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Engine Presentation

“Innovation meets Production”


Hermann Doppler
Head of Global Engine Operations Daimler Trucks
Mannheim, March 17, 2011
Our global production concept:
Base for technical peak performance!
• Mannheim is the Lead Plant in the Daimler Trucks global network for commercial vehicle engines.
• World-wide production and quality standards are centrally developed in Mannheim.
• Global bundling and balancing of production capacities

Lead Plant Trans Plant

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Global supplier management:
Holistic support of world-wide engine production
Global supplier management network with hubs in all regions
Advantages
Advantages

• One-face-to-the-supplier: a
regional team works on all quality
and availability issues with the
supplier
• Vicinity to suppliers – no cultural
or language barriers
• Economies of scale are realized
by bundling of all activities and
implementing at ONE location
• Quick reaction time and presence
Daimler-Production Site Supplier
on site
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Synchronous Plant Mannheim:
From the tradition plant to the plant of the future!
• „Synchronous Plant “ = integrated production chain from melting, casting,
producing all the way to the assembling of components:
• Optimal production process in a perfectly managed overall system

SYNCHRONOUS PLANT

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The most efficient engine with the best technology requires:
Best production processes and highest precision!
Whether at casting ...

Robot controlled core package assembly

• Core packages from ultrapure sand - grain of sand:


diameter 0,35 mm, tolerance 0,02 mm

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The most efficient engine with the best technology requires:
Best production processes and highest precision!
Whether at casting ...

Component engineering by casting simulation

• Prediction of component characteristics


during casting and solidification

• strength
• residual stress
• crystalline structure

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The most efficient engine with the best technology requires:
Best production processes and highest precision!
Whether at casting ...

BIO-Radius
• Transformation of innovative designs in efficient production processes:
example: cylinder crankcase – bearing block connection with BIO-Radius

classic groove BIO-Radius


even load allocation

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The most efficient engine with the best technology requires:
Best production processes and highest precision!
… or all other stations of the production process

World-wide first assembled camshaft in heavy duty engine applications

• highest positioning accuracy of cams (2 µm)


• lower weight (ca. -50%)
• lower waste
• lower production cost (ca. -30%)

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Foto Mitarbeiter

The most efficient engine with the best technology requires:


Best production processes and highest precision!
… or all other stations of the production process

Clinical cleanness

• Mannheim Illig-Value
is benchmark in automotive industry

example for „Illig-Values“


particle deposit = f (running track cleaning)

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Our global production concept:
4 control loops assure quality in production
Worker
Worker Inline
Inline
Quality
Quality Gates
Gates Production Product
Product Audit
Audit
self-check
self-check Production Audit
Audit

RK 1 RK 2 RK 3 RK 4

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Competence and Know-How:
Our employees as fundament of the success
• Highly qualified employees to handle most modern technology and innovative qualification methods, e.g. PLS:
Concept for standardization, problems
problems
qualification and process
maintenance
maintenance
optimization in assembly and
facility
facility
maintenance handling
handling
Qualification
(ASB) PLS

GAB/
GAB/ TPM
TPM
PLS

worker „Tutor“
quality
quality checks
checks

standardization process optimization


(SAB) (Cycle Check)
assembly
assembly

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The New Engine Generation OM 47x:
A new Era in manufacturing internal combustion engines has started!
• With the New Engine Generation OM 47x we start into the next 125 years of automobiles.
• Strictest requirements to efficiency and sustainability are not just for the product, but also for production!
• With best processes and in highest precision we build the most efficient engine with outstanding technology
and quality.

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