n Start: examination and analysis of theactual state

n Concept: worked out by DEUTZ andthe University of Cologn

n Objective: One Piece Flown Path: reduce material requirements

and variants, reorganise delivery, joinery and transportationn Implementation: Mid-August 2012n Controls: fault documentation, fine

tuning and performance measurement


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SPECIAL

It is small, neat and also extremely flexi-ble, thanks to its practical four-wheeledundercarriage: the DEUTZ IdeasMobile.What on first impression appears to bea symbiosis between a laptop and R2-D2 shows you at a second glance whatpotential it has. Accompanied by a spe-cially-trained staff member, the Ideas-Mobile travels to the work stations ofDEUTZ staff members that would like tosubmit an idea but have not yet foundtheir way to the terminal due to a lackof time or l inguistic insecurities. The staffmember supports them using the Ideas-Mobile, discussing their ideas with themand then helping them to enter it into thedatabase. The IdeasMobile is proof as tohow far a good idea can go, as the smallvehicle is itself the result of a submittedidea.

The catalyst for this was an idea involv-ing the subject “Submit support ideas

via a representative and a Wi-Fi PC”. Inorder to support and assist the submit-ting person, a trained staff member witha mobile ideas terminal is to regularly visitthe assembly line to ask if anyone wantsto submit ideas, which are then entereddirectly into the system on behalf of theirco-worker. In a test process, the Ideas-Mobile was quickly constructed in Sep-tember 2012 by Wilfried Riemann’s teamout of an aluminium frame and a laptop;even after the first test runs, the

Deutz Inside 3 2012 en Verlinkt

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