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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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The most efficient engine with the best technology requires:
Best production processes and highest precision!
Component engineering by casting simulation
• Prediction of component characteristics
during casting and solidification
Whether at casting ...
• strength
• residual stress
• crystalline structure
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The most efficient engine with the best technology requires:
Best production processes and highest precision!
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
Whether at casting ...
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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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Clinical cleanness
• Mannheim Illig-Value
is benchmark in automotive industry
example for „Illig-Values“
particle deposit = f (running track cleaning)
The most efficient engine with the best technology requires:
Best production processes and highest precision!
… 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.
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