about berco - Berco S.p.A
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english edition > year 17<br />
issue 62 > december 2011<br />
Free Company Information Periodical<br />
Editor-in-Chief: Beatrice Bissi<br />
Auth. n° 17/94 of Court of Ferrara, 5-12-1994<br />
FOCUS ON:<br />
BERCO adopts SAP<br />
ABOUT BERCO<br />
> <strong>Berco</strong> loyalty prize<br />
> E-Learning: training and competitiveness<br />
FOCUS ON<br />
> 5S method at <strong>Berco</strong>: a further step towards continuous improvement
Editorial<br />
Dear readers,<br />
in this issue:<br />
2-3 EDitorial<br />
3 ABOUT BERCO<br />
<strong>Berco</strong> loyalty prize<br />
4-5-6 FOCUS ON<br />
SAP SPECIAL: <strong>Berco</strong> adopts SAP<br />
6 ABOUT BERCO<br />
E-Learning: training and competitiveness<br />
7 FOCUS ON<br />
5S method at <strong>Berco</strong>: a further step towards<br />
continuous improvement<br />
8 InnovaTION & TecHnologY<br />
<strong>Berco</strong> 2: a new 3000 ton press<br />
9 PRODUCTS & SERVICES<br />
Special undercarriage for ”Nessie 5” cable layer<br />
10 ABOUT BERCO<br />
Remembering Enrico Carbone<br />
Gianni Finessi: a mind made for mechanics<br />
10 NEWS & EVENTS<br />
Thyssenkrupp celebrates 200 years of history<br />
11 DEALERS & CUSTOMERS<br />
ICC Perù and <strong>Berco</strong> at the Extemin 2011 trade show<br />
Verhoeven at Matexpo 2011<br />
<strong>Berco</strong>News is a six-monthly periodical published for <strong>Berco</strong> employees,<br />
customers, suppliers and friends. The articles and photos can be copied<br />
only if expressly authorised by the Editor.<br />
Cover photo: <strong>Berco</strong> – internal yard<br />
Published by: BERCO S.p.A. - Communications Department<br />
Via 1° Maggio, 237 - 44034 Copparo (FE) Italy<br />
Tel. +39 0532 864116 - fax +39 0532 864462,<br />
e-mail: <strong>berco</strong>news@<strong>berco</strong>.com<br />
Editor-in-Chief: Beatrice Bissi<br />
Tel. +39 0532 864431 - fax +39 0532 864462<br />
e-mail: b.bissi@<strong>berco</strong>.com<br />
Editorial Commitee: S. Bottacin, S. Mastellari,<br />
G. Neodo, S. Salatini, S. Salvi, M. Seghieri, D. Musacci<br />
Editorial Secretary: D. Roversi<br />
Tel. +39 0532 864 270 - e-mail: d.roversi@<strong>berco</strong>.com<br />
Graphics and layout: Communications Department<br />
Pictures by: ThyssenKrupp, E. Perelli and others<br />
Printed by: Chinchio Industria Grafica S.p.A. (PD)<br />
Circulation: Italian 2500, English 4.000<br />
as is now customary at the end of the<br />
financial year, I would like to comment<br />
briefly on its main events and<br />
characteristic factors in order to<br />
evaluate and better understand the<br />
final figures.<br />
The year was forecast to be a period of<br />
transition, characterised by further<br />
moderate growth driven mainly by the<br />
so-called emerging countries, accompanied by an overall stability in<br />
the prices of raw materials and basic macroeconomic factors.<br />
It was to be a year in which most of our restructuring plans were to<br />
be brought to completion, with an accompanying rise in production<br />
to an intermediate level between the previous year and the level<br />
forecast for 2011/12 (at the earliest).<br />
The global financial crisis was to draw to a gradual close, restoring<br />
faith in markets and bringing stability to growth and consolidation,<br />
putting the uncertainties, nervousness and volatility that have<br />
wracked the global economy in recent years behind us once and for<br />
all. It is plain for all to see that very little of this actually<br />
happened, as borne out in various ways by our end-of-year figures.<br />
On the growth front, at least for the first 9 months of the year, and<br />
not only in the emerging economies, there was a much bigger than<br />
expected increase in orders, enabling us to increase sales to 45%<br />
higher than the previous year and taking the volume of finished<br />
products to <strong>about</strong> 190,000 tons, at least one year ahead of previous<br />
forecasts.<br />
This major, albeit unexpected and – in some ways – too rapid<br />
increase in volumes, however, had to coexist - not without some<br />
difficulty – with the numerous actions of our current restructuring<br />
plan, which have temporarily limited the production capacity and<br />
efficiency of some of the main process lines at the very time when<br />
we would need to be increasing production to keep pace with<br />
changing market demands.<br />
At the same time, with regard to costs, the sudden rise in volumes<br />
with the consequent greater demand for raw materials and their<br />
derivatives created the illusion, in the first half of the year, that the<br />
world crisis was over, thus generating the ideal conditions for an<br />
immediate, marked, speculative increase in corresponding price<br />
quotes.<br />
Given the composition of our products, it is easy to understand how<br />
such rapid, major variations could have such an immediate impact<br />
on production costs, with inevitable repercussions in terms of<br />
revenue and, unfortunately, without giving us enough time to take<br />
appropriate counter-measures. The scenario was further affected, in<br />
our last trimester - with the Summer break behind us and amidst<br />
expectations for a further increase in demand – by the “cold<br />
shower” of a sudden and worrying redimensioning of orders –<br />
sometimes a total halt – from the main OEMs in the emerging<br />
economies. This was led by China, who had evidently overestimated<br />
their market and had to review and scale down their plans. In a<br />
scenario such as this, even with the significant increase in volumes<br />
and revenue attained, it comes as no surprise that, despite<br />
improving considerably on the previous year, we were able only to<br />
break even, without the satisfaction of a positive result.The<br />
economic and financial events of recent weeks, extensively reported
Editorial<br />
in the daily press, clearly demonstrate how the general<br />
market situation is still highly critical, unstable and<br />
worrying, and the lack of solid growth in industrial<br />
production is further evidence that the global crisis is still<br />
far from over. It is now, therefore, that serious further<br />
efforts have to be made on all levels, with all of us pressing<br />
ahead with conviction, fortitude and determination on the<br />
chosen path of continuous improvement to our business.<br />
Each one of us is called on to draw unreservedly on our<br />
experience, skill and professionalism, in the conviction that<br />
each single contribution is not only useful, but a<br />
determining factor in reaching the necessary goal of<br />
maximum cost containment, which lies at the basis of any<br />
improvement in competitiveness.<br />
Only by so doing can we consolidate our market share and<br />
defend our jobs, achieving the dual goal of making our<br />
company grow and generate the reasonable profit required<br />
as an essential condition for guaranteeing our future. While<br />
being justifiably worried <strong>about</strong> the duration of this critical<br />
and complex economic phase, I am sure that we have the<br />
capacity to take advantage of what has always been our<br />
company's strongest asset, its human resources.<br />
We are a great, well trained and highly motivated team,<br />
spread throughout the Italian factories and our many<br />
foreign branches, and we shall continue to draw on our<br />
renowned professional skill to face up to the trials that still<br />
await us. We will act with courage, honesty, a passion for<br />
our work, team spirit and a proud sense of belonging, with<br />
a constant eye to the interests of the group and the future<br />
of its individual components.<br />
As the festive season approaches, bringing us a brief pause<br />
in our work and a chance to relax for a while with our<br />
nearest and dearest, I wish all of you and your families a<br />
very happy holiday.<br />
Bruno Saturni<br />
Managing Director<br />
About <strong>Berco</strong><br />
<strong>Berco</strong> Loyalty Prize<br />
As has been happening for 25 years, the<br />
<strong>Berco</strong> loyalty prize – the company's way<br />
of acknowledging the dedication of<br />
those who have contributed to its<br />
growth – will be awarded in December.<br />
With this award, <strong>Berco</strong> pays tribute<br />
to the qualities of commitment,<br />
reliability, positive attitude, team<br />
spirit and goal orientation: qualities<br />
that make the workforce a precious<br />
resource, capable of generating real<br />
value added.<br />
The employees, with 30 or 35 years<br />
of “service” to their name, will receive<br />
their awards on Friday December 23<br />
in the Copparo factory conference hall.<br />
BN62 > december 2011<br />
3
Focus On<br />
R<br />
<strong>Berco</strong> adopts SAP<br />
Increased efficiency and the integration of business processes are two of the main goals of an ambitious business<br />
restructuring plan and the use of effective management tools is essential if they are to be achieved<br />
Over a year ago, <strong>Berco</strong> launched an<br />
ambitious business restructuring plan<br />
which, after an initial stage involving<br />
all the areas of the Italian factories,<br />
will then be extended to the foreign<br />
branches.<br />
Increased efficiency and the<br />
integration of business processes<br />
are two of the main goals, and<br />
the use of effective, leading-edge<br />
management tools is essential if<br />
they are to be achieved.<br />
After a series of detailed analyses,<br />
<strong>Berco</strong> has decided to turn its<br />
attention to SAP.<br />
What is SaP<br />
SAP is an IT system created by the<br />
German company of the same name,<br />
SAP AG, one of the leading integrated<br />
management solutions companies in<br />
the world.<br />
SAP integrates all the main business<br />
processes of a company – purchasing,<br />
sales, stock management, production<br />
planning, accounts and finance – in<br />
a single management system.<br />
All the business areas are<br />
interconnected and aligned so that<br />
they can exchange data in reciprocal<br />
data flows.<br />
SAP coordinates, synchronizes and<br />
automates these operations,<br />
drastically reducing the times linked<br />
to information exchanges and<br />
searches and increasing the overall<br />
efficiency of the related processes.<br />
Why SaP<br />
When a company the size of <strong>Berco</strong><br />
decides to update its management<br />
system, it has to enlist the help of<br />
expert, qualified partners and adopt<br />
solutions whose effectiveness has<br />
been amply tested in application<br />
scenarios as similar as possible to<br />
its own. SAP applications and<br />
services are used by more than<br />
176,000 businesses throughout the<br />
world(over 3,500 in Italy), with<br />
measurable results and excellent<br />
satisfaction levels. ThyssenKrupp has<br />
been using SAP for many years in<br />
numerous companies in the group,<br />
and this undoubtedly made the <strong>Berco</strong><br />
management more confident in their<br />
choice of system.<br />
The project team<br />
<strong>Berco</strong> has enlisted the help of top<br />
level partners for the analysis and<br />
planning of its system.<br />
The AtoS team is a pool created from<br />
Atos Origin and Siemens IT Solutions<br />
and Services, which will assist <strong>Berco</strong><br />
in all the development and<br />
implementation stages.<br />
Also, numerous internal resources<br />
have been brought into play: 5<br />
permanent steering committee<br />
members for piloting the project<br />
and coordinating the activities, 21<br />
process owners for implementing the<br />
single business processes in SAP, 39<br />
key users for guaranteeing the<br />
usability of all the new system's vital<br />
functions and 12 IT specialists for<br />
supporting all the data development<br />
and migration activities.<br />
The times<br />
As we go to press, preparations for<br />
4 BN62 > december 2011
SPECIAL<br />
Focus On<br />
the second operational prototype is under way. As you<br />
can see from the diagram on the previous page, the<br />
official go-live of the new system is planned for August<br />
2012. The accounting and finance modules will be<br />
activated at the end of September, to coincide with the<br />
start of the new fiscal year. All customers and suppliers<br />
will be formally asked to organise their delivery schedules<br />
in good time, to reduce the possible problems of the<br />
migration process to a minimum. SAP best practice<br />
actually recommends the early acquisition of all supplies<br />
and the early planning of all deliveries to customers in<br />
relation to the new system's go-live period.<br />
Double interview with Luca Baraldi, director and coordinator of the company restructuring plan, and Giovanni Landi,<br />
SAP implementation Project Manager<br />
Giovanni Landi,<br />
Information Service &<br />
Data Security Manager<br />
Giovanni Landi, you are the<br />
Project Manager for the<br />
implementation of SAP. What has<br />
driven <strong>Berco</strong> to take up this<br />
challenge<br />
”The <strong>Berco</strong> group has grown<br />
greatly in recent years, and in it<br />
there are heterogeneous elements<br />
that have objective interfacing<br />
difficulties. We are fully aware of the need to integrate<br />
the management systems of all the company structures,<br />
and we've decided to do it using the same system that<br />
our stockholder has been using for years in the main<br />
companies in the ThyssenKrupp group.”<br />
Luca Baraldi, you have been given the important task<br />
of directing and coordinating the company restructuring<br />
plan. Is the decision to adopt SAP an integral part of<br />
this plan<br />
”If <strong>Berco</strong> is to continue growing and improving its<br />
performance, it needs to have a high level of integration<br />
between the different stages of the supply chain.<br />
The structural model for the <strong>Berco</strong> of tomorrow must<br />
be based on instruments of proven effectiveness.<br />
SAP is universally acknowledged to be the system that<br />
best responds to these needs.”<br />
What benefits will the adoption of SAP bring to <strong>Berco</strong><br />
Baraldi: ”SAP regulates the ways that information is<br />
recorded and exchanged within a business, and<br />
guarantees that all the data required for any operation<br />
are available at the time the operation has to be<br />
performed.<br />
As well as increasing efficiency, this also increases<br />
management's knowledge. If each phase of a process<br />
is monitored, the people in charge of that processes<br />
performance will be able to identify the bottlenecks<br />
and act in time to remove them.”<br />
Landi: ”The key word is knowledge. An integrated system<br />
encourages the adoption of c ommon working methods,<br />
more oriented to mutual cooperation.<br />
Each user is made to see his or her work in a wider<br />
context, and to realise that the consequences of his or<br />
her actions must necessarily affect the next stage of<br />
the process flow.”<br />
At the ends of the supply chain there<br />
are the customers and the suppliers.<br />
What impact will SAP have on them<br />
Baraldi: ”Actually, SAP is already<br />
standard practice in our industry.<br />
Many customers of primary<br />
importance have turned to SAP for<br />
the renewal of their IT systems.<br />
Potentially, the integration between<br />
Luca Baraldi,<br />
Operations Director<br />
<strong>Berco</strong> and these partners will be perfect. For all the others,<br />
from the very outset <strong>Berco</strong> will be able to give faster<br />
feedback and greater reliability in purchasing schedules(for<br />
suppliers)and delivery schedules(for customers).”<br />
Landi: ”We aim to automate as many external data<br />
exchanges as possible, especially with raw materials<br />
suppliers.<br />
At the same time, we'll be able to acquire orders from<br />
very big OEM customers by means of EDI transfer<br />
procedures, reducing manual intervention to a minimum.<br />
Greater end-to-end integration of supply chain processes<br />
and rapid and precise information availability will facilitate<br />
the accurate scheduling and performance of operations<br />
in all areas.”<br />
So far so good. Is there a negative side<br />
Baraldi: ”A project on this scale involves a certain amount<br />
of risk. In particular, in the data migration stage from<br />
the old process to the new one and in the initial periods<br />
of using SAP, there can be inefficiencies and slow-ups.<br />
Preparations need to be made well in advance, working<br />
together with customers and suppliers and creating special<br />
safety stocks.<br />
Shrewd, pragmatic risk management will help us to<br />
minimise the transitory negative impact.<br />
Even more important is the careful assessment of possible<br />
interference and frictions between the SAP project and<br />
all the other restructuring projects, especially those<br />
initiated in recent years.<br />
Often, these projects have the same goals as SAP, but<br />
with very different methods.”<br />
Landi: ”We're making big efforts to bridge the organisational<br />
gaps that came to light in the project analysis stages.<br />
Introducing SAP doesn't mean just updating our IT systems.<br />
It means changing our way of working, transforming our<br />
BN62 > december 2011 5
Focus On<br />
way of envisaging the company – and adapting its<br />
business structures accordingly.”<br />
Have you planned future developments of the initial<br />
project Is there a ”phase two”<br />
Landi: ”There's more than a phase two. SAP's modular<br />
structure has made it possible for us to define a starting<br />
model that guarantees the vital functions of the<br />
organisation.<br />
Improvements can then be introduced gradually in the<br />
subsequent stages, to avoid overloading the users and<br />
the company in general.<br />
The first step will definitely be the roll-out to the foreign<br />
branches, and this alone calls for a high level of<br />
commitment and elasticity from all the personnel<br />
involved.<br />
The “Italy implementation”, which is what we have<br />
called the current project, will be extended to cover the<br />
complete physical management of stock, the integration<br />
of the related automatic local subsystems, the gradual<br />
inclusion of systems for acquiring data from the main<br />
production units and lines, the drawing up and<br />
implementation of group-level planning and control<br />
systems, the centralisation of orders, data analysis, and<br />
so on.”<br />
Baraldi: ”We have already laid the basis for the creation<br />
of a simulation environment for the development of<br />
complex “what-if” scenarios, above all with regard to<br />
factory load optimisation and the dynamic management<br />
of production capacity according to variations in demand.<br />
It's an ambitious project, but now is the time to give it<br />
everything we've got.<br />
We have to gain ground rapidly, if we want to keep our<br />
leading position in an ever more competitive industry.”<br />
Stefano Salatini<br />
About <strong>Berco</strong><br />
E-LEARNING: TRAINING AND COMPETITIVENESS<br />
Throughout the world, there is a rapid evolution towards a knowledge-based society and economy. Access to<br />
up-to-date information and knowledge is a crucial factor in the strengthening of business competitiveness<br />
E-learning has now come to represent a concrete response to the<br />
demand for continuous training from an adult public already<br />
active in the world of work. This learning and training process<br />
has been made possible by new web technologies that give users<br />
access to various kinds of information in digital form at any time<br />
and from any place with an on-line connection.<br />
The combined use of different channels of communication<br />
(reading, viewing and listening) helps students to memorise<br />
things more easily.<br />
Recent studies have shown that students learn more easily with<br />
these tools than in traditional classroom situations. Training by<br />
”e-learning” also has other advantages over traditional training<br />
methods:<br />
▶ COST REDUCTION<br />
▶ FLEXIBILITY<br />
▶ EFFECTIVENESS<br />
▶ EASILY UPDATABLE<br />
▶ A SINGLE SYSTEM FOR THE COLLECTION AND DISSEMINATION OF COMPANY<br />
KNOWLEDGE; REPRODUCIBLE<br />
▶ EASILY MONITORABLE AND ASSESSABLE<br />
▶ A MINIMUM OF TECHNICAL REQUIREMENTS<br />
▶ E-LEARNING CAN ALSO BE USED BY BRANCHES, VISITORS,<br />
CUSTOMERS, CONTRACTORS...<br />
▶ FREEDOM TO MAKE MISTAKES<br />
▶ LOWER CONSUMPTION OF RESOURCES(ENVIRONMENTALLY FRIENDLY)<br />
WHAT IS BERCO DOING<br />
<strong>Berco</strong> management has decided that the first<br />
area where e-learning is to be used must<br />
necessarily be Health and Safety at work.<br />
Consequently, working with external experts,<br />
we are developing teaching material that<br />
reflects the situation in our company as much<br />
as possible, using images and videos filmed<br />
directly in the workplace. Currently, the <strong>Berco</strong><br />
working group is made up of people from the<br />
Prevention and Protection Service and<br />
Personnel Management, and the courses for<br />
employees will begin by the end of the year.<br />
For technical/organisational reasons, the initial<br />
courses will use a mixture of traditional and<br />
electronic training methods, grouping a certain<br />
number of people together with PCs in a<br />
designated classroom.<br />
The potential of these systems in the near<br />
future is immense:<br />
• home-based training<br />
• contractor training<br />
• training in different languages in different<br />
parts of the world<br />
• transmission via mobile phone, for personnel<br />
on location or on worksites.<br />
Saverio Salvi<br />
Head of Prevention and Protection Services<br />
6<br />
BN62 > december 2011
Focus On<br />
5S method at BERCO:<br />
a further STEP towards<br />
continuous improvement<br />
A methodological approach that aims to eliminate waste, focusing on concepts such as order, cleaning, standardisation<br />
and visual management<br />
”Moving your business ahead”, <strong>Berco</strong>'s<br />
now famous catchphrase, conveys the<br />
idea of development and movement<br />
with an eye to the future.<br />
But the continuous and frenetic<br />
changes affecting the world and<br />
markets are already here in the<br />
present for all to see.<br />
This continuous evolution makes<br />
absolute references impossible:<br />
something seen as excellent one day<br />
can turn out to be mediocre the day<br />
after and can even lead to market<br />
exclusion.<br />
For this reason, <strong>Berco</strong> has decided to<br />
work towards improvement, with the<br />
aim of achieving the ever more<br />
ambitious goals needed to win the<br />
increasingly fierce battle against<br />
competitors.<br />
A battle in which concern for quality<br />
alone is no longer enough; what is<br />
required is a focus on continuously<br />
improving efficiency, leading to a<br />
gradual reduction in internal costs.<br />
WHY BERCO HAS DECIDED TO START FROM THE 5Ss<br />
A methodological approach that aims to start a process for the elimination<br />
of waste, focusing on concepts such as order, cleaning, standardisation and<br />
visual management.<br />
These are notions which, while seemingly banal – at least in the first two<br />
cases – conceal unexpected potential and imply an important change in the<br />
mentality of people in a working environment.<br />
In a company with such deeply entrenched habits like <strong>Berco</strong>, therefore, the<br />
5S method represents not only the first step towards a new change, but also<br />
a “casting out nines” check.<br />
Hiroyuki Hirano, inventor of the 5S method, says that ”good organisations<br />
develop beginning with the 5Ss; bad organisations fall apart beginning with<br />
the 5Ss”.<br />
What we are expecting from this new approach, which is being extended to<br />
the whole factory, is the creation of a different working environment, where<br />
new standards of behaviour help the company to measure up to global markets<br />
in an ever more competitive way.<br />
As Niccolo Machiavelli wrote, ”there is nothing more difficult to take in hand,<br />
more perilous to conduct, or more uncertain in its success, than to take the<br />
lead in the introduction of a new order of things”.<br />
The application of the 5S method thus represents a tangible change which<br />
implies – above all – a mental change, and lays the basis for the continuous<br />
improvement of our company.<br />
Marco Munerato<br />
Workshop Engineering Department – Continuous Improvement<br />
BEFORE<br />
after<br />
5S<br />
5. Shitsuke - sustaining: ensure that this way of thinking<br />
1. Seiri - sorting: sort out the things you need from everything<br />
not essential to the work that upsets order and leads to a<br />
waste of time or resources<br />
2. Seiton - straightening: put everything in its proper place,<br />
as in the old saying ”a place for everything and everything in<br />
its place”<br />
3. Seiso - systematic cleaning: keep everything clean and in<br />
order at all times; a clean, orderly workspace is one that<br />
doesn't “hide” inefficiencies<br />
4. Seiketsu - standardise: define identical, standard procedures<br />
for the continuous rationalisation of resources and workspaces<br />
and acting is sustained in company activities...<br />
BN62 > december 2011 7
Innovation & Technology<br />
BERCO 2: a new 3000 ton PRESS<br />
After 35 years of loyal service, the historic forging hammer in the Castelfranco Veneto factory makes way for<br />
an Eumuco 3000 ton press<br />
After 35 years of loyal service, the<br />
historic forging hammer in the<br />
Castelfranco Veneto factory makes way<br />
for an Eumuco 3000 ton press.<br />
This year, after 35 years of loyal service,<br />
the historic Lasco forging hammer line<br />
has gone into retirement; the<br />
hammering of ”Berta” (as it was known<br />
not just in the factory but all over the<br />
village of Castelfranco Veneto) bore<br />
witness to the fervent activity within<br />
the factory.<br />
The fully automatic, rapid-changeover<br />
line was definitely futuristic in its time<br />
and up to the beginning of 2010 was<br />
allowing us to forge roller halves and<br />
wheel hubs of up to 60 kg.<br />
After so many excellent years of service,<br />
however, the line was due for a major<br />
electronic retrofit which, in any event,<br />
could not have guaranteed the high<br />
performance levels now required.<br />
As the task of the forging line in<br />
the Castelfranco factory is to supply<br />
the roller and hub processing lines, at<br />
the end of 2010, as part of the<br />
restructuring plan, it was decided to<br />
start transferring the Eumuco 3000 unit<br />
from the Busano Canavese factory and<br />
complete the line.<br />
The salient aspects of the line are many<br />
and regard all the components: the Saet<br />
heating furnace (the first ever on a<br />
<strong>Berco</strong> line), the robotized cell<br />
(manufactured by a completely new<br />
external supplier) serving the trimming<br />
press and the main Eumuco 3000 press<br />
itself, fully overhauled with state-ofthe-art<br />
electrical retrofitting. The result<br />
is a technologically evolved, extremely<br />
high-performance production line,<br />
conforming to the latest workplace<br />
safety regulations and capable of<br />
producing large-size items already<br />
hardened in-line.<br />
The Saet heating furnace,<br />
equipped with the latest IGBTbased<br />
1500 KW static converter<br />
model, also has a filtration/<br />
rephasing system to upgrade the<br />
power factor.<br />
The robotized cell is structured<br />
around two Kuka KR 150/2000<br />
heavy-duty handling robots,<br />
which, thanks to the lay-out,<br />
is able to supply the trimming<br />
press in very competitive times;<br />
in future, it will be possible to<br />
add a further<br />
upset forging<br />
press, as the cell<br />
for this is already<br />
designed.<br />
The main item in<br />
the line is obviously<br />
the extremely powerful<br />
and newly retrofitted<br />
Eumuco 3000 ton press,<br />
which, despite its many<br />
years of active service,<br />
still has much to offer.<br />
The electrical control<br />
panel has one of the most modern PLC<br />
control devices available, with a builtin<br />
safety system that guarantees<br />
complete operator safety in forging<br />
operations.<br />
Retooling is fast and safe thanks to a<br />
totally new rapid forging tool change<br />
device, installed on one of our lift<br />
trucks.<br />
When the performance of the new line<br />
is analysed and matched to that of the<br />
old forging hammer, the advantages are<br />
clear to see: an approximately 15%<br />
saving in forging time for 30-ton class<br />
rollers, which increases with the<br />
increase in size up to 25% for 40 tons;<br />
as the forging of net-shaped rollers is<br />
possible, there is also a saving in steel<br />
consumption and roughing time.<br />
We can safely say that, with the<br />
implementation of this new hot forging<br />
line, the factory's potential in this<br />
strategically important process has been<br />
considerably increased and improved.<br />
Marco Balducci<br />
Operations and Maintenance<br />
<strong>Berco</strong> Castelfranco Veneto<br />
8<br />
BN62 > december 2011
Products & Services<br />
SPECIAL UNDERCARRIAGE for<br />
”NESSIE 5” cable layer<br />
<strong>Berco</strong> Deutschland working together with its customer Petry Maschinenbau GmbH on<br />
the production of a special model<br />
<strong>Berco</strong>, as global market leader, not only supplies<br />
individual undercarriage components to OEMs<br />
(e.g. Liebherr, Atlas Copco, Volvo/ABG) and to<br />
aftermarket customers, but is also constantly involved<br />
in special projects.<br />
A particularly spectacular example of a special project<br />
is the undercarriage that our customer Petry<br />
Maschinenbau GmbH, Edewecht, designed and<br />
manufactured in only three and a half months in<br />
cooperation with <strong>Berco</strong> Deutschland.<br />
Christoffers Onshore and Subsea GmbH use this<br />
undercarriage in the tidal flats off the British coast for<br />
laying cables.<br />
The machine has an overall weight of 120 tons without<br />
cables and is powered by a 1000 HP - 12 cylinder diesel<br />
engine via 4 travel gears.<br />
The base plate width is 2750 mm, a total overall length<br />
of 10000 mm for each track frame.<br />
The base plates are mounted on three chains, each<br />
with 155 links. A total of 260 track rollers are used.<br />
The cable drum too is driven by a track chain.<br />
The uniqueness of this special model and the technical<br />
challenges in this field of use can be seen particularly<br />
well in the photos.<br />
Due to the excellent performance of “Nessie 5”, intensive<br />
work is already going on for the project “Nessie 6”.<br />
Rainer Schumburg<br />
Aftermarket Sales Director <strong>Berco</strong> Deutschland<br />
BN62 > december 2011<br />
9
About <strong>Berco</strong><br />
Remembering Enrico Carbone<br />
Sadly, Enrico Carbone died in July<br />
of this year. He worked at <strong>Berco</strong>,<br />
first of all as a metallurgist and head<br />
of heat treatments, and then as a<br />
consultant, from<br />
the 1950s until<br />
after the new<br />
millenium.<br />
Even though he left<br />
<strong>Berco</strong> almost<br />
10 years ago,<br />
the signs of his<br />
presence remain in<br />
many key areas<br />
of the company:<br />
the heat treatment lines, the<br />
metallurgical laboratory and the<br />
steels used for the products were<br />
instigated by him and developed<br />
thanks to his undisputed technical<br />
skill, backed up by an insatiable<br />
curiosity and innovative drive.<br />
I joined <strong>Berco</strong> as a metallurgist<br />
in 1998 and was one of the last<br />
people to<br />
work in<br />
close<br />
contact<br />
with Luca<br />
Carbone.<br />
I still<br />
remember<br />
him as a<br />
man of<br />
extraordinary energy, mental lucidity<br />
and precision in the analysis of<br />
technical problems, with a rigorous<br />
work ethic, always wanting to be up<br />
to date on the latest innovations<br />
and always berating everybody, from<br />
the Managing Director to the<br />
youngest of his colleagues, <strong>about</strong><br />
critical questions emerging in the<br />
company.<br />
He was a constant stimulus and a<br />
point of reference on metallurgical<br />
subjects, not only for his colleagues<br />
in the company but for anybody who<br />
approached him respectfully and<br />
sincerely to discuss a technical<br />
point; these highly fruitful<br />
discussions often developed into<br />
lively exchanges, with his Ligurian<br />
soul expressing itself in shrill tones.<br />
Stefania Bottacin<br />
Quality and Reliability<br />
Division Manager<br />
Gianni Finessi: a mind made for mechanics<br />
I am one of the few people, not yet retired,<br />
who had the opportunity to work with Gianni<br />
Finessi, who died this summer.<br />
I believe that he, more than anybody else, has<br />
left an indelible mark on the company.<br />
He was more than just a responsible engineer.<br />
He had a mind made for mechanics. In his long<br />
career he designed an enormous number of<br />
machines and devices, both for the machine<br />
tools produced and sold by <strong>Berco</strong> and for the<br />
machines and production lines in our workshops.<br />
Despite his apparently gruff manner, he was<br />
always ready to help anybody encountering<br />
difficulties in their work and to find solutions<br />
together. He was a man of few words, sometimes<br />
hard to understand, but we all new that at the<br />
start of every project he had clear ideas on<br />
what to aim for and how to<br />
get there. I am very grateful<br />
for the things I learnt from<br />
him, and consider myself<br />
fortunate to have worked<br />
with a person of his calibre<br />
for <strong>about</strong> 25 years.<br />
And I think I'm speaking on<br />
behalf of many other people<br />
who worked with him when<br />
I express a heartfelt: THANK<br />
YOU MAESTRO!<br />
Andrea Cornetti<br />
Special Devices Designer<br />
10<br />
News & Events<br />
BN62 > december 2011<br />
THYSSENKRUPP CELEBRATES<br />
200 YEARS OF HISTORY<br />
This important anniversary<br />
was marked by a ceremony in<br />
Villa Hügel on the 20th of<br />
November, to commemorate<br />
and celebrate the first<br />
foundation stone laid by Friedrich Krupp in<br />
1811. The event was attended by <strong>about</strong><br />
200 guests, including representatives of<br />
the German government and numerous<br />
managers.
Dealers & Customers<br />
ICC Perù and <strong>Berco</strong> at the<br />
Extemin 2011 trade show<br />
Extemin 2011, the most important<br />
mining industry trade fair in South<br />
America and one of the most important<br />
in the world, was held last September<br />
in Arequipa, Perù. The presence at<br />
Extemin 2011 of the<br />
biggest mining<br />
companies in the<br />
world reflects the<br />
growth trend in the<br />
Peruvian mining<br />
industry.<br />
Currently, Perù is the<br />
biggest producer<br />
of metals in South<br />
America, apart from<br />
copper, and the third<br />
biggest attractor of<br />
investment funds.<br />
ICC Perù, a leading<br />
supplier of top<br />
quality components<br />
at competitive prices, has been <strong>Berco</strong>'s<br />
dealer in Perù since 1996. It has<br />
branches in all the main cities and<br />
offers its customers a wide range of<br />
quality products, together with<br />
supporting services and technical<br />
training.<br />
ICC Perù was at the Extemin 2011<br />
trade fair with an important stand,<br />
where high quality components<br />
from Copparo were on show<br />
together with the other products<br />
it distributes.<br />
Thanks to the precious support<br />
given by <strong>Berco</strong> during the fair,<br />
we were able to demonstrate to<br />
our customers the highly<br />
productive teamwork and<br />
excellent relationship that bonds<br />
<strong>Berco</strong> to ICC Perù, which<br />
contributes to strengthening the<br />
quality guarantee of our products<br />
and the pledge to our customers<br />
to strive for excellence and<br />
continuous improvement.<br />
And so, our presence this year at<br />
Extemin has helped to strengthen<br />
the bonds that ICC Perù has not<br />
only with its customers and<br />
suppliers, but also with the<br />
biggest mining and construction<br />
companies on the market.<br />
Verhoeven at Matexpo 2011<br />
On 8 – 11 September, Benelux distributor Verhoeven<br />
Grondverzetmachines BV attended the Matexpo Fair in Belgium,<br />
which takes place every 2 years. This is the most important fair<br />
in the Belgian construction industry, but with an increasing<br />
number of Dutch visitors every year.<br />
Verhoeven, the Benelux specialist in undercarriage parts solutions,<br />
together with its partner <strong>Berco</strong> exhibited all its product groups<br />
to more than 38000 visitors.<br />
For more info visit: www.verhoevenbv.com<br />
BN62 > december 2011<br />
11