How to set up a Porsche GT3 for the “Porsche Mobil 1 ... - Loctite

Official Loctite ® Customer Magazineno. 2/09How to set up a Porsche GT3 for the“Porsche Mobil 1 Supercup” challengeRead more on pages 4 – 5

10Leadingin Health & SafetyOur contribution to your safety at work.Read more about this topic on page 10.at work | no. 2/09

Editorial | 3Cédric BerthodVice PresidentLoctite Industrial GroupHenkel AdhesiveTechnologies EMEADear Readers,Welcome on board. Once again, we are going to take you on a trip behind the scenes of some the world’s mostfamous and successful companies. In this second issue of our customer magazine at work, we will take you tothe desert, where the iconic Porsche 911 raced down the track in Bahrain’s scorching heat. Another destinationis Scotland, where Terex ® produces a mining truck of gigantic dimensions. The journey will also take you to Italy,where Gessi, the exclusive interior design manufacturer opened its factory gates for us.What is it that powerful race cars, luxurious bathroom fittings and monstrous mining trucks have in common?They all rely on a technology without which modern life as we know it would be unthinkable, but which remainsinvisible for most people: adhesive technology. “This is the golden age of glue” writes the American author BruceSterling and continues: “During the past 30 years, there has been a silent revolution in adhesion.” In this issue, wegive a voice to that silent revolution and open the door to our engineers in Munich and Dublin. They'll share theirinsights and experiences as a part of Sterling’s silent revolution.In our trend report, we follow up on this theme, taking an in-depth look at the history of maintenance, a topicclosely linked to the development of sealants, adhesives and threadlockers.Yours sincerely,Cédric Berthod4 6 14 18Contents4 14Highlight: Porsche MotorsportTake a look behind the scenes of PorscheMotorsport and discover exciting details aboutthe Porsche 911 GT3 Cup car.6 18Reliability Report 3: Terex ®100 ton trucks exerting up to 1000 horsepower.We are paying a visit to the site where thesegiants are manufactured.10 22RD&E InsightsEnvironmentally compatible threadlockersset new standards in Health & Safety andsustainability.12 23Integrated SolutionsDeveloping adhesive formulations tailored tothe needs of a wide variety of industries. One ofHenkel’s core competencies.Trend ReportMaintenance and repair. The future economicpath.Reliability Report 4: GessiLuxury bathroom design "Made in Italy".Manufactured by experts skilled in the fineart of technology.Handy HintsInsights online – let us bring you closer to ourtechnologies and help you find the right Loctite ®product faster and easier.OutlookSome of the topics for the next issue of Loctite ®at work.at work | no. 2/09

4 | HighlightWinning togetherLoctite ® and Porsche Motorsport start their technical partnership at full throttlePorsche Motorsportand Henkel:a winning teamPartner status:Official TechnologyPartner to the PorscheMobil 1 Supercup.Official Partner toPorsche MotorsportFirst participation:2009Main technicalapplications:Engine, Transmission,Differential.Threadlocking:Loctite ® 243,Loctite ® 270Flange Sealing:Loctite ® 574,Loctite ® 5188Cleaning:Loctite ® 7063On a race circuit in Bahrain, a parade of tiny dotswhizzes by in the blistering heat. The icons on parade arethe cars that make up the field of the Porsche 911 GT3Mobil 1 Supercup. The Porsche 911 is a legendary vehicleand a physical symbol of brand awareness rivalled only bya select few. It is one of the few products that have becomea globally recognizable symbol, like Coca-Cola.However, what is not as well known as the elegant, curvedshape of the 911 GT3 that just raced by under the burningdesert sun is this "minor" detail: the construction of the carrelies on modern adhesive technology. In order to drawattention to this fact, Porsche and Henkel, with its strongLoctite brand, have engaged in a partnership to supportthe Porsche Mobil 1 Supercup.The Supercup competition is the overture to Formula 1,the most popular motorsport event in the world. PorscheMobil 1 Supercup races are held on every Sunday beforea Formula 1 race. After the opening event in the Kingdomof Bahrain this spring, ten more races in different Europeancountries are scheduled throughout the course of theyear.The Porsche 911 GT3 Cup cars, which only weigh1130 kg, boast engines with 420 bhp and a top speed of290 kilometres per hour. This lightweight co nstruction ismade possible using alternative materials like aluminiumand composites, which is where adhesives come intoplay. Since aluminium and composites don’t lend themselvesto thermal welding, alternative solutions neededto be found.Porsche and Loctite ® engineers worked together to findexactly those solutions, in the race car as well as in theseries model 911 GT3. Loctite ® products are used in theconstruction of the engine, the gearbox and differential.Porsche relies on the proven Loctite ® durability when itcomes to threadlocking and flange sealing, ensuringreliability of these vehicles even under extreme conditionslike the heat of Bahrain. Loctite ® 243 is used to securebolts on the gearbox clamping plate, the fixing bolts ofthe oil spray tube inside the gearbox and fixing bolts ofthe sequential gear shift system. While Loctite ® 574, afast curing gasketing product, seals the two-part gearboxhousing.The fixing bolts of the differential housing, the stud boltsof the gearbox housing as well as the fixing bolts of the oilpump housing and the bolts of the mounting frame of apinion wheel shaft are secured with Loctite ® 270. Loctite ®products are also used for component manufacturing:Loctite ® 270 for the tappet pins onto the wheel hub, andLoctite ® 243 for the heat protection shield mounted tothe brake caliper protecting electronic sensors from thebrake heat.Loctite ® is heavily used in the manufacturing of thevehicles, but it plays a part in their maintenance, too. Atthe beginning of the season in March, all 14 cars takingpart in the Supercup were provided with a full set ofLoctite ® threadlocking, gasketing and cleaning products.The cooperation between the two companies goes a lotfurther than that, however. Engineers of the two firms arein constant contact and Porsche’s demands often spurinnovation in the Loctite ® labs in Dublin and Munich.at work | no. 2/09

Highlight| 5Bernd Homberg is the Loctite ® Sales Engineer responsiblefor the cooperation with Porsche Motorsports. “It can goboth ways: either we have a new product and approachthe Porsche engineers, they test it and check whether it’shelpful for them. Or, Porsche hits on a problem that canbe solved with adhesive technology and they turn to usfor assistance”. He explains the way the partners worktogether. “At the moment, Porsche is testing Loctite ® 5188as a gasket for the differential housing. When they werelooking for a way to attach a stopper to the tank we wereable to solve the problem with high temperature resistanttwo-component epoxy adhesive Loctite ® Hysol 9492,” hecontinues.This commitment to the high-end of innovation and qualityrepresents only two of the values that Henkel and Porscheshare. The fact that both firms are family businesses thatmaintain long-term relationships with their employees isone of the similarities in company culture that facilitatescommunication.Both companies are used to being consultants as well asmanufacturers. Loctite ® provides its customers with hightechsolutions and individual support. Porsche actuallystarted as an engineering consulting company and hasretained that feature until today.One of the interesting features of what the Americanauthor Bruce Sterling calls the “silent revolution in adhesivechemistry” is the fact that adhesive technology doesn’talways receive a great deal of attention in academia.Groundbreaking research and innovative ideas are oftena result of business needs and take place in companiesrather than natural science faculties. Henkel is trying toremedy this situation, however, and is making its longyears of experience and extensive know-how availableto universities in a number of cooperation projects. As aprofessional partner to young engineers and a productsupplier to their racing teams, Loctite ® has been part of“Formula Student” for several years.Threadlocker Loctite ® 2700:Health & Safety countsFlange sealant Loctite ® 574:fast cure speedThreadlocker Loctite ® 270:high strength for extreme loadsThreadlocker Loctite ® 243:vibration resistant, removable assemblyHigh-speed engineering for professionalsThe Bahrain story of the German driver René Rast makes abundantly clear how crucial good engineering and maintenanceis to succeeding in the Supercup. Ten minutes before the start of the race, René Rast wanted to drive out of the garage,but suddenly there was a loud crack! His chances of making it to the grid in time didn’t look good. One of the two driveshafts had gone. Seven mechanics instantly swarmed the car and managed to do the impossible: within only 8 minutesand 23 seconds they had replaced the shaft, using threadlocker Loctite ® 243 to secure the six bolts holding the shaftto the gearbox. “The change of the drive shaft was done in just over eight minutes”, says engineer Frank Funke, proudof his team Veltins MRS Racing, in an interview with racecam.de. “I owed this result to my boys”, a grateful Rast saidafter the race. He came in second, beaten only by Bleekemolen. Richard Westbrooke, Supercup winner in 2005 and2006, achieved a third place on his comeback to the Supercup.at work | no. 2/09

6 | Reliability Report 3Hard workSiberia, minus 50 °C. A giant truck rumbles along the gravel of the coal mines, with thepowerful determination of an angry rhino. The giant used in the Siberian mines wasmanufactured in Scotland, just like its twin brother doing hard work in copper minesunder the blazing Mexican sun.The factory in Scotland Ready for delivery A wheel as big as a man Wheel suspension of a 100 ton truckat work | no. 2/09

Reliability Report 3| 7These trucks, used for heavy mining work in some of the world'smost treacherous areas, are produced by the American companyTerex ® . Vehicles exposed to the full force of extreme climates and loadsrely on high-end technology in combination with solid engineering to getthe job done. This is where Loctite ® products make an impact, and thetwo companies have a long standing business relationship.22 bolts are secured with Loctite ® 648at work | no. 2/09

8 | Reliability Report 3Terex ® markets more than 50 brands covering a broad range of equipmentfor the construction, infrastructure, quarrying, recycling, surface mining,shipping, transportation, refining, utility and maintenance industries. Henkelhad the chance to send a film crew to the Terex ® plant in Glasgow, Scotlandto see Loctite ® products in action.The enormous power the Terex ® machines wield requires the reliability thatLoctite ® adhesives and sealants can ensure. Locating studs – locked withhigh strength anaerobic compound Loctite ® 648 – allow easy and fastfixturing of the differential, a crucial construction part exposed to strongforces. The rigid flanges of the differential housing are sealed with Loctite ®518. Besides instant seal, Loctite ® 518 guarantees the reliable long-termperformance because there is no gasket relaxation, and correct clamp loadis maintained throughout the life of the assembly. This is a perfect exampleof how Loctite ® products provide optimisation in production.A wheelas big as a manInspiring strong feelingsHow do you measure a company’s appeal? Is it the level of brand awareness?The market position? Customer loyalty?There is another way of doing it, by asking a simple question: whoseproducts will inspire more excitement in a conversation amongst schoolchildren? Applying that measure, even Porsche and Ferrari will have hardtime competing with Terex ® . The American firm is the manufacturer of thebiggest digger and the strongest crane in the world.The list of awe-inspiring products from Terex ® doesn’t stop here. At theScottish location, gigantic coal-mining trucks and other heavy dutyapplications are assembled. To get an idea of how big these trucksreally are, just picture a wheel that is as tall as a grown man. Terex ®produces seven different models of these trucks, with loadingcapacities up to 100 tons.Attention to detail and emphasis on good craftsmanship are theattributes that Terex ® and Loctite ® engineers share. “Jackie is alwaysjust a phone call away,” says Steven Macholecki, a supervisor atthe Scottish Terex ® plant in a video documenting the use of Loctite ® inproduction. Jackie is Jackie Marshall, the Loctite ® sales engineer responsiblefor Terex ® in Glasgow.Marshall spends at least one day a week at the plant in Glasgow, andthe cooperation with the Terex ® engineers seems to be working well forboth parties. “I’m involved in finding adhesive and sealant solutions for newdesigns, but I’m also there when they encounter maintenance problems,”he explains.at work | no. 2/09

Reliability Report 3| 9Long-life, reliablegasketing solutionGlobally, Terex ® is a well-known name when it comes toequipment for the construction, infrastructure, quarrying,recycling, surface mining, shipping, transportation, refining,utility, and maintenance industries. Among its portfolio is animpressive range of heavy duty vehicles including cranes,dumpers, excavators, digger derricks and rollers, as wellas both rigid and articulated trucks.“The company has built a reputation for providing highquality products that do their jobs with efficiency,” explainsDavid Brown, Technical Support Engineer at the Terex ®base in Motherwell, Scotland. “The differential flangemust be sealed in a way to ensure long-term reliability byeliminating leak paths.”Terex ® already used a number of Loctite ® products on itsvehicles for a variety of applications, so it was natural tocall in the local Henkel sales engineer, Jackie Marshall, torecommend a solution.“The answer was to use a liquid gasketing product,” statesDavid. “It was recommended that Loctite ® 518 was trialledfor the purpose – and this provided the solution we wereseeking.”vehicle differentials, but also on gearbox, axle and engineflanges such as timing covers. It provides an instant sealagainst low pressures, fills gaps up to 0.25 mm, and iseffective at temperatures ranging from -55 °C to +150 °C.The size of the flange surface meant that applicationtechniques needed to be taken into consideration. “Weare talking about a two-inch wide film on a three-footdiameter flange,” declares David. “With such an area tocover, normal application methods – such as the use of astandard dispensing gun – were not really suitable. Again,Henkel through its Loctite ® products was able to help.”That help came in the form of the Loctite ® Trax Roller.This is a roller (similar to the one used for painting) that isattached to a dispensing gun, allowing the gasket materialto be applied quickly with a very even film over the wholearea.“Since we have put this solution into practice, we havenever experienced any problems with leakage," concludesDavid.Reliabilityat workCustomer:Terex ® ,ScotlandTask:Provide a long-lastingseal on a three-footdiameter rigid flange atthe rear axle differential.Products:Loctite ® 518Loctite ® 648Liquid anaerobic gaskets conform totally to the flangesurface, filling all gaps and irregularities. Bolts, flange, andgasket act as a unit, sharing operational stresses. Loctite ®518 is designed for sealing rigid flange faces – not only onSource: Terex ® case studyThe rear axle shaft ready for furtherprocessingCleaning the flange of the rear axledifferential with Loctite ® 7063Sealing the flange of the rear axledifferential with Loctite ® 518Differential is ready for assembly22 bolts holding the differential to therear axle are retained with Loctite ®648Transmission and wheel suspension areassembledRear axle ready for the next assemblystepTransmission assembly in a 100 tontruckat work | no. 2/09

10 | RD&E InsightsReliabilityat workBenefits• Medium andhigh strengththreadlockers• Outstandingperformance• Added benefitof enhancedoccupational H&S• No hazard symbols• No risk phrases• No safety phrases• No declarable CMRsDefining sustainabilityEnvironmental awareness has come a long way. Oncethe domain of bearded men wearing Birkenstock sandals,they have now arrived in corporate boardrooms all overthe world. Sustainability has become a buzz word in thebusiness community. What exactly does sustainabilitymean to you, though?That is the question that Henkel Product Manager ErikEdelmann and his team asked their industrial customers.“For most customers it is rather difficult to clearly definesustainability. The term generally encompasses energyand climate, materials and waste, water consumption,health and safety, as well as social progress. However, theprimary focus is clearly on occupational health and safetyand environmental responsibility,” says Edelmann.A clean sheetThis was not an entirely new challenge for Henkel, as thecompany has always placed great importance on nonhazardoussubstances and minimal eco-toxicity in themore than one hundred years of its history. With the newthreadlockers Loctite ® 2400 and Loctite ® 2700, Henkel hasbroken new ground in occupational health and safety. Themedium strength threadlockers Loctite ® 2400 and the highstrength threadlocker Loctite ® 2700 are a leap forward,because they both have a “white” MSDS (Material SafetyData Sheet).Never sacrifice performanceAs usual, the Henkel specialists in the Dublin Technologycentre were working together very closely with theircustomers during the development process. “In the caseof Loctite ® 2400 and Loctite ® 2700, we were collaboratingwith two large customers in France,” says Edelmann. Hisprofessional background is in chemical engineering, atraining which greatly facilitated the communication withleading developer David Condron in Dublin. “The customerstook a very cautious approach and insisted that not eventhe decomposition products should be hazardous,” saysCondron.Not willing to sacrifice performance, Condron and hiscolleagues worked for more than a year on the projectand finally made it happen: they developed products thatretained the customary high Loctite ® performance with a“white” health and safety bill.“We were lucky to have the chance to cooperate withhighly sophisticated and demanding customers,” saysEdelmann.“A white MSDS means that according to the toughregulations of (EC) No. 1907/2006 - ISO 11014-1 boththreadlockers do not carry any hazard symbols, risk or safetyphrases. In addition, they do not contain any declarableCMRs (Carcinogenic, Mutagenic and Reproductive toxins),”explains Edelmann and continues: “You will be surprisedto see that your ordinary dishwashing agent or all- purposecleaner carries more hazard symbols than these industrialproducts.”RD&E InsightsThe evolution of new adhesivesDavid CondronSenior Chemist, Product Development Europe,Dublin, Irelandat work | no. 2/09

RD&E Insights| 11The medical officers in France took a personal interestin the project and gave direct feedback on the variousprototypes. By meeting the customer’s needs, Loctite ®engineers set a new standard in the realm of industrialthreadlocking. “I have to say that we are proud of thisachievement and the fact that we were able to reaffirmHenkel’s position as a technological industry leader,”Condron stated at the end of the interview.Because safety matters: Loctite ® threadlockerswith a “white” health and safety billQuality and responsibility have always been important issuesat Henkel. Continuously striving to improve the Health & Safety ofits products, the company breaks new ground with the medium strengththreadlocker Loctite ® 2400 and high strength threadlocker Loctite ® 2700. Thesetwo products retain the same outstanding level of performance customers have cometo trust, with the essential added benefit of enhanced occupational health and safety:®• Loctite 2400 and Loctite ® 2700 require no hazard symbols, no risk phrases and nosafety phrases on Material Safety Data Sheet complying with the tough EU regulations• They do not contain any declarable CMRs (Carcinogenic, Mutagenic and Reproductivetoxins)• They do not require any entries in sections 2, 3, 15 and 16 of the MSDS according to(EC) No. 1907/2006 - ISO 11014-1No compromise on performanceMedium strength threadlocker Loctite ® 2400 is fluorescent blue with a viscosity of3000 mPa·s and a shear strength on steel of 9 N/mm 2 . The high strength Loctite ® 2700 isfluorescent green, has a viscosity of 500 mPa·s and a shear strength of 18 N/mm 2 . Oncecured, both products offer excellent resistance against most industrial chemicals. Theyachieve good thermal resistance, withstanding continuous operating temperatures up to150 °C.at work | no. 2/09

12|Integrated SolutionsA perfectcombinationWhat do cars, aeroplanes, syringes, shoes, trucks, water taps, arrows from ancientMongolia, spaceships and tunnel boring machines have in common? The answer is:the use of a ubiquitous, yet rarely noticed technology- adhesive engineering. Eventhough the use of glue can be traced back to the Neanderthals, the last 30 yearshave seen an enormous increase in its reliability as well as in industrial adhesiveapplications.Stefan FrischApplication TechnologistHenkel Engineering AdhesiveHermann HandwerkerManager European TechnicalService, Henkel MunichAccording to Stefan Frisch and Hermann Handwerker from Henkel in Munich, thisis not only a fact normally ignored by the layman; even engineers and academicsdon’t give adhesives the credit they deserve. “University courses only touch brieflyon adhesives, one of the “youngest” joining technologies, if they include them at all,”says Frisch, an application technologist. “A lot of the research and the innovationresults from companies like Henkel who are trying to meet customer needs," addsHandwerker.at work | no. 2/09

Integrated Solutions | 13Handwerker, who holds a PhD in chemistry, continues:“After university, I didn’t even think about the adhesiveindustry as a possible employer. And I think it’s the samefor most engineers, too; using adhesives is somehow seenas second best, something to be avoided,” he explains.This is of course completely unjustified, according to Frischand Handwerker, who almost seem like missionaries for theadhesive cause during this lunch-time interview, their zealhardly allowing them to finish their meals.Standard or tailor made?They might have a point, as a look around the Henkeltest centre in Munich demonstrates. Just behindthe entrance there is a showcase displaying avariety of items produced with the use ofadhesives: Loudspeakers, syringes andinfusion bottles to name just a few. Thecentre in Munich is one of the placeswhere Loctite ® specialists conductthe research that Handwerkerand Frisch referred to during theinterview.Frisch points to a differentialgear in one of the rooms andexplains: “This is a project we’vebeen working on for more thana year. A customer from theautomotive industry wanted usto find an adhesive solution forputting together the parts of thisdifferential.” This is one of the benefitsof working for Henkel: Finding andtesting solutions is a service that Henkeloffers as a support to customers in theirdevelopment process.conditions. Applying the products prevents fretting andcorrosion, minimises costly breakdowns and extendsservice life. Appropriate dispensing equipment is availablefor manual as well as other application jobs in the workshop.And should there be problems: the local sales engineer isjust a phone call away.Product applications can be found in a wide range ofindustries. Special packages have been developed forapplications on pump, centrifuge, power plant, shaft and,last but not least, water treatment which by all accounts willbe one of the growth industries of the 21st century.Is there further room for development when it comes to theuse of industrial adhesives? Silly question: “Of course thereis,” says Handwerker. “This is a relatively new technologyand we have just scratched the surface of what’s possible.”This sentence almost exactly echoes a statement madeby his colleague featured in the first issue of this magazineabout the Tear Down Centre. There, an interdisciplinaryteam of specialists looks at each component of a finishedproduct to see whether the value of the product can beenhanced or the cost of manufacturing can be reduced.All these efforts help to spread the word about the powerof adhesives and sealants.But finding or creating the right product is only thefirst step; the second step is applying and dispensingthe product in the right manner. This is the area thatFrisch specialises in. “We offer a large variety of standardequipment, both for manual and automatic dispensing,” hesays. Again, the Loctite ® engineers work on a problem untilthey have come up with a solution that will stand the finaltest of continuous use on an assembly line or in a factoryworkshop. “If no combination of standard equipment willdo, we have a team responsible for designing tailor-madesolutions,” Frisch continues.One of the advantages of being the market leader for sucha long time is the wealth of experience and know-how theteam in Munich has accumulated. The customer gets theright product and the appropriate dispensing equipment allin one, which leads to very user friendly solutions.The omnipresent customer need to cut costs is very muchon the minds of the Loctite ® crew in Munich. Loctite ®adhesives offer benefits not only in manufacturing, butalso for maintenance and repair. Loctite ® engineers havedeveloped solutions that emphasise prevention rather thanrepair. A good example for this strategy is the gearboxand shaft package they have assembled: a range of morethan 20 products developed to perform under extremeat work | no. 2/09

14 | Trend ReportMaintenance −the invisible power of developmentSince humans first began developing tools, there has always been a need to maintainthem. The careful maintenance of an economic production process was often anecessity for survival, especially in times of scarce and valuable commodities. Theroad to implementing modern industrial maintenance was a long one. Given thedevelopments ahead of us, we are still at the beginning of that road.at work | no. 2/09

Trend Report| 15The history of maintenance is also the history of culture andan allegory to the industry's conception and philosophy.Effective and efficient maintenance is, more than ever, vitalfor development, particularly in times of financial crises andreduced turnover, increasing costs for energy, commoditiesand labour.Today, Maintenance, Repair and Overhaul (MRO) costsmore than € 1,500 bn per year in the EU alone, andmore than € 7,000 bn worldwide. Over 50 million jobsare directly related to MRO, and 150 million jobs areindirectly related. However, requirements for MRO areincreasing and, especially in times of financial crisisand reduced budgets, are difficult to meet. Laws aretightening the scope to respond to these requirements,as well as meeting customers’ demands, incorporatingnew technologies, and considering economic and ecologicnecessities. However, modern industry would not be ableto work efficiently without up-to-the-minute and innovativemethods of maintaining tools and equipment.The early years of industry − maintenance byaccidentIn the early stages of industrial development, breakdownswere commonplace due to the means of production and,consequently, down-times were high.The symbol of early maintenance was “the man with theoil can”. And, beside this basic service, one simply had torepair the damage as it occurred. There were no monitoringsystems available at that time, and the analysis of probabilityof failure was in the early developmental stages.The transformation of failure based on preventivemaintenance began with traffic engineering; initially from therailways, and later with aviation technology. The immediatedanger to human life and the difficulties encountered on theway to carry out maintenance work were the driving forcesin the development of preventive maintenance.Prevention is better than a cure − preventivemaintenanceThe reorientation of preventive maintenance in the industrydid not start in Europe or the US, but in post-war Japan.In an exemplary manner, industrial production wastransformed after World War II. The simple concept wasto follow manufacturers’ recommendations about thecontrolled care and maintenance of machines and devices,which was not so usual in the 1950s. It was part of theJapanese Kaizen philosophy, which means (in this context)“continuous improvement toward the better”.Looking into the crystal ball − predictivemaintenanceBy the 1960s, increasing competitive pressure led to asteady improvement and continuity of production plants.Consequently, the reliability of equipment and the probabilityof error intervals became predictable, depending on loadand production time. This knowledge led to the increasingquality standards of used materials and manufacturingprocesses. Predictive maintenance was not able toforesee occurrences caused by incidence or failure butthis approach led to distinct statistical knowledge, whichwas reused by modern technology and software.at work | no. 2/09

Trend Report| 17structure to be monitored, allow a precise data on criticalzones. It also enables Smart Monitoring, which balancesactivities and controls measures.Increase profits through increasedmaintenance efficiency€ 133 mDowntime in a highly-effective plant can cost enormousamounts each minute. A modern power plant, for example,produces up to 1,500 MW from each turbine. Large powerplants, such as Itaipú in South America, have 20 lines.Measured by international energy spot market prices, eachminute of downtime costs the plant roughly €1,500. Farmore error-prone in production is the automotive industry.Here a line has clock rates of less than a minute. So eachminute of downtime could exceed the total amount of onecar’s gross profit.RFID – smart objects everywhereSmart tagging by RFID technology is another approach torealise cost-effective maintenance for complex industrialmachines and plants. RFID enables the implementation ofa smart object from planning to construction, assembling,maintenance, disassembly and reassembly. Maintenancewill be much easier with self-monitoring smart objects,which are able to store their data history, to communicatewith a CMD, to stimulate necessary steps automatically,and to lead service teams to the area where the workis required. In this context, the concept of ubiquitouscomputing will lead to a new approach in dealing with thegrowing complexity of plants and technology.Mobile maintenance communication servicesIn order to avoid downtime, the 24/7 availability of allrequired service parts has to be guaranteed. Successfuland fast operating logistics is a key factor of efficientmaintenance. Requirement and delivery times will bereduced to a minimum through mobile communicationsystems. In connection with RFID technology, specificationsof work pieces, maintenance instructions, technical detailsand construction plans of even the most complex systemswill be available at any time and place.The chemistry of maintenanceFor a long time, maintenance has been seen primarily asa matter of material technique, handcraft and physics.With the development of complex and sensitive plants,chemistry has increasingly found its way into processes.Today, a maintenance team not using numerous chemicalaids such as lubricants, metalworking fluids, protectingsprays or silicone speciality products is inconceivable.Improving maintenance is imperative to cost-effectiveproduction. Given to a standard industrial net profit ratio, areduction of 1 % in maintenance costs may have the sameeffect a 33 % increase in turnover. Even in times of lowerturnover, the demand to reduce the cost of labour (whichcovers 60 % of MRO spendings) will meet maintenance aswell as all other aspects of production. Therefore, the smartreplacement of procedures, such as the substitution ofwelding by bonding technologies, will be able to contributean important share to this goal.€ 100 m8 %3 % ROS€ 100 m€ 3 m € 4 m7 % 8 %4 % ROS 4 % ROSMaintenanceefficiency€ 4 mSalesgrowthmilitary-driven development is able to provide very usefulinformation. Currently, some US universities are developingKnowledge-based Augmented Reality for MaintenanceAssistance. These systems are tentatively using ahead-mounted display to explain maintenance information,construction plans or sensor data.New materials for a new worldIn 1912, the Krupp company developed a new kind ofsteel (a mixture of iron, chromium and nickel) with excellentstrength and durability against corrosion. At that time, it wasa significant step toward reliability. Today, new materialswith outstanding properties are available to enable newapplications. Plastics, composites and carbon fibre havebeen available for some time now and are widely used innumerous industries, from tunnelling to aviation. Along withthese new materials, new maintenance requirements willbe sent to the suppliers of MRO.Currently, self-healing products with the ability to partiallyrepair damages are in development, but are not incommercial use. Another approach to future maintenanceare the amazing capabilities of nano-tech materials with ahigh capability of increasing the stability of equipment byimproved components and processes.From the outset, the goal of maintenance has been toincrease profit by reducing losses in productivity. Plants andproduction of the future will have to be far more complexthan they are today. Highly sophisticated maintenancetechnologies are part of the solution.TurnoverShare of maintenanceReturn on salesProfitProfit increase bySource: MCP GmbHReliabilityat workGlossarybn:billions 1 billion =1,000,000,000m:millions 1 million =1,000,000MW:Megawatt = 1,000,000WattTPM:Total ProductiveMaintenanceCM:Condition MonitoringCMD:Central MaintenanceDatabaseRFID:Radio frequencyidentification bytransponders withintegrated circuitsROS:Return on salesSee, feel, learn − augmented realityAugmented reality deals with the combination of real-worldand computer-generated data, where computer graphicsobjects are blended into real footage in real time. Thisat work | no. 2/09

18 | Reliability Report 4The poetryof added valueA slight, but unmistakable scent of vanilla pervades the hallway, and the attention ofthe visitor is captured by the nostalgic beauty of some antique Italian motorcyclesdecorating the room. What seems like the entrance to an exclusive spa or a fancyhang-out for motorcycle enthusiasts actually leads to a showroom for water taps andshowerheads. But if you associate water taps and shower heads with the appropriateaisle in the DIY store, you need to think again.Gessi company headquarters inVercelli, ItalyEntrance to Gessi’s showroomDesign meets reliability: RettangoloColour water tapRaw material ready for processingat work | no. 2/09

Reliability Report 4| 19Pre-applied coating of water tapsat work | no. 2/09

20 | Reliability Report 4Loctite ® 2701 is put to use onpassive metal surfacesAssembly of plated parts with Loctite ®2701Bagno “Small” is ready for useLoctite ® 638 is used for locking andsealing of threaded parts, even at roomtemperatureReflecting on the morality of objectsBoth Gessi’s and Henkel’s company philosophies emphasise theimportance of beauty. Since its foundation in 1876, Henkel’s missionstatement has remained “to produce products to make life easier, betterand more beautiful”. Beauty, not just the beauty of products, also playsan extremely important role in the Gessi philosophy, which sometimesreads like an artistic manifesto and dazzles with sentences like these:“The core value of the business system is beauty. Beauty does not referexclusively to the aesthetic value of the product since it’s a dimensionthat pervades every aspect of the business.”The average DIY store customer will probably be astonished to learn thata manufacturer of water taps believes that “the true added value of abrand is its poetry content and its respect for the world”. Therefore, themanufacturer hasem barked on a mission to create artistic consumergoods, goods that are meant to “induce a reflection on the morality ofobjects”.Manufacturing beautyGessi, however, doesn’t only talk the talk; at the plant in SerravalleSesia, it walks the walk: “We don’t want to compete with low pricemanufacturers in China. We deliver the highest quality, both in design andfunctionality and it’s working very well for us,” explains Andrea Renna,the Quality Assurance Director. This is no exaggeration: the company’sturnover grew by a stunning 23 % in 2007.Reliabilityat workCustomer:Gessi,ItalyTask:Locking and sealingexclusive sanitaryaccessories for a wholelifetime.Products:Loctite ® 2701Loctite ® 7063Loctite ® 638Loctite ® 243Gessi’s coloured light taps are a good example of this dedication tobeauty and functionality. The Rettangolo Color tap lines feature thetrademark minimalist elegance, relying on geometrical shapes: in thiscase an open rectangle. When water passes through, a temperaturesensitiveLED lights up in different colours – blue, purple, or red –according to the water temperature.Loctite ® has been a partner to Gessi from the very beginning, and Loctite ®threadlockers play an important role in the manufacturing process of alarge number of Gessi products. “We use Loctite ® products for everyscrew that needs to be secured and watertight,” explains Andrea Renna.Be it the extraordinary square showerheads or the huge water taps forindustrial kitchens, Loctite ® always plays a vital part in ensuring thedurability of the fittings.Elegant productionThe plant in Serravalle Sesia, which is just across the road from theshowroom, is another reflection of the company’s emphasis on beautyand design. The production facility resembles a giant lab styled in thecompany colours – orange and black. Every worker wears a shirt or asweater with the company logo. The preferred means of transportationwithin the plant are bicycles. These are, of course, black and orangeand bear the company name as well as the name of the user or thedepartment.at work | no. 2/09

Reliability Report 4| 21Assembly of water taps for handwashbasins with Loctite ® 638Rettangolo Color tap is ready for useAssembly of water taps for kitchensinks with Loctite ® 243Quadro High Tech is ready for useEven though Gessi sells its products to business and private customersall over the world, the entire production process takes place in theSerravalle Sesia plant. Producing in a high-wage region like northern Italyis not seen as a liability, but as an integral part of a company philosophywhich emphasises quality and a high standard of human relationships.Modern times haven’t stopped at Gessi’s doorstep, however. The factory,which is clean and orderly to the point of sterility, belying all stereotypicalperception of Italian chaos and laissez faire, employs robots and otheradvanced production technology wherever possible. The yellow robotsin their metal cages with their graceless, yet effective, movements featureprominently, especially at the beginning of the assembly line.“We automate where we can,” says Renna. “But due to the sophisticationof our products, a lot of work has to be done by hand and this willcontinue to be the case.” While showing us through the plant, Rennapoints to red Loctite ® bottles that can be seen on top of many of thework benches inside the facility. Gessi handles, soap dispensers ormirrors all rely on the performance of Loctite ® 638.Creative solutionsHowever, the collaboration between Henkel and Gessi transcends theusual supplier-customer relationship. As companies whose successdepends heavily on a continuous process of innovation and the abilityto respond quickly to global market demands, Gessi and Henkel haveentered a relationship that can be best described as a form of partnership.Quality Assurance Director Renna recalls the case of a soap dispenserthat Gessi sold to Russia. “Because of the temperature differences, theregular glue we used gave out and broke the glass. We were able tosolve the issue by making use of the flexibility built into certain Loctite ®products,” says Renna.Andrea Renna,Quality Assurance Director,Gessi Spa“Gessi is the leader in bathroom and kitchen sanitary ware and accessories.As of today, we are a worldwide reference for the “Made in Italy” seal asa company whose products are featured in the most exclusive hotels,in the best wellness spas and on the most expensive yachts. Althoughit is a designer product, it is, above all, a quality product.Quality of production, quality of the working environment, qualityin the way we produce our appliances and the way we choose oursuppliers.Loctite ® is a partner which fully meets our philosophy.”“If there is a challenge where we can assist, we take care of itimmediately,” says Massimigliano Moneta, Loctite’s Technical SalesConsultant responsible for Gessi. Loctite ® maintains a laboratory inMilan and the response comes within a matter of days.“Up to now, we have always been able to find asolution, normally by pointing out an alternativeuse for one of the products from our range,”says Moneta. Even if that shouldn’t be thecase at some point in the future, there isalways the European Technology Centrein Dublin ready to take on the task offinding a creative adhesive for a creativecustomer.at work | no. 2/09

22|Handy HintsThe knowledge toolboxWhether you are designing a new product, or looking to keep existing machines running efficiently,Loctite ® can help. Discover the complete capabilities of Loctite ® anaerobic adhesive solutions andinnovations and find the right product for your application needs. Get connected to Loctite ® ’s webplatform designed for engineers, by engineers: www.loctitesolutions.com/ukSee exciting applicationvideos and share ourcustomers’ experiences.Find your specific product solution for yourthreadlocking, thread sealing, retaining andgasketing applications.Order the next issue of at work magazine on:www.loctitesolutions.com/ukat work | no. 2/09

Outlook | 23551 tons of grain within 8 hours. That’ s the kind of speedthat turned the new generation of New Holland combineharvesters into the Guinness world record holder.... coming soonJoin us on our trip to Zagrebwhere we'll visit Končar ElectricVehicles Inc. Witness the production oftheses modern low-floor trams, there are overa hundred which reliably serve the Zagreb publictransportation system on a daily basis.at work | no. 2/09

ImprintPublisherHenkel AG & Co. KGaAAdhesive TechnologiesHenkelstraße 6740191 DüsseldorfGermanywww.henkel.comEditorial DepartmentMarketing Department EMEA:Christian ScholzeAndreas EnglBeate SchneiderIsabelle FeixErik EdelmannFrank FischerContactAndreas Engl (Project lead)Phone: +49-211-797-6758Andreas.Engl@henkel.comCreationblösch.partnerWerbeagentur GmbHwww.bloesch-partner.deHenkel LimitedWood Lane EndHemel HempsteadHertfordshire HP2 4RQTel. 01442 278100Fax 01442 278071www.loctitesolutions.com/ukwww.loctite.co.uk® designates a trademark of Henkel AG & Co. KGaA or its affiliates, registered in Germany and elsewhere © Henkel AG & Co. KGaA, 2009