Annual Report 2010 - Knorr-Bremse AG.

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96 RepoRt | CoMMeRCIAL VeHICLe SYSteMS Value-stream factory opens in Czech Republic Development of a new facility in the town of Liberec, Czech Republic, involved more than just transferring production activities. In early June 2010, Knorr- Bremse Commercial Vehicle Systems introduced an entirely new approach to production and logistics based on its globally standardized production system KPS and taking the form of a “value-stream factory”. The result was a significant increase in efficiency and flexibility in both areas. The new production and sales center in the northern Bohemian town of Liberec replaced the existing facility in Hejnice, some 30 kilometers away. On a site measuring almost 8,000 m² Knorr-Bremse Commercial Vehicle Systems now produces components for truck braking systems such as brake cylinders, clutch servos, foot and hand brake valves and filter cartridges.
RepoRt 97 Focus on value creation All processes at the new factory are focused on value creation, with a particular emphasis on flexibility and economy. The proverbial key to success is synchronization of processes, with individual production processes no longer regarded separately but rather as part of a single process. Thus the focus is no longer on optimizing and maximizing capacity utilization of individual workplaces but on the process as a whole, optimizing resource utilization and eliminating deviations. The basic elements of a value-stream factory were incorporated into the planning process from the very outset. Logistics are situated immediately next to production processes, with standardized, modularized product islands and workstations. Tugger trains ensure a coordinated and efficient supply of materials to assembly operations, reducing inventory and improving component availability. In addition to standardization, another focus was on further developing shopfloor management. The company value chain was concentrated on the production process itself, with all supporting processes aimed at making production as cost-effective, flexible and error-free as possible. The right time, the right workplace Modular factory design provides the basis for an ideal materials flow. The layout of the plant and its individual buildings is based on current value streams, but is designed to be flexible enough for the materials flow to be maintained even when a change in product and production structures is introduced. The new layout with its optimized processes guarantees the right quantity of the required material being sent at the right time to the right place. The many advantages of Liberec The decision to move to Liberec came as part of Knorr-Bremse’s strategic development of its production network. In addition to having good transport links, the region of Northern Bohemia also offers large numbers of highly skilled workers. And the town of Liberec, which has engineering and mechatronics faculties at its university, is home to many engineers. Proximity to Knorr-Bremse’s former plant at Hejnice also facilitated the transfer of expertise to the new site. Long tradition of links with Czech Republic This latest move to a new site is one further step in Knorr-Bremse‘s long history of activities in the Czech Republic. In 1992, shortly after the fall of the Iron Curtain, the Knorr-Bremse plant in Aldersbach started to co-operate with the Czech company AUTOBRZDY a.s. A year later the German-Czech joint venture Knorr-Autobrzdy s.r.o. was set up, and in 1998 was fully taken over by Knorr-Bremse and incorporated into the Knorr-Bremse Group.
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Annual Report | 2010 Knorr-Bremse G
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Main Majority-owned Subsidiaries of
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1/Overview 04 06 08 10 12 2010 at a
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Knorr-Bremse Rail Vehicle Systems i
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EXECUTIVE BOARD 7 Dr. Dieter Wilhel
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SUPERVISORY BOARD 9 Heinz Hermann D
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SUPERVISORY BOARD 11 Statements and
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14 The State and Development of Kno
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16 Development of the Knorr-Bremse
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18 the Daxing site a new production
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20 Overall assessment of the econom
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22 Regional developments by divisio
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24 for example, procured another 18
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26 ket also throttled back domestic
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28 Research and development As a te
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30 Social responsibility and sustai
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32 Report on risks and opportunitie
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34 Outlook In 2011 the Knorr-Bremse
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2/ Report Against a background of g
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40 RepoR t | RAIL Ve HICLe SYSteMS
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Page 66 and 67: 62 HIGHLIGHt RepoRt | RAIL VeHICLe
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Page 81 and 82: Commercial Vehicle Systems Followin
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Page 87 and 88: RepoR t 83 Market Successes Against
Page 89 and 90: RepoR t 85 North America Bendix bec
Page 91 and 92: RepoRt 87 Consistent performance th
Page 93 and 94: RepoRt 89 Asia Successes in China K
Page 95 and 96: RepoR t 91 PACCAR quality award The
Page 97 and 98: RepoR t 93 Projects During 2010 Kno
Page 99: RepoR t 95 By the end of the year u
Page 103 and 104: RepoR t 99 Products Reliable, safe,
Page 105 and 106: RepoR t 101 Tire Pressure Monitorin
Page 107 and 108: RepoRt 103 20-inch disc brake for C
Page 109 and 110: RepoR t 105 Service Knorr-Bremse’
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Page 114 and 115: 110 RepoR t | KnoRR-BR e MSe GR o U
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Page 139 and 140: 3/ Notes to the Consolidated Financ
Page 141 and 142: NOTES TO THE CONSOLIDATED FINANCIAL
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NOTES TO THE CONSOLIDATED FINANCIAL
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CONSOLIDATED CASH FLOW STATEMENT 15
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SEGMENT REPORT 157 Fiscal Year 2010
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INDEPENDENT AUDITOR’S REPORT 159
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CONSOLIDATED STATEMENT OF INCOME 16
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Annual Report 2010 - Knorr-Bremse AG.

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