Present a Tie Hermann Doppler Head of Global Engine Operations Daimler Trucks

Engine Presentation

“Innovation meets Production”Hermann Doppler

Head of Global Engine Operations Daimler Trucks

Mannheim, March 17, 2011

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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 PlantTrans Plant

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Global supplier management:

Holistic support of world-wide engine production

Global supplier management network with hubs in all regions

• 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

on site

AdvantagesAdvantages

Daimler-Production Site Supplier

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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!

Robot controlled core package assembly

• Core packages from ultrapure sand - grain of sand:

diameter 0,35 mm, tolerance 0,02 mm

Whether at casting ...

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Component engineering by casting simulation

• Prediction of component characteristics

during casting and solidification


• strength

• residual stress

• crystalline structure

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BIO-Radius

• Transformation of innovative designs in efficient production processes:

example: cylinder crankcase – bearing block connection with BIO-Radius

BIO-Radius even load allocation

classic groove


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… 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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Clinical cleanness

• Mannheim Illig-Value

is benchmark in automotive industry

example for „Illig-Values“

particle deposit = f (running track cleaning)



… or all other stations of the production process

Foto Mitarbeiter

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Our global production concept:

4 control loops assure quality in production

RK 1 RK 2 RK 3 RK 4

Product AuditProduct AuditInline Production Audit

Inline Production Audit

Worker self-check

Worker self-check Quality GatesQuality Gates

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• Highly qualified employees to handle most modern technology and innovative qualification methods, e.g. PLS:

Competence and Know-How:

Our employees as fundament of the success

PLSPLSPLS

assemblyassemblyassembly

quality checksquality checksquality checks

GAB/ TPMGAB/ TPMGAB/ TPM

facility

handling

facilityfacility

handlinghandling

problemsproblemsproblems

maintenancemaintenancemaintenance

worker

standardization

(SAB)

Qualification

(ASB)

process optimization

(Cycle Check)

PLSPLSPLS

„Tutor“

Concept for standardization,

qualification and process

optimization in assembly and maintenance

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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.

Present a Tie Hermann Doppler Head of Global Engine Operations Daimler Trucks

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