THE MOOD IS UPBEAT AND NO END IN SIGHT - Rheinmetall Automotive

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THE MOOD IS UPBEAT AND NO END IN SIGHT - Rheinmetall Automotive
www.kspg.com
                                       The magazine of the KSPG Group                         ISSUE 01/2015

                                             SLOWING DOWN
                                             ON TWO WHEELS
                                             Manfred Mäules’s heart belongs to an old Harley

                                             SPORT IS THE DRIVING FORCE
                                             Sponsoring and health management at KSPG

                                       // THE MOOD IS
                                            ­ PBEAT AND NO
                                            U
                                            END IN SIGHT
                                             China’s booming market

A Rheinmetall Company
THE MOOD IS UPBEAT AND NO END IN SIGHT - Rheinmetall Automotive
EDITORIAL/CONTENTS

                                                                                                                                       // CONTENTS
                             PASSIONATE                      WILD WORLD OF ENGINES                      NEWS FROM KSPG
                             DEVELOPERS
                                                         4                                          8
       Day by day our developers are busy working
                                                         Inspiration in steel By gondola over the   The latest news from the company
       on products that reduce emissions and con-
                                                         Nervión—the Vizcaya Bridge in Bilbao
      sumption, prolong engine life and help shed
vehicle weight. This passion for details, precision                                                     FOCUS
        and perfection is an essential aspect of our
 success story that stretches back over a century.
   Yet we don’t want to simply rest on our laurels.                                                 10
       Autonomous driving, alternative propulsion
     systems, networking, downsizing: terms that                                                     THE MOOD IS
                                                                                                    ­UPBEAT AND

                                                                                                                                                                                         26
    20 years ago seemed rather utopian, has now
 become reality. KSPG is already represented in a
        multitude of vehicles with alternative types                                                 NO END IN SIGHT                                                                                                      34

                                                                                       4
         of propulsion. These components are also
                                                                                                    China’s booming market                                                                                                A test drive with Olaf Hedden Head of
    relevant for the Chinese market. In China, too,
                                                                                                                                                                                                                          KSPG’s Mechatronics division
      which has the world’s steepest growth rates,
  efficient and eco-friendly solutions are much in
     demand. In discussing China, the main topic                                                                                                                                                                          37
         of this issue, we are taking a look at these.
                                                                                                                                                                                                                          It pays to hit the books A voyage of
        Heartbeat is presenting to you people from
                                                                                                                                                                                                                          ­discovery in the Far East
 various parts of KSPG such as basketball “giant”
   Marvin Kruchen and Pierburg CEO “test driver”
  Olaf Hedden. And you will learn more about our                                                                                          TECHNOLOGY                               PEOPLE                                    GOOD TO KNOW
          social and local community commitments
     in the article about our sponsoring activities.
                                                                                                                                       16                                       22                                        38
                                      Enjoy your read!
                                                                                                                                       New generation of plain bearing          Milliseconds for cleaner air In China,     A megacity with a traditional soul
                                                                                                                                       partners: metal and polymer Marriage     PhD student Yintong Liu is researching     ­Shanghai—from tiny fishing village to
                                                                                                                                       of convenience                           into more efficient and cleaner engines   ­teeming metropolis

                                     Peter Hartung                                                                                     18                                       26
                              Senior Vice President
                                                                                                                                       Inside StreetScooter KSPG technology     Slowing down on two wheels Manfred
                         Corporate Communications
                                                                                                                                       helps deliver letters and parcels        Mäules’s heart belongs to an old Harley
                                                                                                                                       with the battery-powered StreetScooter
// IMPRINT                                                                                                                                                                      30
Published by: KSPG AG—A Rheinmetall Company                                                                                               HIGHLIGHTS                            From dribbling to controlling
Karl-Schmidt-Strasse, D-74172 Neckarsulm, www.kspg.com
Responsible: Peter Hartung, Folke Heyer
                                                                                                                                                                                Marvin Kruchen talks about discipline
Edited by: Folke Heyer, Marco Kittel, Markus Koch,
Philipp Mattheis, Bernhard Schenk, Stefan Schlott,
                                                                                                                                       20                                       and team spirit

                                                                                                             10
Ulrike Volkmann, Stefanie Wesslein                                                                                                     Innovations by Kolbenschmidt and
                                                                                                                                                                                32
                                                                                                                                                                                                                          34
Implementation: RTS Rieger Team Werbeagentur GmbH,
                                                                                                                                       ­Pierburg
Publik. Agentur für Kommunikation GmbH
Picture Credits: KSPG, Getty Images, Shutterstock,                                                                                                                              Sport is the driving force Sponsoring
StreetScooter GmbH/Deutsche Post DHL, Team AutoArenA
Motorsport, Dwight Cendrowski, Memo Filiz,
                                                                                                                                                                                and health management at KSPG
Kay Herschelmann, Karl-Heinz Leitz, Hartmut Oehmen,
Giovanni Perna, Michael Rennertz, Jan Siefke, Private

2            HEARTBEAT                                                                                                                                                                                                                                              3
THE MOOD IS UPBEAT AND NO END IN SIGHT - Rheinmetall Automotive
WILD WORLD OF ENGINES

// INSPIRATION
          IN STEEL
                 By gondola over the Nervión—the Vizcaya Bridge in Bilbao

                                                                            Because of its spectacular esthetics and trend-
                                                                            setting technology, UNESCO added it to the
                                                                            World Cultural Heritage list on July 13, 2006.

4    HEARTBEAT                                                                                                                5
THE MOOD IS UPBEAT AND NO END IN SIGHT - Rheinmetall Automotive
Steel frame structure modeled on
                the Eiffel Tower in Paris. The architect
                  Palacio was a student of renowned
                                         Gustave Eiffel.   You never know where you’re going                The task facing architect Alberto de     towers supporting the two ends of a 160 m        fully integrated in the city’s transport system
                                                                                                     Palacio y Elissague was anything but simple.    long girder truss. Suspended from it on steel    and saves travelers a 20 km detour on the
                                                           to find drives next. In this case, a      It was his job to join the Bilbao communities   ropes is a gondola that crosses the river        freeway. The gondola carrying up to six cars
                                                                                                     of Portugalete and Getxo separated by the       without disrupting passing ships. This stroke    and 200 foot passengers runs at 8 minute
                                                           remarkable twelve motors can be found     Nervión River that meanders from the interior   of genius served as a model worldwide and        ­intervals, with a trip costing 35 cents. The
                                                                                                     of the country into the Bay of Biscay. While    stimulated a boom in Spanish technology           gondola was originally driven by a steam
                                                           in a UNESCO World Cultural Heritage       serving as an important traffic link in the     abroad. The Bizkaiko Zubia, as it is known        engine, but today the required power comes
                                                                                                     city, the bridge was not to disrupt shipping.   in Basque, has been the inspiration for 20        from twelve electric motors. A few years back,
                                                           monument—making it one you can not        Long approach ramps that would scar the          such bridges in Africa, America and Europe.      the bridge operator introduced a new attrac-
                                                                                                     townscape were also out of the question.                                                          tion when the panorama footbridge via the
                                                           only admire, but also ride on. To the     But the Basque architect solved the problem     Beautiful and functional                          girder truss was opened by former King Juan
                                                                                                     with bravura. As a student of the famous        The Vizcaya Bridge was justifiably included       ­Carlos and his wife Sophia in 1999. Those
                                                           joy of locals and tourists, the Vizcaya   Gustave Eiffel, he was fully conversant with    in the UNESCO World Cultural Heritage list         with a head for heights take an elevator up
                                                                                                     the construction of steel frames. Palacio’s     in 2006 and is Bilbao’s pride and joy. It is       the tower to the walkway across the steel
                                                           Bridge in Bilbao is still going strong    masterpiece, the world’s first transporter      important for Bilbao’s population not only as      girder truss. Ideal for enjoying the sunset over
                                                                                                     bridge, was officially opened in 1893. On the   a cultural monument, but also as a means           the city and its port or for looking down at
                                                           122 years after its construction.         shores of the Nervión stand 45 m tall steel     of transport. The bridge, even today, is still     passing ships from a breath-taking height.

                                                                                                                                                                                                      The gondola and the steel rope system
                                                                                                                                                                                                      make it possible to carry a weight of up to
                                                                                                                                                                                                      22 t across the river.

                                                                                                                 UNESCO
                                                                                                     WORLD CULTURAL HERITAGE
6   HEARTBEAT
THE MOOD IS UPBEAT AND NO END IN SIGHT - Rheinmetall Automotive
NEWS FROM KSPG

                                                                                                                                                                                                                                             PERSONNEL
PRODUCTION UP AND RUNNING
AT THE NEW PIERBURG PLANT                                                                        16,500
                                                                                            KS Gleitlager
                                                                                                                                  sqm         KS GLEITLAGER GMBH
                                                                                                                                                                                                                                             KSSP UNDER NEW
                                                                                                                                                                                                                                             MANAGEMENT IN CHINA

                                                                                                                                              BUILDS NEW
                                                                                            factory in Supa

                                                                                                                                              PLANT IN INDIA
                                                                                                      Over    100             languages,
                                                                                                              23 of them official                                                            The plain bearings unit, KS Gleitlager, is
                                                                                                                                                                                             setting up a new modern plant this year
                                                                                                                                                                                                                                             Since March 1, Ralf Buschbeck has been
                                                                                                                                                                                                                                             General Manager at Kolbenschmidt
                                                                                                                                                                                             in Supa, India, some 75 km to the east of       Shanghai Piston (KSSP) in Shanghai,
                                                                                                                                                                                             Pune, population of around 3 million, in the    China. He succeeds Wen Jiang who
Production at the new Pierburg plant in Neuss has started up successfully                                                                                                                    federal state of Maharashtra. The foundation    is taking on new responsibilities for the

                                                                                       1.252
and meanwhile almost all of the employees from the previous Neuss and                                                                                                                        stone was laid on January 28 and before the     future organization of the China orga-
Nettetal plants have migrated here. The move will have been completed                                                                                                                        end of the year it is planned to complete       nization of the KSPG Group. Previously,
mid-2015. After a construction period of only 1 year and starting from the                                          billion                                                                  construction of the 16,500 m² factory. Em-      Buschbeck had been in charge of Prod-
spring of 2014, the production machinery from Neuss and Nettetal was                              people in India                                                                            ployees and equipment from the previous         uct and Technology Development of the
shipped step by step to the new Lower Rhine plant to be reinstalled. Con-                                                                                                                    plant in Ahmednagar, located not far away,      Pistons division with R&D locations in
currently, the ultramodern high-bay warehouse was commissioned. Next                                                                                                                         will then move into the new premises. This      Japan, China, Germany, USA, and Brazil.
on the movers’ list was the finish-machining shop. Right from the planning                                                                                                                   ultra­modern production facility will allow     KSSP is a 50/50 joint venture between
phase of the construction project Pierburg had set its sights on certifica-                                                                                                                  KS Gleitlager to re-emphasize its presence      KS Kolbenschmidt GmbH and HUAYU Au-
tion to DGNB Silver (German Sustainable Building Council). This latter sets                                                                                                                  on the important growth market of India.        tomotive Systems Co., Ltd. The company
­stringent criteria when awarding its certificates and Lower Rhine is very                                                                                                                                                                   was established in 1997. Annual ship-
 likely the first production plant with a foundry to have received certification.                                                                                                                                                            ments this year will be around 27 million
                                                                                                                                                                                                                                             piston modules.

                                                                                                                                              REWARDS FOR QUALITY EXCELLENCE
MORE SPACE AT NEUENSTADT                                                                                                                      BY PIERBURG
                                                                                                                                                                                                                                             DIETER SCHADENBERGER
                                                                                                                                              Pierburg, the KSPG Group’s Mechatronics        suppliers. Pierburg’s pump plant in Hartha,
Motorservice’s Neuenstadt location is busy building: the present offices
                                                                                                                                              division, is doubly happy to have received     Saxony, likewise has reason to be proud of
                                                                                                                                                                                                                                             MOVES TO SHANGHAI
are being topped up to add space for 30 new jobs. The Logistics depart-
                                                                                                                                              two customer awards. The Czech plant,          having pocketed the coveted Ford Q1 Award.
ment is also being remodeled: a new automated small-parts warehouse
                                                                                                                                              Pierburg, s.r.o., was recently presented the   Presented annually since 1981, this is Ford’s
is designed to shorten the order-picking times, allow more efficient space
                                                                                                                                              General Motors Supplier Quality Excellence     highest recognition and appreciation of
utilization and generally leaner logistics processes. Work on the office
                                                                                                                                              Award for exceptional product and delivery     supplier quality. Pierburg Hartha thus joins
building started in March, completion is scheduled for October. The con-
                                                                                                                                              quality of its solenoid valves, exhaust-gas    the US plant in Fountain Inn/South Carolina,
struction of the new warehouse will begin in September and the building
                                                                                                                                              flaps, and secondary-air pumps. This was       the Mexican piston and pump plant in Cel-
will be up and running as from January 2016.
                                                                                                                                              the third time that the Supplier Quality       aya and KSPG in India among those having
                                                                                    KSPG AND HASCO:                                           Excellence Award has gone to outstanding       earned this prestigious distinction.
                                                                                    JOINT VENTURE NOW
                                                                                    LEGALLY CONSUMMATED                                                                                                                                      Since March 1, Dieter Schadenberger
                                                                                                                                                                                                                                             has stepped into the position of Director
                                                                                    Following the signing of the agreement between KSPG                                                                                                      Finance and Controlling (CFO) at Kolben-
                                                                                    and HUAYU Automotive Systems Co., Ltd. (HASCO), a                                                                                                        schmidt Shanghai Piston (KSSP). Previ-
                                                                                    member of China’s SAIC Group, the o.k. to the venture                                                                                                    ously he had been CFO at the Castings
                                                                                    has now been given by the relevant cartel authorities                                                                                                    division and on the Management Board
                                                                                    and hence the transaction was legally consummated.                                                                                                       of KS HUAYU AluTech GmbH, a Joint
                                                                                    Each party has a 50-percent stake in the new company                                                                                                     Venture between KSPG AG und HUAYU
                                                                                    whose name is KS HUAYU AluTech GmbH and in                                                                                                               Automotive Systems Co., Ltd. (HASCO)
                                                                                    Werk­zeugbau Walldürn GmbH, which belongs to it,                                                                                                         which is majority owned by the Chinese
                                                                                    as well as in the 50-percent stake in the joint venture                                                                                                  SAIC Group. Since 2005, Schadenberger
                                                                                    KS ATAG TRIMET Guss GmbH.                                                                                                                                has served in various positions at the
                                                                                                                                                                                                                                             KSPG Group.

8        HEARTBEAT                                                                                                                                                                                                                                                                   9
THE MOOD IS UPBEAT AND NO END IN SIGHT - Rheinmetall Automotive
FOCUS

                                          The Chinese automobile market has kept the
                                          industry on the edge of its seat for several years

// THE MOOD
                                          now. Dynamism and double-digit growth are its twin
                                          hallmarks. For KSPG, too, investing in China has
                                          long since paid off. Last year alone, sales jumped
                                          by 30 percent, well above the industry average.

           IS UPBEAT                            When it comes to the Chinese auto mar-
                                          ket, journalists, commentators and analysts
                                          understandably turn to super­latives. They
                                          call it the engine of growth for the entire
                                                                                         Volkswagen Automotive Company Ltd.
                                                                                         (SVW) paved the way for motorizing Chinese
                                                                                         ­society. Until then, the bicycle ruled the
                                                                                          road in China. Then came a period when

           AND NO END
                                          industry, the world’s most important car        car buyers in China had a choice between a
                                          market—and a profit-spinner for the German      VW Santana and a VW Santana.
                                          automotive sector. And the numbers cer-
                                          tainly support these statements. “Auto­            IN RAPID ­SUCCESSION,
                                          motive sales in China went into high gear:
                                          2013 over 16 million new cars were sold in
                                                                                             AUTOMAKERS AND
                                          the People’s Republic—weaker economic              PARTS SUPPLIERS
                                          growth notwithstanding, car sales in China

           IN SIGHT
                                          rose by a brisk 23 percent, making it the
                                                                                             HAVE BEEN REPORTING
                                          world’s largest single market in terms of         ­RECORD FIGURES
                                          volume”, writes the German Association of
                                          the Automotive Industry (VDA) in its latest    The pioneering success of SVW did not go
                                          “Markt international” analysis. Based on       unnoticed. Before long, flights between
                                          preliminary figures, sales in 2014 are sup-    Chinese cities and western centers of the
                                          posed to have reached 18.4 million units,      auto industry were booked solid. One after
                                          while the forecast for this year points to a   another, original equipment makers and
                                          further increase approaching 20 million.       their suppliers announced new joint ven-
                                          In order to comprehend the dynamic expan-      tures, plant openings—and record-breaking
                 China’s booming market   sion of the automotive industry in China,      figures. By the turn of the century, the former
                                          it’s important to look at recent history. It   bastion of the bicycle had wholeheartedly
                                          was only 31 years ago in 1984 that China       embraced the automobile, its roads suddenly
                                          began to open up and reform its economy.       crowded, hectic and loud. Frenetic honking,
                                          The founding of the joint venture Shanghai-­   lane changing without signaling, passing

10   HEARTBEAT                                                                                                                       11
THE MOOD IS UPBEAT AND NO END IN SIGHT - Rheinmetall Automotive
KSPG IN CHINA

                                                                                                                                        PRODUCTION:
                                                                                                                                        Pistons, exhaust gas recycling
                                                                                                                                        valves, throttle valves, coolant
                                                                                                                                        and oil pumps, cylinder heads
                        TOTAL SALES*:                                                                                                   for cars**, aluminum structural
                                                                                                                                        parts and engine blocks
                        €680 MILLION
                                                                                                                                        ** largest producer in China
                        * joint ventures at 100%

                                                             NUMBER OF LOCATIONS: 9
                                                             (joint ventures and wholly owned subsidiaries)

RATE OF GROWTH,                                                                                               PRESENT IN THE MARKET
YEAR ON YEAR: +30%                                                                                            SINCE THE ’80s

wherever there’s room, and countless pe-                  of rapidly multiplying mega traffic jams and        In addition, with incomes on the rise and car
destrians in the middle of the road are now               a road system that’s often groaning under           density still lower, new automobile sales are
par for the course in China—all of which can              the strain. At the very least, this is certainly    being driven by increased demand in C   ­ hina’s
be quite a shock for western visitors. The at             true of the metropolises in the country’s           cities of the third and fourth rank. Many
times anarchic free-for-all on the highways of            northeast. In the meantime, the regional            observers compare modern China to West
the People’s Republic is a result of China’s              authorities there are attempting to get a grip      ­Germany in the ’50s and ’60s: a self-con-
car ownership boom, which is unparalleled                 on the situation by introducing limits on new        sciously hard-working, dynamic, ambitious,
anywhere and shows no sign of slowing.                    car registrations, etc. China’s automotive in-       highly motivated nation with rising aspira-                 company took the daring step of cooperating      owned subsidiary of Shanghai Automo-             ­ bsolescent technologies with low value
                                                                                                                                                                                                                                                                             o
Indeed, in 2015 the desire to own a car is as             dustry is currently experiencing a shift in its      tions. In post-war Germany, too, consumers                  with a Chinese partner, Shanghai Piston          tive Industry Corporation (SAIC), to set up      added, including simple die cast compo-
strong as ever in China—this despite reports              center of gravity toward the south and west.         were initially happy with vehicles like the                 Factory. At the start of 1989, a complete        the joint venture Kolbenschmidt Pierburg         nents and intake manifolds, focusing instead
                                                                                                               Messerschmitt Kabinenroller, the Opel                       piston manufacturing facility was shipped        Shanghai Nonferrous Components (KPSNC).          on future-oriented products such as pres-
                                                                                                               Laubfrosch or the Goggomobil, which at least                to China, where it was installed in a newly      KPSNC develops, produces and markets             sure-cast aluminum engine blocks, alumi-
                                                                                                               provided them with individual mobility.                     built plant in Shanghai. Pierburg too secured    suction modules, cylinder heads, steering        num wheel rims, structural and chassis parts
                                                                                                                                                                           a foothold in China by moving an entire          components as well as complete oil and           along with other advanced components.
                                                                                                                  KSPG HAS BEEN                                            factory there: when European emission            water pumps.                                     This period also witnessed KSPG’s endow-
                                                                                                                                                                           regulations put an end to the carburetor era                                                      ment of a professorial chair for automotive
                                                                                                                  ACTIVE IN CHINA                                          in Germany, it found a new lease on life in      Sales double in the space of a few years         technology at Tongji University in Shanghai,
                                                                                                                  SINCE THE ’80s                                           China. The People’s Republic entered into        In this phase of the Group’s entry into China,   whose current incumbent is the long serving
                                                                                                                                                                           an agreement with state-owned automaker          which lasted until the start of 2005, the main   vice dean of the Institute for Mechanical
                                                                                                              As car ownership gradually became some-                      First Automobile Works (FAW) for the sale of     challenge was to get production up and           Engineering, Prof. Dr. Liguang Li (see short
                                                                                                              thing to take for granted, expectations rose                 large-scale series production equipment for      running and to create structures. Moreover,      interview). Establishing two wholly owned
                                                                                                              with regard to dependability, performance                    2E carburetors, which were supplied to FAW       the first employees had to be initiated into     subsidiaries in China was another aspect of
                                                                                                              and comfort. In the phase that followed,                     in Changchun at the end of 1992. Five years      KSPG’s culture of quality. The reward for        the second of phase of KSPG’s entry into the
                                                                                                              the focus shifted to safety as well as fuel                  later, things really took off. Partnering with   these efforts: in 2005 the two new joint ven-    Chinese market. MS Motor Service Shang-
                                                                                                              efficiency and lower emissions, though                       Deutsche Entwicklungsgesellschaft (DEG,          tures generated sales of € 80 million. Eager     hai Trading Co. Ltd., the first wholly owned
                                                                                                              consumers also expected to see simultane-                    the German Development and Investment            to build on this, between 2005 and 2009          subsidiary of KSPG AG in China, was founded
                                                                                                              ous improvements in other areas. Against                     Corporation) and the previous licensee,          KSPG continued to invest in further growth.      in 2008, emerging from the Representative
                                                                                                              this backdrop, it is easy to understand how                  Shanghai Piston Works (SPW), in July 1997        At the same time, it became necessary to         Office established in 2007 in the free trade
                                                                                                              KSPG – with its comprehensive array of                       Kolbenschmidt became the first major piston      automate parts of the production process in      zone in northeast Shanghai. The following
                                                                                                              lightweight parts and emission reduction                     producer to be present in China in a joint       order to boost output. The creation of new       year saw the creation of Pierburg China Ltd.
                                                                                                              solutions – has been so successful in China.                 venture. In 2001 Pierburg followed suit and      production capacities went hand in hand          in Kunshan. A further glance at the num-
                                                                                                              As early as the second half of the ’80s,                     joined forces with Shanghai Automobile           with changes in the product range. The joint     bers reveals just how quickly investments
                                                                                                              management of the then-Kolbenschmidt                         Nonferrous Casting Plant (SANCP), a wholly       venture partners jettisoned obsolete and         in China can pay off. By 2009, sales had

The secret of KSPG’s success in the Middle Kingdom: our people.

12        HEARTBEAT                                                                                                                                                                                                                                                                                                   13
THE MOOD IS UPBEAT AND NO END IN SIGHT - Rheinmetall Automotive
Increasingly significant: Components for
                                                                reducing emissions are becoming more
                                                             and more important in the Chinese market.

                                                                                                                                                                                           Inquired!
                                                                                                                                                                                                                              and other market factors are the large        // Is the implementation of connected
                                                                                                                                                                                                                              financial incentives from both central and    cars or autonomous driving systems also
                                                                                                                                                                                                                              local government. Nonetheless, invest-        being discussed in your country?
                                                                                                                                                                                                                              ments are tied to heavy financial risks as    This is a hot topic in China and lots of
                                                                                                                                                                                                                              batteries and related areas are attracting    research institutes, universities and
                                                                                                                                                                                                                              large sums of money, especially since         OEM’s Research & Development Centers
                                                                                                                                                                                                                              the Internet companies are planning and       are involved in this topic and research
                                                                                                                                                                                                                              actually investing in this area. Because      programs. Some of the research over the
reached €160 million, double the figure for        dedicated to manufacturing and marketing                                                                                                                                   of the challenges posed by the driving        next 5 to 10 years is focusing on various
2005. Events continue to proceed apace.            pumps. In order to create customer-specific                                                                                                                                distances and the high costs involved it      product dimensions and levels. However,
After 2009, the Group pursued a policy of          applications on location, this joint venture is                                                                                                                            is hard to forecast the BEV market over       these are subjects of very high safety
consolidating what it had already achieved,        also equipped with a test bed and prototype                                                                                                                                the next five years. Financial support from   concern and at present there are no cor-
widening its lead, diversifying its product        center for developing new applications.                                                                                                                                    government will stop in 2020 and so the       responding laws, either in China or else-
range and building new plants—all aimed at                                                                                                                                                                                    next five years will be critical in showing   where in the world. So, before discussing
further strengthening its powerful position            KSPG LEADS THE WAY                                                                                                                                                     whether BEVs can survive without govern-      any relevant legislation it is hard to say
in the market. As part of this strategy, at the                                                                                                                                                                               ment aid.                                     when and how this technology will be
end of 2012 the Group opened KSPG House
                                                       IN CHINA IN LIGHT-                                                                                                                                                                                                   applied. If and when it is, it will certainly
in Shanghai, which serves as the head office           WEIGHT ENGINEERING                                                                                                                                                     // What about fuel-cell cars compared         lead to another revolution in automobile
for its wholly owned Chinese subsidiaries and                                                                                                                                  Prof. Ph.D. Liguang Li                         to BEVs in China?                             driving mode.
as an initial point of contact for all customers   In November 2013 a new large pistons factory           used for casting and processing aluminum                             Executive Vice Dean, College of Mechanical     At present there is no sign of FCVs
                                                                                                                                                                               Engineering, Tongji University
in China. In 2013 a new production facility        went into operation at Shanghai. And in                engine blocks and cylinder heads, which                                                                             entering the market before 2020. FCVs
was built for Pierburg China Ltd., which           March 2014 the Group’s longstanding                    already takes place at its sister plant across                                                                      face many more challenges even though
produces pneumatic pumps, electric throttle        cooperation with SAIC subsidiary HASCO                 the street, or at facilities in Waigang,                                                                            ­Toyota has launched such vehicles
valves and magnetic valves. A few months           ­expanded to include another new produc-               Kunshan and Yantai. This plant marks the                             // What are China’s major emission-­            onto the market. There is a shortage of
later, another plant followed—a joint venture       tion facility. The new plant won’t just be            launch of a new product segment in the                               reduction challenges?                           hydrogen supply and other infrastructure
                                                                                                          increasingly important field of lightweight                          For passenger cars, to comply with Euro 6       facilities and so these cars will not be
                                                                                                          automotive ­engineering. In the future, alumi-                       or newer regulations by 2018 or later. The      among the market players before about
                                                                                                          num structural components will be cast and                           biggest challenge, however, is to arrive at     2025. Later by 2030 or 2050, they may
                                                                                                          processed here for the Chinese automobile                            a fuel consumption goal of 5 L/100 km by        become reality depending on CO2 limits
                                                                                                          industry. “This makes us one of the first                            2020. Regarding commercial vehicles, a          and adequate supplies of low-price H2.
                                                                                                          companies in China to offer our customers                            severe challenge will be to meet Euro 5 or
                                                                                                          ­additional weight-saving potential in auto-                         newer emission control limits.
                                                                                                           mobile design thanks to this forward-looking
                                                                                                           approach, which in turn helps to protect                            // What is the present market situation
                                                                                                           the environment”, declared Horst Binnig,                            for hybrid propulsion systems in passen-
                                                                                                           Chairman of the Executive Board of KSPG                             ger cars in China?
                                                                                                           at the opening ceremony, underscoring the                           Because of consumption reduction pres-
                                                                                                           importance of the new facility.                                     sure future production will increasingly
                                                                                                                                                                               feature hybrid propulsion—from mild
                                                                                                          Cooperation benefits Europe, too                                     hybrid with start/stop to plug-in systems.
                                                                                                          Incidentally, early commitment and a                                 HEV will become more popular over the
                                                                                                          sound working relationship with Chinese                              next decade.
                                                                                                          partners have benefitted KSPG outside of
                                                                                                          China as well. At the Group’s headquarters                           // Do you see a relevant market for
                                                                                                          in Neckarsulm, Germany, a joint venture                              battery electric vehicles (BEVs) in China
                                                                                                          company was founded in summer 2014 with                              within the next five years?
                                                                                                          its longstanding partner HASCO. The mutual                           It is very hard to predict the market for
                                                                                                          goal of the two partners, each of which has                          BEVs in China in the next five years. In
                                                                                                          an equal stake in the new company, is to                             2014, there were about 37,500 p   ­ assenger
                                                                                                          promote the current positive trend in cast                           and bus BEVs produced plus other
                                                                                                                                                           By Stefan Schlott

                                                                                                          lightweight ­automotive components on an                             low-speed micro passenger BEVs with
                                                                                                          enduring global basis. Global in this context                        lead-acid batteries, giving a total of
                                                                                                          doesn’t just mean China and Germany, but                             some 183,000 in the Shandong province.
                                                                                                          all relevant triad markets.                                          Driving distances are still an issue there

14       HEARTBEAT                                                                                                                                                                                                                                                                                                          15
THE MOOD IS UPBEAT AND NO END IN SIGHT - Rheinmetall Automotive
TECHNOLOGY

 //NEW GENERATION
       OF PLAIN BEARING
       PARTNERS: METAL                                                                                                                                                                                                              Friction reduction across the entire engine
                                                                                                                                                                                                                                    speed range

       AND POLYMER
                                                                                                                                                                                                                                    Among the prime objectives in the devel-
                                                                                                                                                                                                                                    opment of KS R55Q was to reduce crank-
                                                                                                                                                                                                                                    shaft-related friction and wear. Especially
                                                                                                                                                                                                                                    low engine speeds and low-viscosity oils
                                                                                                                                                                                                                                    lead to critical mixed-friction conditions
                                                                                                                                                                                                                                    while new operating strategies for cutting
                                                                                                                                                                                                                                    back fuel consumption considerably in-
            Marriage of convenience                                                                                                                                                                                                 crease the number of start/stop cycles com-
                                                                                                                                                                                                                                    pared with conventional modes. Counteract-
                                                                                                                                                                                                                                    ing these are the wear-abating fillers of the
                                                                                                                                                                                                                                    polymer layer combined with the high wear
                                                                                                                                                                                                                                    resilience of the bearing metal. The special
        Until now bi-material bearing metals were largely left                                                                                                                                                                      feature of the new generation of bearings
                                                                                                                                                                                                                                    is, however, that this friction-reducing
        to themselves but on the new plain bearing generation                                                                                                                                                                       effect is not limited to lower engine speeds.
                                                                                                                                                                                                                                    “We are especially proud that despite the
        KS R55Q, metal and polymer act as the perfect couple.                                                                                                                                                                       polymer layer we have been able to retain
                                                                                                                                                                                                                                    the hydrodynamically advantageous grooved
        With the new technology from Kolbenschmidt engines run                                                                                                                                                                      texture of the spindled contact surface,”
                                                                                                                                 A closer look reveals a high-tech product.                                                         emphasizes Jens Reepmeyer, project engi-
        more efficiently and CO2 emissions are reduced.                                                                          It may not be easy to see, but plain bearings
                                                                                                                                 are the product of a massive R&D effort and
                                                                                                                                                                                                                                    neer who has introduced the new coating
                                                                                                                                                                                                                                    technology at Kolbenschmidt. “Even at low
                                                                                                                                 state-of-the-art manufacturing techniques.
                                                                                                                                                                                                                                    engine speeds we can now ensure minimum
                                                                                                                                                                                                                                    hydrodynamic losses.”
                                     Lowering average CO2 emissions in        metal and hence the counterpart to the                                                                20 percent added resilience
                               their car fleets to 95 g/km by 2020 is a       shaft,” explains Dr. Klaus Pucher, head of                                                            “The bearing metal we use is our own propri-
                                                                                                                                                                                                                                       THE CONTACT SUR­-
                               prime objective of European automakers.        R&D at KS Gleitlager GmbH.                                                        Steel back
                                                                                                                                                                           in   g   etary silicon-enriched aluminum alloy that         FACE HAS BEEN IN
                               To achieve this, they are moving in various                                                                                                          is both highly resilient and extremely wear
                               directions with regard to engine technolo-                                                                                AISnSi be                  resistant,” says Pucher. Sprayed onto this
                                                                                                                                                                                                                                       SERIES PRODUCTION
                               gy: from downsizing and the use of lower
                                                                                  ADAPTABILITY,                                                                      aring met
                                                                                                                                                                              al
                                                                                                                                                                                    is a layer of polymer made up of a tempera-        SINCE MID-2014 AND
                               and lower viscosity oils and employing             WEAR RESISTANCE AND,                                                Polymer
                                                                                                                                                                contact
                                                                                                                                                                                    ture- and fluid-resistant polyamide resin
                                                                                                                                                                                                                                       MARKET RESPONSE
                               new running strategies such as start/stop                                                                                                  surface   comprising a generous proportion of fillers
                               and cruising, right through to fully hybrid
                                                                                  AT THE SAME TIME,                                                                                 for reducing friction and wear. To this end,       HAS BEEN GOOD
                               power trains. The crankshaft main bearings         THE ABILITY TO AB-                                                                                Kolbenschmidt applies a special coating
                               and the connecting rod bearings play an                                                                                                              process whose precision largely determines      Because of its high resilience, wear resis-
                               important role in this context. Thanks to
                                                                                  SORB PUNISHMENT—                                                                                  optimum bearing functions within the en-        tance and ruggedness it is now being tried
                               the KS R55Q, its new generation of plain           THESE ARE THREE                                                                                   gine. “The outcome of this marriage of metal    out on light- to medium-duty commercial
                               bearings, ­Kolbenschmidt is helping OEMs                                                                                                             and polymer: 20 percent greater resilience      vehicle engines. Pucher identifies vast
                               move closer to achieving the new CO2 limits.
                                                                                  VERY CONTRASTING                                                                                  over conventional bi-material bearings. A big   potential for polymer layers on engine plain
                               “Until now aluminum alloys have mainly            ­REQUIREMENTS                                                                                      step in the right direction since the added     bearings. “Our aim is to develop further
                               been used on bi-material bearings as the                                                                                                             resilience helps our customers both in their    products on the basis of the technology first
                               bearing or contact metal. Since the steel      Kolbenschmidt’s answer is to give KS R55Q                                                             systematic downsizing efforts and in dimen-     used on the KS R55Q to allow customers
                               backing simply serves as the seat within the   an extra polymer contact surface so that the   Current plant capacity                                 sioning for optimum friction effect both the    to maximize engine efficiency and perfor-
                               housing, it is left to the aluminum alloy to   bearing metal and the polymer layer can take                                                          main and connecting rod bearings,” says the     mance, ideally merging the two on future
                               do all the work, acting as the anti-friction   over complementary functions.                  per year:                                              Head of R&D.                                    engine generations!”

16   HEARTBEAT

                                                                                                                             6 million units                                                                                                                                   17
THE MOOD IS UPBEAT AND NO END IN SIGHT - Rheinmetall Automotive
TECHNOLOGY

                                                                                                                                                                                                                                 ment services provider, FEV GmbH, is (as yet)
                                                                                                                                                                                                                                 powered by a 2-cylinder gasoline engine in
                                                                                                                                                                                                                                 V design which is installed as a pre-assem-
                                                                                                                                                                                                                                 bled module. This makes it relatively easy to
                                                                                                                                                                                                                                 be integrated via just a few interfaces into
                                                                                                                                                                                                                                 StreetScooter Work and other vehicles of this
                                                                                                                                                                                                                                 type. The extender also permits installation
                                                                                                                                                                                                                                 of a smaller, less costly lithium-ion battery.
                                                                                                                                                                                      Battery powered with extended range.
                                                                                                                                                                                    The universally installable unit reduces
                                                                                                                                                                                 battery costs and size while adapting readily      DEVELOPMENT WORK
                                                                                                                                                                             to any operating mode.
                                                                                                                                                                                                                                    GOES ON: THE RANGE
                                                                                                                                                                                                                                    EXTENDER WILL SOON
                                                                Easy on nature and easy to operate: letters and parcels         If the term “scooter” conjures up the     delivery. Deutsche Post DHL had commis-
                                                                                                                                                                                                                                    BE RUNNING ON

// INSIDE
                                                                              delivered by electric vehicle and bicycle.   funfair you’re not far off. Amusement park     sioned the Aachen-based engineers to                      BIOGAS METHANE
                                                                                                                           rides normally use electric autos and the      develop a compact battery electric ­vehicle
                                                                                                                           StreetScooter fleet is battery powered when    for delivering letters and parcels. Job de-            As part of a combined Green Rex project,
                                                                                                                           working as a mail and package carrier. The     scription: on duty up to 300 days a year, up           KSPG and FEV have joined up with the
                                                                                                                           inventor is StreetScooter GmbH, a spin-off     to 200 stop/re-start cycles a day, enough              research institute Fraunhofer ICT to develop

       STREETSCOOTER
                                                                                                                           from a project at RWTH Aachen university       loading space, robust, and safe. Meanwhile             a natural-gas powered range extender that
                                                                                                                           headed by Prof. Dr.-.Ing. Achim Kampker.       over 50 StreetScooter Work units are on de-            made its debut at the commercial vehicle
                                                                                                                           Since mid-2010, the ingenious innovators       livery duty throughout Germany. At the start           fair IAA Hannover in 2014. A power unit that
                                                                                                                           have been re-inventing urban mobility and      of 2015, the Aachen-based company was                  uses biogas methane instead of normal
                                                                                                                           come up with a unique vehicular concept:       taken over by Deutsche Post DHL.During the             fuel, is likely (when) to undergo testing in
                                                                                                                           reasonably priced electric vehicles engi-      design phase, not just environmental crite-            StreetScooter Work—one more step toward a
                                                                                                                           neered around an eco-friendly propulsion       ria were taken into account, but economic              lightweight commercial vehicle run on purely
                                                                                                                           system.                                        factors as well. This led the designers to             regenerative resources.
            KSPG technology helps deliver letters and parcels                                                                                                             opt for a modular lightweight construction
                                                                                                                              ELECTRIC, ENTER­                            to serve as the basis for the functional               Efficient heating and cooling
            with the battery-powered StreetScooter                                                                            PRISING, EFFICIENT:                         ­architecture, from which individually de-
                                                                                                                                                                           signed model variations could be derived in
                                                                                                                                                                                                                                 Likewise engineered as a compact plug-and-
                                                                                                                                                                                                                                 play system is the heater/cooler module
                                                                                                                              STREETSCOOTER                                an easy, cost-efficient manner. The flexible          being tested by KSPG and a number of
                                                                                                                                                                           design also allows damaged parts to be                customers. The innovation here is that
        Among the vehicles being used by Germany’s parcel service Deutsche Post                                               WORK IS THE COMPACT                          inexpensively replaced, while minimizing              existing equipment such as the propulsion
                                                                                                                              SOLUTION FOR                                 service and maintenance costs.                        unit and generator acts as heat sources. In
        DHL on urban services in the city of Bonn is a transporter from Aachener                                              HAULAGE DISTANCES                                                                                  summer, the module has a cooling effect
                                                                                                                                                                          Greater range thanks to KSPG                           and serves as a comfortable air conditioner.
        StreetScooter GmbH which has engineered its own version of electric-                                                  OF UP TO 80 KM                              There was still the mileage challenge and              Its high energy efficiency spares the battery
                                                                                                                                                                          in order to further prolong the distances trav-        and helps StreetScooter Work carry its letters
        propulsion vehicle. Combined with range extender unit and thermo module                                            The transporter version of the StreetScooter   elled between recharging, a range extender             and parcels to their destinations, quietly
                                                                                                                           fleet is named Work and that’s just what it    will in future be installed. The extender, a           humming to itself. The extended range is
        from KSPG the scooter’s range before recharging will become even greater.                                          does: act as a tool for “last mile” doorstep   joint effort between KSPG and the develop-             now 80 km.

18   HEARTBEAT                                                                                                                                                                                                                                                              19
HIGHLIGHTS

USA: COMPACT EGR VALVE FOR GASOLINE ENGINES                                                                                                                                                          75 MILLION EGR VALVES
TO GO INTO SERIES PRODUCTION                                                                                                                                                                         FROM THE BASQUE COUNTRY
                                                      Pierburg, international leader in the market     in the ongoing reduction of engine compart-                                                   The end of 2014 saw the 75 millionth exhaust-    and this is made possible with the specially
                                                      for diesel engine EGR systems, has devel-        ment space on present engine series. The                                                      gas recirculating valve (EGR) exiting the        developed low-pressure EGR valves. Pierburg
                                                      oped a compact EGR valve which can also          compact EGR valve is operated by a geared                                                     assembly line at Pierburg S.A. in Abadiano,      has a varied product lineup to achieve further
                                                      be used on gasoline engines. Starting from       DC motor and has a contactless Hall sensor                                                    Spain. Fueling the success of this emis-         emission and consumption reduction on
                                                      2016 it will be built at Pierburg’s South        for detecting valve position. Depending on                                                    sion-abating component have been the             present and future I.C. engines. Pierburg’s
                                                      Carolina facility for delivery to a notable US   customer wishes, it may feature electro-                                                      worldwide ever stricter emission stan-           newest model is an especially compact,
                                                      OEM. Ever since the early ’80s, exhaust-gas      magnetic protection and integrated water                                                      dards. As from Euro 4, cooled recirculating      low-weight product and since 2013 has been
                                                      recirculation valves have been employed          cooling. It is available in standalone, plug-in                                               exhaust gases have become increasingly           used on series-production models of a major
                                                      chiefly for emission control on diesel en-       as well as fully integrated cooler module                                                     necessary and for this purpose Pierburg          German OEM.
                                                      gines. Given their incremental fuel-savings      versions. The newly developed module will                                                     has come up with complete EGR modules
                                                      potential they are now also increasingly         enable Pierburg to further expand its posi-                                                   combining outstanding and lasting cooling
                                                      being adopted on and adapted to gasoline         tion on the North American market.                                                            performance with compact dimensions.
                                                      engines. With its relatively compact foot-                                                                                                     With the advent of Euro 6 an even higher
                                                      print, the newly developed valve plays a role                                                                                                  rate of exhaust-gas recirculation is required

LARGE ORDER
FOR TANDEM PUMPS
KSPG has been awarded by a notable US auto-
maker a series contract worth triple-digit million
dollars for a combined oil and vacuum (tandem)
pump. The pump is due to go into series produc-                                                                                                                                                                                                       Size comparison of old and
tion at the start of 2015 at Pierburg’s Mexican                                                                                                                                                                                                       new generation valves
plant at Celaya. This innovative product allows
fuel savings and reduced CO2 emissions. Both
the oil and vacuum pump as well as the related
drive components are engineered for especially                                             COPPER FOR
quiet operation. Another advantage of this de-
sign is the compact footprint which more readily
                                                                                           DRINKING WATER
allows installation where space is tight. The                                              SYSTEMS
vacuum pump permits parallel activation of two
circuits with differing levels of pressure. A sole-                                        Under the banner “Your Strong Supplier for
noid valve specifically developed by Pierburg for                                          Drinking Water Systems” KS Gleitlager GmbH
                                                                                                                                                                     Front:
hydraulic applications is used for controlling                                             exhibited mid-March at ISH, the world’s                       new 5th generation
the oil pump and allows it to operate according                                            leading trade fair for the Bathroom Experience,                   compact valve
to two performance curves.                                                                 Building, Energy, Air-conditioning Technolo-
                                                                                           gy, and Renewable Energies, proven copper
                                                                                           alloys as well as leadfree options for drinking
                                                                                                                                                                                                                 ANOTHER CAUSE FOR CELEBRATION:
                                                                                           water systems. Included was the leadfree                                                                              25 MILLION DIVERT-AIR VALVES
                                                                                           alloy Ecocast which the manufacturer has                                                         Back:
                                                                                           been the first in Europe to industrialize with                                     4th generation valve               One more record at the start of 2015, this time a record number of
                                                                                           the continuous casting p ­ rocess. The alloy has                                                                      divert-air valves, altogether 25 million, so far shipped out to customers.
                                                                                           been marketed since 2013 under license from                                                                           Back in 2004 Pierburg was the first in the world to commence series
                                                                                           Wieland-Werke AG and is included on the                                                                               production of a wholly new electric divert-air valve. On turbocharged
                                                                                           official recommen­dation list for drinking water                                                                      engines this device is indispensable in preventing unnecessary turbo­
                                                                                           systems of Germany’s Environmental Agency.                                                                            charger braking when the throttle suddenly closes and hence reducing
                                                                                           On its Frankfurt fair stand the company also                                                                          “turbo lag.” Divert-air valves are a standard product used by almost
                                                                                           displayed round and hollow bars and rods,                                                                             all the notable OEMs. Because of the downsizing trend, which has been
                                                                                           hexagonal and octagonal sections plus special                                                                         going on for years now, there is a rising demand for valves coupled with
                                                                                           shapes all continuously cast. Shown alongside                                                                         the need to repeatedly adapt to more and more sophisticated challenges.
                                                                                           these were finished customer products.                                                                                With its just developed fifth generation Pierburg is fit for the future.

20      HEARTBEAT                                                                                                                                                                                                                                                                                21
PEOPLE

// MILLISECONDS
         FOR CLEANER AIR
            In China, Ph.D. candidate Yintong Liu is investigating ways                                                                     In China’s megacities, traffic is in­
                                                                                                                                      creasing exponentially and air pollution

            of making engines cleaner and more efficient                                                                                       is one of the biggest problems.
                                                                                                                                             This makes the need for efficient,
                                                                                                                                      low-emission engines especially urgent.

         Yintong Liu’s life currently takes place behind armored glass.
         Not far from Shanghai and its multi-million population,
         for Liu everything revolves around his engine test bench and
         the goal of perfecting the gasoline engine.                                                                                                                                                                                           I’VE BEEN WORK-
                                                                                                                               At renowned Tongji University he is                  important, more and more companies are                     ING IN RESEARCH
                                                                                                                         carrying out experiments on a futuristic                   ­setting up their own R&D centers in China.
                                                                                                                         experimental engine fitted out with a host of               In fact, it is in R&D the Liu sees his personal           FOR THE PAST
                                                                                                                         colored measuring wires and cables. On the                  future. “For seven years now I have been
                                                                                                                         surface of the cylinder head cover are the                  looking into this subject,” he says. “This is             SEVEN YEARS
                                                                                                                         words “Pierburg UniValve” and “Tongji-Uni-                  what I would like to go on doing.”
                                                                                                                         versität.” Together with Pierburg of Neuss,
                                                                                                                         Germany, Liu has developed an engine with                  The KSPG workforce: more than 4,000 strong
                                                                                                                         a mechanical, fully variable valve train, which            China is booming. For 20 years now the
                                                                                                                         is dotted with dozens of sensors and fitted                economy of this vast nation has been
                                                                                                                         with the very latest instrumentation, now                  expanding at a rate of almost ten percent
                                                                                                                         being meticulously fine-tuned and measured                 annually. This growth has allowed millions
                                                                                                                         for performance here in China. Separated by                of Chinese to enjoy a life of new prosperi-
                                                                                                                         the protective screen and within reaching                  ty. More and more foreign companies are
                                                                                                                         distance of the engine, Liu is seated at his               investing in this market—especially carmak-
                                                                                                                         computer and noting the latest measure-                    ers, closely followed by their component
                                                                                                                         ments. Carefully he modifies certain of the                suppliers. In 1997, KSPG opened its first
                                                                                                                         valve train parameters and observes how                    plant in China, followed by many others,
                                                                                                                         output, torque, consumption and emissions                  mostly around Shanghai, one of the nation’s
                                                                                                                         move up and down. Analyzing and refining                   biggest business centers. KSPG has a
                                                                                                                         this innovative valve train is the subject mat-            workforce of over 4,000 in China. Sales in
                                                                                                                         ter of the 28-year-old’s doctoral dissertation.            2014 exceeded €650 million. Yet not all
                                                                                                                                                                                    aspects of development in the country are
                                                                                                                         Car ownership in China is still surging                    keeping pace with this rapid growth. Many
                                                                                                                         The relatively new Jiading campus of Tongji                companies complain about a lack of trained
                                                                                                                         University is a good one-hour drive by car from            and skilled employees. Resourceful firms
                                                                                                                         the 23 million-strong metropolis of Shanghai.              are therefore training their own people. In
                                                                                                                         The route stretches along a brand new high-                fact, there are already promising signs that
                                                                                                                         way. The cars are almost all new: BMWs, VWs,               Chinese apprentices are being trained in           Chinese-German College for Postgraduate
                                                                                                                         and Audis. With its burgeoning middle class,               accordance with Germany’s Dual System,             Studies, a cooperative venture between the
                                                                                                                         this vast nation has become one of the most                while professorships jointly sponsored by          German Academic Exchange Service and
                                                                                                                         important buyers of German cars. In 2014,                  German companies and Chinese universi-             Tongji University. The long-serving executive
                                                                                                                         more than 20 million light vehicles were sold              ties are also being established. Since 2007,       vice dean of the Tongji College of Mechanical
                                                                 With its striking architecture, the Jiading Campus of   in China, and each year it will be even more.              KSPG has been funding one such project,            Engineering, Prof. Ph.D. Liguang Li, holds the
                                                                  Tongji University is Yintong Liu’s academic home.      Because this market is becoming increasingly               which is organized under the aegis of the          Chair of Automotive Engine Technology.

22   HEARTBEAT                                                                                                                                                                                                                                                                    23
swimming pool is just being built. But Liu        was German cuisine that he enjoyed most.            very tight in China. Being able to care for
                                                                                                                                                            has little time for sports at present, as he is   “I love sausages in curry sauce,” he says.          one’s parents is something that many young
                                                                                                                                                            too busy with the project. “Normally I play       And yet there can hardly be a cuisine more          Chinese value highly. With annual growth
                                                                                                                                                            basketball and table tennis but right now         different from the German than that of his          in China still running at 7 percent, Liu will
                                                                                                                                                            the dissertation enjoys priority.” Part of        home region. The province of Sichuan,               certainly be needed in an economy where
                                                                                                                                                            his work is done in an open-plan office in        where Liu is from, is noted and notorious for       skilled employees are in short supply.
                                                                                          SOMETIMES I SPEND                                                 the neighboring building. This is where the       its hot and spicy dishes.                           But that’s not all. More efficient and cleaner
                                                                                                                                                            measurements are analyzed and summa-                                                                  engines are urgently need in China, too.
                                                                                          TEN OR MORE HOURS                                                 rized in writing. Liu hopes to have completed     Family is still very important.                     On this late wintry afternoon, through the
                                                                                                                                                            the measurements in two months from now.          Back in China, he spends his precious time          murky air the reddish sun is setting. Shang-
                                                                                          IN THE LAB                                                        Then comes the written work. “If all goes         off with his girlfriend, who lives in Pudong,       hai, too, suffers from severe air pollution
                                                                                                                                                            smoothly, I’ll have finished the project by       a newly developed district of Shanghai, at          and more efficient engines are an important
                                                                                                                                                            the summer of this year,” he says.                the other end of the city. To see her he has to     way to combat this.
                                                                                                                                                                                                              drive for at least ninety minutes. Just like Liu,
                                                                                                                                                            A love of the famous German “currywurst”          she comes from Chongqing and works in the
                                                                                                                                                            For seven years now Liu has lived and             auto industry. Liu’s parents still live there.
                                                                                                                                                            engaged in research here. He spent the first      He visits them twice a year. The boom that
                                                                                                                                                            three years of his studies in Mechanical          began in China’s big east coast cities some
                                                                                                                                                            Engineering on another campus in the city         20 years ago is gradually spilling over into
                                                                                                                                                            center, before moving on to the Anting cam-       the interior of the country. With a popula-
                                                                                                                                                            pus close to the Volkswagen plant for his         tion of 30 million, Chongqing—depending
                                                                                                                                                            master’s degree. For two years now he has         on what you include—ranks as the world’s
                                                                                                                                                            been working on his Ph.D. The cooperation         most populous city, and is already experi-                  IN THE LONG RUN,
                                                                                                                                                            agreement existing between the university         encing the boom. More and more foreign
                                                                                                                                                            and KSPG allowed him to spend a 12-month          companies are moving into the mega-­                        I’D LIKE TO LIVE
AUTOMOBILE MARKET                                                                                                                                           research stay in Germany in 2013, where he        metropolis and the surrounding province of
IN CHINA (2014)                                                                                                                                             lived with a German family in Neuss near          Sichuan. This is fine with Liu. “In the long                AND WORK CLOSE
                                                                                                                                                            Düsseldorf. During the day he worked at the       term, I would like to live and work close to
                                                                                                                                                            local KSPG plant. Besides the work itself, it     my parents,” he says. Family ties are still                 TO MY FAMILY

 Since 2012
 biggest car market in the world

                   6.9%
               LCV production growth rate
                               2014-2017         The longstanding focus of Liu’s research is an engine with a mechanically
                                                 fully variable valve drive. Over and over again, he makes minute changes

 18.4
                                                 to the parameters, conscientiously documenting the effects.

                      million
 new cars sold
 (largest automobile market worldwide)           It was the latter who proposed Liu for the                  restart the engine, modify the parameters
                                                 project. “Of course, I’m very proud of this,”               by a fraction of a second, and note down
                                                 he says in English. Liu introduces himself                  the results. “There are times when I spend

                           9%
                                                 as Leon since, lkie many young Chinese,                     ten or more hours here,” says Liu. “The only
                                                 he has given himself an English first name.                 interruptions are for lunch and dinner.”
                                                 His day starts at 8 o’clock in the morning in
                                   growth
                                                 his single room. As a postgraduate he no                         LIFE REVOLVES AROUND
                                                 longer sleeps in a multi-bed room as do the
                                                 other students. He makes his way to the
                                                                                                                  THE CAMPUS FOR SOME

 Beijing 5
                                                 canteen, a large hall loud with the rattling                     15,000 STUDENTS
                                                 of hundreds of spoons and plates. By nine
                                   (= Euro 5)    at the latest, he’s at work in the lab. “Right              The campus of Tongji University is a town
 Emission standard                               now we’re measuring for seven to ten hours                  in itself. Some 15,000 scholars from all
 Starting in 2016: Beijing 6                     daily,” he says. There are another five stu-                over China live and study here. The campus
                                                 dents in his team, one of whom is also doing                has its own supermarkets, restaurants,
                                   Source: IHS   postgraduate studies. Again and again they                  sports grounds, and dormitories. An indoor

24     HEARTBEAT                                                                                                                                                                                                                                                                                             25
PEOPLE

                                // SLOWING DOWN ON
                                         TWO WHEELS
                                             Manfred Mäules’s heart belongs to an old Harley

                 How much passion can someone muster
                 for an old motorcycle? In search of an answer,
                 Heartbeat learned a lot about style,
                 craftsmanship and the art of never finishing.

                       This man doesn’t conform to the          wall hangs a doctoral certificate from the       A stable full of chrome horses
                 standard biker cliché. The Chief Operating     Academy of M ­ aintenance. “A little joke from   At the MeMoTech company, we are greeted
                 Officer of KS HUAYU AluTech GmbH wears         my colleagues”, he grins. He appreciates a       by workshop manager Alexander Ronto.
                 a conservative suit and a clean white shirt.   relaxed work atmosphere—and his old ­            “Alex”, confides Manfred Mäule, is someone
                 Chatting over a cup of coffee with him,        Harley, too, a 1972 Shovelhead Hydraglide.       he knows he can trust, and a welcome spar-
                 we can already tell that this senior execu-    We naturally want to have a look, and make       ring partner when it comes to technical and
                 tive is a pleasant person. Colleagues and      our way to nearby Flehn, where the machine       aesthetic questions. It quickly becomes clear
                 staff pass by for a quick word: “My door is    was due to have new brakes installed.            that he shares Mäule’s passion for beautiful
                 always open”, says Manfred Mäule. On the                                                        motorcycles—only with him it became his

26   HEARTBEAT                                                                                                                                             27
IT’S ABOUT DOING
                                 IT YOURSELF, GETTING
                                 YOUR HANDS DIRTY

                                                                                                                                                                                                                                                         HEAVY UP FRONT,
                                                                                                                                                                                                                                                         ­NARROW IN THE BACK

                                                                                                                 The incomparable silhouette of
                                                                                                                 a 1972 motorcycle

vocation. We’re surrounded by a plethora of      dures. When it comes to improving the bike’s        also from actual encounters with men and
vintage bikes—countless Harleys, but also        performance, though, engineering trumps             motorcycles. His thing? “Heavy up front,
exotics like the MV Agusta from the ’80s or      nostalgia: instead of an oily wet clutch for his    narrow in the back.” Anybody who’s seen
an antique Triumph from the ’20s. Having         Shovelhead, he developed a more effective           his special interpretation of a Hydraglide will
so many models means the staff needs             dry clutch, including the pinion. After all, this   know exactly what he means: the massive
­tremendous know-how—which is exactly            is what he’s trained to do.                         headlight—known as the “ox head” by afi-
 why Manfred Mäule turns to them for help
 with his Shovelhead.
                                                     KOLBENSCHMIDT
Tightening bolts instead of shooting                 • HARLEY-DAVIDSON SUPPLIER FOR OVER 30 YEARS
the breeze
                                                     • SUPPLIED SOME TEN MILLION PISTONS
And he knows a lot himself—he’s not one of                                                                                                             desires. For example, the two exhaust pipes     The ideal counterbalance                           maybe that’s the whole point. You have to
those ostentatious bikers who spend tens             • A 90% SUPPLIER SHARE AT HARLEY                                                                  that run parallel from the header to the back   What’s so fascinating about tightening             keep coming up with no ideas and approach-
of thousands on a glitzy machine and would                                                                                                             unfortunately won’t be allowed to stay that     screws on old Harleys? “It’s the ideal             es, always striving for the optimum solution.
rather show off than tighten a screw: “The       Beauty is in the eye of the beholder                ciandos—and the powerful fork with the first      way. “In the USA it’s okay, but in Germany      counterbalance for what I do all day at            With the Shovelhead, that’s no problem: the
last thing I wanted was a high-priced cus-       Apart from engineering, aesthetics kept             hydraulic shock absorbers give the Harley         it’s too loud for the TÜV inspectors”, notes    Kolbenschmidt”, declares Mäule. “At work           brakes may soon be repaired, but the iconic
tom-built bike where everything was new and      coming up in our conversations. “There are          its distinctive front-heavy look. Naturally       Mäule, his pained expression revealing the      it’s mostly numbers—here I can get my hands        mount is still missing a seat. “We still need to
different. I wanted to keep as much of the       so many different Harley models and types           enough, the back of the bike looks very dif-      disapproval of a true motorcycle aesthete.      dirty and literally get to grips with a prob-      talk about that”, adds Alexander Ronto, with
original Shovelhead motor as possible and        and different ways of modifying them”, says         ferent—in fact it seems almost effeminately       It’s easy to see how the neutered version       lem.” On the job, everything revolves around       a mischievous wink. Fortunately, Manfred
restore the rest as accurately as possible”,     Mäule. “Over the years, everyone develops           delicate, while the rear tire is barely wider     with “bags”—as the experts dub the exhaust      efficiency; here he enjoys the luxury of           Mäule must be thinking. In two weeks he’s
he explains. As a matter of fact he does a lot   his own preferences”, he adds. Inspira-             than the front one. “And the opposite exists,     muffler terminals—just don’t pack the same      having tons of time. “To be honest, restoring      off to Daytona Beach on vacation. Waiting for
of the work himself, machining the smaller       tion comes from every direction—pictures            too”, he tells us: “But I don’t like it.” Yet     aesthetic punch as the original design.         a machine like this is a process that never        him there won’t just be thousands of Harleys,
parts and even carrying out difficult proce-     in magazines and books, of course, but              sometimes the powers that be constrain our                                                        really ends”, he confesses with a sly grin. But    but plenty of inspiration to boot.

28      HEARTBEAT                                                                                                                                                                                                                                                                                     29
PEOPLE

                                                                                                                                                 Along with a basketball career and grad school,
                                                                                                                                                 Marvin Kruchen wants to make his mark at Pierburg, too.

// FROM DRIBBLING
         TO CONTROLLING
                                                                                                // Basketball, grad school, your job—
            Marvin Kruchen talks about discipline and team spirit                               that sounds like a pretty busy schedule.
                                                                                                Do you ever have time to relax?
                                                                                                It’s all a question of time management. In the
         What influence can sport have on life at work? Heartbeat met                           meantime I only train three times a week, a
                                                                                                lot less than before. The 1st Regional League
                                                                                                is the fourth- highest league, meaning you
         with the Pierburg employee and graduate student,                                       can just barely combine it with a day job.
                                                                                                I use my free time to study, because work
         who plays basketball in Germany’s 1st Regional Division.                               and basketball games mean that I can’t
                                                                                                always attend lectures. It works pretty well.

                                                                                                // Team spirit—is being a team player
                                                    The fact that most people look up to
                                                                                                ­important in other areas, too? At work,
                                               him clearly has something to do with his
                                                                                                 for instance?
                                               height: Marvin Kruchen is 2.10 meters tall –
                                                                                                 Since I haven’t been at this all that long,
                                               that’s almost 6 foot 9 inches. But in an
                                                                                                 I really appreciate it when my colleagues
                                               interview with Heartbeat, it was his friendly,                                                    // Apart from basketball, what are your                   quickly. Things can get stressful at work, too.
                                                                                                 give me a hand. The team spirit that you
                                               open manner that impressed the most.                                                              greatest talents?                                         But it’s like comparing apples and oranges
                                                                                                 ­develop playing basketball can definitely
                                                                                                                                                 That’s a tough one. I guess my main talent—               and grapefruits.
                                                                                                  help at work. You become better at em­
                                               // Mr Kruchen, you work at Pierburg. What                                                         if that’s what you can call it—is being
                                                                                                  pathizing with others and getting along with
                                               do you there?                                                                                     an open-minded, communicative person.                     // When you’re always being called a “giant”
                                                                                                  different kinds of people.
                                               I work part-time in Sales Controlling on a                                                        That’s a big advantage at work, at school                 or a “colossus”, does that lead to greater
                                               30 hour a week basis. Our team produces                                                           and in sport.                                             pressure to perform in other areas? Do you
                                               monthly reports for the company’s sales
                                                                                                   THE 1ST REGIONAL                                                                                        have that feeling that more is expected of
                                               people. Right now we’re preparing the bu-           ­LEAGUE CAN JUST                              // What are you most passionate about                     you than from others?
                                               siness plan for the next few years. Basically                                                     right now?                                                No, I don’t think so. I don’t really put myself
                                               we collect data and process it in a way that
                                                                                                    BARELY BE COMBINED                           I’ve always been fascinated by the auto-                  under pressure, expect when it comes to
                                               our colleagues can use it. This is the kind of       WITH A DAY JOB                               mobile industry, especially the big German                basketball. And we’re not under nearly as
                                               work you do at a desk, of course, interrupted                                                     makers. Not that I make enough yet to drive               much pressure to perform as professional
                                               by the occasional meeting.                       // Somebody who plays so well and is so          a big German car!                                         soccer players, for example, including from
                                                                                                eager to get ahead must be ambitious.                                                                      the press. I take off my hat to Germany’s First
                                               // And you’re studying at the same time?         Does this same ambition affect they way          // Do you approach a basketball game, a test              Division players.
                                               That’s right. I’m doing my Master’s in           you study and work?                              or a project at work with the same attitude,
                                               Business Administration at the University of     A little bit, I guess, though I’m not sure if    the same methods and the same tactics?
                                               Cologne, where I’m now in my third semes-        it doesn’t just have something to do with        It’s not really the same. A test is always going
                                               ter. Once I’ve completed by degree, I plan to    my personality. Many of my fellow students       to make you nervous. Basketball’s different.
                                               work for Pierburg full time.                     have had semesters when they’ve hardly           Despite a thousand spectators, there’s a
                                                                                                lifted a finger. That’s not the case with me.    certain routine involved that takes over pretty

30   HEARTBEAT                                                                                                                                                                                                                                          31
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