HYDRAULIKPRESSE - HANSA-FLEX Hydraulics Canada Inc.
HYDRAULIKPRESSE - HANSA-FLEX Hydraulics Canada Inc.
HYDRAULIKPRESSE - HANSA-FLEX Hydraulics Canada Inc.
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12/07<br />
06<br />
12<br />
14<br />
Issue 12/2007<br />
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<strong>HYDRAULIKPRESSE</strong><br />
Mining excavators<br />
Giants in oil sand<br />
Everything from one<br />
source<br />
Moulded hoses now<br />
also available<br />
<strong>HANSA</strong>-<strong>FLEX</strong> Czech<br />
Republic<br />
Development in fast<br />
motion<br />
Mining excavators<br />
Giants in oil sand<br />
Page 6
CONTENT | IMPRESS<br />
Content<br />
Editorial 03<br />
XWORLD Off -Road Events – With a tiger on rough terrain 04<br />
Mining excavators - Giants in oil sand 06<br />
In conversation with Diethelm Kappe 10<br />
Everything from one source – Moulded hoses now also available 12<br />
<strong>HANSA</strong>-<strong>FLEX</strong> Czech Republic – Development in fast motion 14<br />
<strong>HANSA</strong>-<strong>FLEX</strong> branch Nordhausen – A region undergoing upheaval 15<br />
Getting to the top with Magaziner – Adaptation of high-lift trucks 16<br />
<strong>HANSA</strong>-<strong>FLEX</strong> Switzerland – <strong>Hydraulics</strong> service by helicopter 18<br />
Oil treatment made easy– An ABC: Which hydraulic fl uid is right? 20<br />
20 successful years in the hydraulics sector – Change in management at Willmann 22<br />
Quiz, Figures & Facts, Preview 23<br />
02<br />
<strong>HYDRAULIKPRESSE</strong><br />
Editor:<br />
<strong>HANSA</strong>-<strong>FLEX</strong> Hydraulik GmbH<br />
Zum Panrepel 44 · 28307 Bremen<br />
Germany<br />
Phone: 0421 - 48 90 70<br />
Telefax: 0421 - 4 89 07 48<br />
E-Mail: info@hansa-fl ex.com<br />
www.hansa-fl ex.com<br />
Compilation: Dietbert Keßler, Enrico Kieschnick,<br />
Horst Otto (PAPP Werbeagentur)<br />
Layout: N. Staciwa<br />
Print: Berlin Druck · www.berlindruck.de<br />
Responsible for contents: Wolfgang Rink<br />
Frequency: Bimonthly<br />
Subscribe to the on our website.<br />
ISSUE DECEMBER 2007
ISSUE DECEMBER 2007<br />
Dear Reader,<br />
2007 is drawing to a close, and it has been a successful year for <strong>HANSA</strong>-<strong>FLEX</strong>. New branches both at home<br />
and abroad have been added to what is already a dense network. We only recently opened our 300th branch<br />
of the company, guaranteeing even greater proximity to the customer. And with <strong>FLEX</strong>XPRESS we are quickly<br />
on hand to help wherever there are urgent problems with hydraulics.<br />
Our customers tell us time and time again that besides such proximity and our strong focus on service, it is<br />
above all the outstanding commitment shown by all <strong>HANSA</strong>-<strong>FLEX</strong> staff that strengthens the reputation of<br />
our company as a system partner for hydraulics. Our clientele acknowledge such customer orientation by<br />
placing new orders and endowing us with increasing responsibility. Responsibility we are happy to take on<br />
as customer proximity is our guiding principle.<br />
A growth rate of more than 15 percent in 2007 speaks for itself. We are making every eff ort to safeguard such<br />
growth through development of the company. This also includes extending our product range. One new article<br />
in our programme is <strong>HANSA</strong>-<strong>FLEX</strong> moulded hoses, which we not only stock in many diff erent sizes but can<br />
also be manufactured according to customer specifi cations. You can fi nd out more on page 12 of this issue.<br />
We continue to do everything possible to make sure that all customers are fully satisfi ed with the support<br />
they receive. Whether extracting potash in Thuringia, at a diamond mine in South Africa or mining oil sand<br />
at an open pit in <strong>Canada</strong>. Whether quickly sending out a replacement hose line or off ering support to OEMs<br />
with fi nished subassemblies ready for installation directly on site.<br />
With our customer Terex Mining we are even going a step further. On page 6 we describe a tailor-made<br />
solution and show how <strong>HANSA</strong>-<strong>FLEX</strong> can off er effi cient help to its OEM customers directly at their works<br />
with the prompt manufacture of hose lines or curved pipes and a good stock of parts. <strong>HANSA</strong>-<strong>FLEX</strong> develops<br />
such service packages carefully tailored to the requirements of each customer in close cooperation with the<br />
company concerned to help them cut costs and also boost productivity and added value.<br />
As 2007 moves into 2008, we should like to thank our staff for their hard work and commitment giving new<br />
impetus to customer proximity. We also thank our customers for the trust they have put in our company. We<br />
wish you all health and success in the coming year.<br />
The Management Board<br />
The managing directors<br />
FOREWORD<br />
Editorial<br />
Uwe Buschmann Thomas Armerding<br />
<strong>HYDRAULIKPRESSE</strong><br />
03
XWORLD<br />
Mud splashes against the windscreen. The massive<br />
tread of the tyres digs its way forward through the<br />
tough morass. Each pothole is deeper than the last.<br />
The path between the trees narrows, becoming more<br />
and more bumpy - a trial of strength for both the<br />
drivers’ nerves and the axles of the off -roaders. And<br />
now they have to concentrate and make sure they<br />
don’t get stuck!<br />
To date the people taking part in the XWORLD Off -<br />
Road Events have been able to enjoy such adventurous<br />
scenarios. Before the fi rst stage of the tour<br />
starts in March 2008, staff , partners and external<br />
guests will have had the opportunity to try out the<br />
qualities of the upgraded Toyota Land Cruisers far<br />
away from the road. Since this February there have<br />
been over a dozen off -road events and test drives<br />
off ering the chance to experience the XWORLD vehicles<br />
live. A comfortable interior, a powerful 173<br />
hp engine, permanent four-wheel drive and special<br />
equipment for the tour will guarantee safety and<br />
enjoyment in each car. Whether equipped with a<br />
“snorkel” for driving through water, a cable winch<br />
or GPS navigation plus altimeter – the XWORLD vehicles<br />
are not mass-produced items off the shelf but<br />
special custom vehicles designed to cope with the<br />
high demands of the diff erent stages.<br />
Testing in an opencast pit<br />
The jungle-green Toyota Land Cruiser approaches<br />
the high sand dune covered with reed in fi rst gear.<br />
The challenge: The XWORLD off -roader must force<br />
its way up the steep slope without swerving or worse<br />
still, tipping over. The damp sand slips and slides, and<br />
with it the rear of the vehicle. The wheels slowly dig<br />
themselves higher and higher in the tracks up the<br />
dune. Putting your trust in the vehicle with a tiger<br />
on its side is a real thrill. And the off -roader actually<br />
manages to negotiate the crumbling slope without<br />
diffi culty.<br />
4<br />
XWORLD Off -Road Events<br />
With a tiger on rough terrain<br />
<strong>HYDRAULIKPRESSE</strong><br />
The fi rst test drives in testing terrain were performed<br />
by Enrico Kieschnick and the XWORLD project team<br />
at the beginning of 2007. The ideal spot for this<br />
was the disused opencast mine of Meuro near<br />
Senftenberg and Großräschen in Brandenburg. On<br />
this enormous area of land the off -road vehicles<br />
showed what they could do for the fi rst time on<br />
the occasion of the <strong>HANSA</strong>-<strong>FLEX</strong> regional manager<br />
meeting in March. In the middle of October 2007<br />
it was then the turn of the trade press to try out<br />
all XWORLD automobiles in a one-day event held<br />
at the mine. Verdict: The cars can cope with the 43<br />
stages through Europe and Asia!<br />
Grey hills as far as the eye can see. Deep gashes run<br />
down the slopes. The sky-blue Toyota sporting a<br />
panoramic view of the Himalayas disappears in a<br />
cloud of coal dust as it approaches a jagged edge between<br />
boulders. It suddenly lurches forward but the<br />
passengers are safe and secure in their seat belts. The<br />
vehicle slips and rolls in the loose sand until it gets<br />
going again a few metres later on, shortly afterwards<br />
ploughing through a fi eld of grass as tall as a man at<br />
high speed.<br />
Learning how to drive off -road<br />
Thrills and a surge of adrenalin are part of every<br />
event like the obligatory splashes of mud on trousers<br />
and jacket. The spectacular off -road events<br />
are however specially designed to familiarise drivers<br />
with the handling of off -road vehicles in general<br />
and more specifi cally, with the XWORLD Toyota<br />
Land Cruisers. “When driving off -road, there’s a<br />
whole load of things to consider. Even experienced<br />
car drivers need to fi rst learn how to handle our<br />
specially equipped XWORLD vehicles,” comments<br />
project manager Enrico Kieschnick. Together with<br />
<strong>HANSA</strong>-<strong>FLEX</strong> employee Roelof Wittler, the two men<br />
already form a well-rehearsed team of instructors<br />
thank to extensive special training. They are responsible<br />
for the initial briefi ng beforehand and<br />
ISSUE DECEMBER 2007
keep an eye on drivers throughout the entire event,<br />
in some cases remaining in contact by radio. “To<br />
start with, most are impressed by the technology<br />
and size of the vehicle, but this is generally forgotten<br />
after a few laps on site and the fi rst successful<br />
manoeuvres. Afterwards, everyone is delighted at<br />
what the cars can do.”<br />
On the fi rst major test drive in May 2007 the participants<br />
set off punctually over the Alps, heading for<br />
the Balkans to attend the 5th <strong>HANSA</strong>-<strong>FLEX</strong> football<br />
tournament in Croatia. In the Tyrolean mountains<br />
the suitability of the vehicles for long-haul driving,<br />
the tyre-wheel combination and chassis tuning<br />
were put to the test. The vehicle technology managed<br />
the over 1500 km section to Split with fl ying<br />
colours. In the subsequent football tournament in<br />
the blazing sunshine the <strong>HANSA</strong>-<strong>FLEX</strong> players from<br />
Germany had to content themselves with a successful<br />
third place against the fl eet-of-foot Czechs and<br />
the home team from Croatia.<br />
Murky brackish water slops against the white sandy<br />
beaches of the little island on the driver’s door of the<br />
South Sea Land Cruiser. The curtain of reed grass<br />
parts under the light bow wave ahead of the bonnet,<br />
off ering a glimpse of the nearby bank. The off -roader<br />
continues rocking its way forward through deep furrows<br />
and underwater craters. The water level now<br />
starts to fall, and the bank is reached at long last. The<br />
passengers’ feet remain dry but reeds are still caught<br />
in the radiator grille.<br />
Until the start of the tour in March 2008 another<br />
series of diff erent off -road events and show dates<br />
are planned. Until then the XWORLD Toyota Land<br />
Cruisers will cause a stir on German roads. The detailed<br />
XWORLD brochure will give you a taste for<br />
adventure.<br />
ISSUE DECEMBER 2007<br />
Just look on www.xworld.cc or call +49 – 661 - 440<br />
77 27 70 to request your own copy. Every trip will offer<br />
its very own adventures and diff erent highlights<br />
in terms of the scenery. Certain XWORLD stages are<br />
proving very popular so you shouldn’t hesitate if<br />
you are interested in taking part.<br />
Katharina Bader<br />
PRG Werbeagentur GmbH<br />
XWORLD<br />
<strong>HYDRAULIKPRESSE</strong> 5
TEREX GMBH<br />
In the search for crude oil rising oil prices and a foreseeable<br />
scarcity of resources have now prompted the<br />
exploitation of sources which were not previously lucrative<br />
enough. One example of this is the enormous<br />
oil sand fi elds at Fort McMurray in <strong>Canada</strong>.<br />
The province of Alberta contains around one third<br />
of the world’s available stocks of oil sand, which is<br />
mined at open pits by mighty crawler excavators. It<br />
is here that North America’s largest crude oil producer<br />
Syncrude <strong>Canada</strong> Ltd. (SCL) operates three<br />
opencast mines. Gigantic RH 400 mining excavators<br />
from Terex O&K are used to extract the oil sand.<br />
Terex GmbH based at Dortmund, a successor company<br />
to O&K AG founded in 1876, has repeatedly set<br />
milestones in the development of hydraulic excavators<br />
and specialises in extraction and conveying<br />
at opencast mines. At Fort McMurray not only hydraulic<br />
but also cable-operated and bucket-wheel<br />
6<br />
Mining excavators - giants in oil sand<br />
„Works in works“ - a tried and tested concept<br />
<strong>HYDRAULIKPRESSE</strong><br />
excavators are in use. Among them is the RH 400.<br />
With an operating weight of some 1,000 tons it is<br />
the world’s largest hydraulic excavator, with jumbosized<br />
dimensions. The excavator bucket alone has a<br />
capacity of 45 cubic metres, able to handle around<br />
100 tons of oil sand in a single pass. This calls for<br />
enormous forces - something that the RH 400 can<br />
deliver thanks to an engine output of 4400 HP and<br />
hydraulics that can cope with operating pressures<br />
of up to 310 bar. Oil sand can be mined in winter<br />
at - 40 °C when the ground is frozen rock-hard, but<br />
also in summer at + 40 °C when the oil sand has<br />
become a stringy mass.<br />
The extracted oil sand is then loaded onto gigantic<br />
heavy-duty trucks with payloads of up to 360 tons,<br />
which take it away for processing, fi nally resulting<br />
in the coveted crude oil. Four buckets from a RH<br />
400 will fi ll a heavy-duty truck. The mining excava-<br />
tor is controlled from the third fl oor so to speak. It<br />
is at this level that the driver’s cab is to be found,<br />
equipped with a control panel as well as a kitchenette<br />
complete with microwave and area for relaxing.<br />
The precise control system is designed to ensure<br />
easy operation although the skill of the driver<br />
also plays a key role here. Surprisingly, women are<br />
now increasingly to be found in this job: Experience<br />
has shown that they handle their machines with<br />
greater fi nesse.<br />
Ordered at short notice, delivered<br />
promptly<br />
A new RH 400 from Terex O&K is already scheduled<br />
to go into service at one of the three oil sand deposits<br />
in Alberta in January 2008. The time scale<br />
from ordering the mining excavator from the German<br />
manufacturer to commissioning is rather<br />
tight. Nowadays the construction of such mighty<br />
“workhorses” must be performed in record time.<br />
Once a mining company has decided to exploit<br />
a new oil fi eld, it cannot wait months for delivery<br />
of the machine required. For Terex O&K as the<br />
partner to the mine operator this makes high demands<br />
on its readiness to deliver. There must be<br />
no delay in assembly under any circumstances.<br />
Terex O&K therefore expects each subsupplier to<br />
off er special services, something that naturally<br />
also applies to the manufacturers of the hydraulic<br />
connecting elements. The completed excavator is<br />
based on designs, drawings and parts lists from an<br />
existing model but this was last built by Terex O&K<br />
three years ago - mining excavators of these dimensions<br />
are not mass-produced on an assembly line.<br />
As technical progress has not stood still since then,<br />
technological advances must of course also be taken<br />
into account and incorporated during construction<br />
of the machine. This may involve new units with<br />
modifi ed connections or new routings for pipes and<br />
hose lines, which have come about from the experiences<br />
evaluated by the operator over the last few<br />
years. In such cases fi ttings need to be changed,<br />
as well as nominal widths, with pipe manifolds<br />
ISSUE DECEMBER 2007
undergoing redesign, etc. For the hydraulic hose<br />
lines alone, some 150 diff erent types are installed<br />
in the RH 400, with nominal widths ranging from<br />
4 to 204. In addition to the various pipes, the RH<br />
400 excavator also includes 900 metres of hoses,<br />
containing more than 13,000 litres of hydraulic oil.<br />
To build jumbo-sized machines like the RH 400 in<br />
record time, fast solutions are required, so making<br />
high demands on the fl exibility of the hydraulic<br />
hose line supplier due to short-term planning. And<br />
<strong>HANSA</strong>-<strong>FLEX</strong> recently took on this role.<br />
Since 1 July 2007 the hydraulics service provider<br />
from Bremen has been represented at Terex O&K<br />
with its own on-site production facility. The works<br />
in works concept used there gives <strong>HANSA</strong>-<strong>FLEX</strong> the<br />
necessary fl exibility to make changes to components<br />
at short notice whenever required.<br />
Re-orientation calls for change<br />
Cooperation between Terex O&K and <strong>HANSA</strong>-<strong>FLEX</strong><br />
came about after work was disrupted on the installation<br />
sites at Terex O&K following major increases<br />
in production which caused delays in delivery with<br />
various suppliers. The provisioning time for hose<br />
lines was to be slashed from one week to one day<br />
in order to cater for the ever-growing customer<br />
demands. Supply in its existing form was no longer<br />
suffi cient with short-term changes to components<br />
and increasingly tight delivery times for spare parts.<br />
Terex engineers Andreas Bruns and Frank Gorczak<br />
quickly made up their minds and set off to fi nd suppliers<br />
who could guarantee to deliver on the dot.<br />
The search took Andreas Bruns to <strong>HANSA</strong>-<strong>FLEX</strong>’s<br />
Oldenburg branch, where he showed a strong interest<br />
in the production of hydraulic hose lines.<br />
In their discussions it quickly became apparent to<br />
branch manager Jens Bruhn that this was a potential<br />
customer who was after fundamental solutions<br />
according to his specifi cations. He informed key<br />
account manager Matthias Henke at <strong>HANSA</strong>-<strong>FLEX</strong>’s<br />
Head Offi ce about this contact without further ado.<br />
He called Terex Lean Manager Andreas Bruns directly,<br />
and May 2006 then ushered in a period of famil-<br />
ISSUE DECEMBER 2007<br />
iarisation for the two companies. In the following<br />
weeks <strong>HANSA</strong>-<strong>FLEX</strong> teamed up with Terex O&K to<br />
draw up a concept providing for the 9,000 diff erent<br />
articles required for the hydraulic excavators in the<br />
specifi ed quality and guaranteeing 100% availability.<br />
<strong>Inc</strong>luding hose lines in various nominal widths<br />
and with a whole range of special fi ttings, stainless<br />
steel pipes for the air intake system, hoses for the<br />
air conditioning, special steel parts such as pump<br />
fl anges and pipe manifolds with unusual dimensions<br />
and geometries, screw fi ttings and mountings.<br />
A winning concept<br />
<strong>HANSA</strong>-<strong>FLEX</strong> was not only able to supply all that but<br />
also demonstrated the fl exibility and focus on service<br />
required by Terex O&K. In line with its philosophy<br />
of customer proximity <strong>HANSA</strong>-<strong>FLEX</strong> declared itself<br />
willing to set up an individual workshop for this<br />
cooperation, including a complete production line<br />
to manufacture hose lines of all dimensions at short<br />
notice on Terex O&K’s site in Dortmund, as well as<br />
a warehouse stocking the 9,000 associated article.<br />
This solution guaranteed compliance with the<br />
specifi ed delivery time of just one day: The decisive<br />
criterion for Terex O&K! With this so-called “works<br />
in works” concept <strong>HANSA</strong>-<strong>FLEX</strong> has demonstrated<br />
its readiness to fully engage with the customer’s<br />
production processes, something that of course not<br />
only calls for the willingness to run a two-shift system<br />
but also to provide direct help with assembly:<br />
On site <strong>HANSA</strong>-<strong>FLEX</strong> staff measure the dimensions<br />
of the hose lines, establish the angle of rotation for<br />
fi ttings and manufacture the parts in the shortest<br />
possible time. Keeping to their word: If delivery has<br />
been promised within three hours, it will be there<br />
in three hours!<br />
Once this fundamental willingness to cooperate<br />
had been established, everything happened very<br />
quickly.<br />
TEREX GMBH<br />
<strong>HYDRAULIKPRESSE</strong> 7
TEREX GMBH<br />
Ready to go in minimum time<br />
Ralf Vogeler, technical expert at <strong>HANSA</strong>-<strong>FLEX</strong>’s<br />
Head Offi ce, took over the responsible task of comparing<br />
all Terex specifi cations with <strong>HANSA</strong>-<strong>FLEX</strong>’s<br />
delivery programme and ensuring technically fl awless<br />
solutions. This involved analysing all available<br />
engineering drawings and parts lists as Terex O&K<br />
did not want to incur costs for new components<br />
approvals so that cooperation could get off to a<br />
smooth start. The result was impressive, and buyer<br />
Frank Gorczak was able to use these analyses to<br />
check that <strong>HANSA</strong>-<strong>FLEX</strong> fulfi lled all expectations<br />
as the supplier. “We opted for the company who<br />
off ered us the greatest certainty in terms of supply<br />
with its focus on service, product quality and avail-<br />
8<br />
<strong>HYDRAULIKPRESSE</strong><br />
ability of materials.” However, it is not only troublefree<br />
work processes that speak for <strong>HANSA</strong>-<strong>FLEX</strong>, but<br />
also certifi ed quality documented according to EN<br />
DIN ISO 9001 and by Germanischer Lloyd.<br />
To ensure that everything was prepared for the<br />
start of operations in the shortest possible time,<br />
the Sales department in Bremen took over coordination<br />
of the project, appointing Matthias<br />
Henke as project manager. Following conclusion<br />
of the contract in December 2006, the new<br />
<strong>HANSA</strong>-<strong>FLEX</strong> branch was opened in July 2007 at Terex<br />
O&K by Thomas Armerding, managing director of<br />
<strong>HANSA</strong>-<strong>FLEX</strong> Hydraulik GmbH, and Dr. Heribert<br />
Bussmann, managing director of Terex GmbH.<br />
A lodger rigged out in red and<br />
white<br />
From this date the “works in works” concept has<br />
proved a hit. The seven <strong>HANSA</strong>-<strong>FLEX</strong> staff employed<br />
at the works are housed in a 1,300 m2 hall right<br />
next to the installation points. With the help of fi tters<br />
from ThyssenKrupp Industrieservice (TKIN) the<br />
hall was specially tailored to the requirements of<br />
<strong>HANSA</strong>-<strong>FLEX</strong>’s production processes, the machinery<br />
and electrics were installed and the entire facility<br />
of course painted in the colours of <strong>HANSA</strong>-<strong>FLEX</strong>’s<br />
Corporate Identity. The layout of the machines and<br />
storage areas was planned by key account manager<br />
Ralph Rehberger, who will in future also be<br />
in charge of other tasks such as the Cost Reduction<br />
Project in cooperation with Terex O&K. This project<br />
forms part of the contract with Terex O&K and is<br />
meant to cut procurement costs for the excavator<br />
manufacturer within 30 months.<br />
It involves for example suggestions how to optimise<br />
line engineering, e.g. by improving routings,<br />
minimising fi ttings and installation eff ort with new<br />
solutions and streamlining parts lists. The customer<br />
is free to implement the suggestions developed<br />
<strong>HANSA</strong>-<strong>FLEX</strong> as required. The advantages of having<br />
a workshop directly on the customer’s site are<br />
obvious and made themselves felt after just a few<br />
weeks. <strong>HANSA</strong>-<strong>FLEX</strong> off ers just-in-time delivery,<br />
something that is a key factor for Terex when it<br />
comes to complying with assembly times. In addition,<br />
the high level of contact on site provides scope<br />
for close cooperation. When there were design<br />
changes in the length dimensions and angles of rotation<br />
for suction line fi ttings on the world’s largest<br />
hydraulic excavator, a solution was quickly found.<br />
The staff reporting to production manager Marius<br />
Vennemann and his deputy Jörg Schulmeistrat<br />
made precise measurements of the excavator and<br />
soon afterwards the required connecting elements<br />
were ready for installation. And proved to be an<br />
exact fi t: For hose lines with the nominal width of<br />
204 there is almost no leeway for correcting errors<br />
in geometry on installation.<br />
ISSUE DECEMBER 2007
From the warehouse directly to<br />
the oil sand<br />
Stockkeeping is also in the hands of the hydraulics<br />
specialist from Bremen, so allowing Terex O&K to<br />
scale down its own supplies of hydraulic connecting<br />
elements to zero and thereby cut costs. The<br />
components required are arranged in trolleys by<br />
<strong>HANSA</strong>-<strong>FLEX</strong> so they are ready to hand for the fi tters<br />
at their individual workstations. Here the HDS<br />
high-pressure hose lines are also included in the<br />
deliveries.<br />
The close cooperation between <strong>HANSA</strong>-<strong>FLEX</strong> and<br />
Terex O&K is demonstrated every morning when<br />
a work scheduling meeting is held at Terex O&K,<br />
attended by managers from Job Planning, Procurement,<br />
Design and Quality Assurance in order<br />
to assess the level of progress at the installations<br />
points and to determine action for ensuring work<br />
continues swiftly. The members of the <strong>HANSA</strong>-<strong>FLEX</strong><br />
team are also present so are able to quickly respond<br />
ISSUE DECEMBER 2007<br />
to every requirement of Terex O&K without wasting<br />
time. The process will be optimised even further by<br />
the changeover to an electronic ordering system in<br />
2008. The paperless system will speed up the ordering<br />
process as it no longer involves manual system<br />
inputting, so ruling out incorrect delivery due to<br />
data entry errors or misunderstandings.<br />
With the works in works concept <strong>HANSA</strong>-<strong>FLEX</strong> of<br />
course also provides backup to Terex’s customer<br />
TEREX GMBH<br />
service department, which supplies the spare parts<br />
required for the mining excavators from Dortmund<br />
that are used all over the world. Mining excavators<br />
are the key links in the logistics chain for oil sand<br />
extraction and therefore have to function without<br />
interruption as far as possible. Terex O&K can now<br />
off er fast help, with backup from <strong>HANSA</strong>-<strong>FLEX</strong>’s effi<br />
cient warehouse in Dortmund.<br />
<strong>HYDRAULIKPRESSE</strong> 9
IN CONVERSATION<br />
Over 20 years of service at <strong>HANSA</strong>-<strong>FLEX</strong>, to start with<br />
at the workshop, then as a member of the fi eld team,<br />
followed by a position as branch manager. Now four<br />
years spent as regional manager for the branches<br />
of Boff zen/Höxter, Korbach, Paderborn, Blomberg,<br />
Warburg and Lemgo. Diethelm Kappe is a man who<br />
combines theory and practice to come up with customised<br />
solutions.<br />
He was recruited to the company in Boff zen by Peter<br />
Weidtkamp Senior in 1986 and initiated into the<br />
10<br />
In conversation with Diethelm Kappe<br />
„We can‘t manage without training“<br />
<strong>HYDRAULIKPRESSE</strong><br />
world of hydraulics. In 1987 the dynamic growth<br />
enjoyed by <strong>HANSA</strong>-<strong>FLEX</strong> resulted in the founding of<br />
the Paderborn branch, where Diethelm Kappe was<br />
taken on at the workshop. Branch manager Hans<br />
Lohmann quickly spotted Kappe’s suitability for<br />
work in the fi eld and encouraged him to develop<br />
these skills. In 1999 he succeeded his mentor, taking<br />
over his position as branch manager in Paderborn.<br />
He became one of the fi rst regional managers<br />
in 2003 and since 2002 has also been responsible<br />
for internal auditing at the Group’s branches. He<br />
spoke to <strong>HYDRAULIKPRESSE</strong> about his career and<br />
the future of specialist staff .<br />
: Did your time working in<br />
Boff zen leave its mark on you?<br />
Diethelm Kappe: Oh yes, I owe an awful lot to Peter<br />
Weidtkamp Senior. I was very impressed by his<br />
aspiration to run the company like a family fi rm. He<br />
motivated us all with his strategic approach combining<br />
challenge and encouragement, so ensuring<br />
growth of the Boff zen Group. Since then I know<br />
how important it is to have committed staff . In the<br />
meantime the Boff zen Group has been taken over<br />
by one of the shareholders, Peter Weidtkamp Junior,<br />
with whom I enjoy a working relationship based<br />
on partnership. And this is also the case with this<br />
sister Sabine Weidtkamp.<br />
: You have a bond with<br />
Peter Weidtkamp Junior from having worked together?<br />
Diethelm Kappe: You are speaking about my<br />
time in Niederaula. Following a period of intensive<br />
training I worked together then with Peter Weidtkamp<br />
Junior, looking after the tunnel building<br />
sites for the ICE line with a mobile workshop. We<br />
were always on hand with a well-stocked assortment<br />
of parts so spare hose lines could be supplied<br />
without delay. The customer was impressed by the<br />
fast availability and focus on service off ered by<br />
<strong>HANSA</strong>-<strong>FLEX</strong>. Here we virtually acted as pioneers,<br />
with this experience being subsequently incorporated<br />
in the concept of the <strong>HANSA</strong>-<strong>FLEX</strong> mobile<br />
service centre. Today <strong>FLEX</strong>XPRESS off ers a range<br />
of mobile services, guaranteeing fast support for<br />
customers.<br />
: This was soon followed<br />
by a stint in the fi eld team?<br />
Diethelm Kappe: In those days at Paderborn<br />
Hans Lohmann realised that I not only have a good<br />
understanding of technology and am able to get<br />
to grips with a subject but also that I know how<br />
customers’ minds work and speak their language.<br />
I enjoy working outside the offi ce, not least as this<br />
meant I received training from “old hands” such as<br />
Horst Klarholz, Werner Rode and Jürgen Marx. Their<br />
experience and tips were often a great help to me.<br />
on training?<br />
: What value do you place<br />
Diethelm Kappe: We can’t manage without<br />
training - I too received systematic encouragement<br />
and support. Today the opportunities for training<br />
within the <strong>HANSA</strong>-<strong>FLEX</strong> Group are quite diff erent.<br />
For example, courses at the training centre or at<br />
the branches, as well as product familiarisation organised<br />
by suppliers. I set great store by systematic<br />
training for all staff in my region as the continuous<br />
growth shown by <strong>HANSA</strong>-<strong>FLEX</strong> calls for the strategic<br />
cultivation of junior staff at every level.<br />
We can only play an active role in shaping the future<br />
with qualifi ed staff . In the region we have four<br />
youngsters training in the wholesale and export<br />
sector as well as in warehouse logistics. They are<br />
fully involved in processes at the individual companies,<br />
where they learn to act on their own initiative<br />
and take on board our customer and serviceoriented<br />
approach from the very outset. One great<br />
idea is <strong>HANSA</strong>-<strong>FLEX</strong>’s initiative to train a hydraulics<br />
specialist – even providing a diploma. Our workshop<br />
manager in Paderborn, Hans-Josef Denzer,<br />
is due to complete this training course in Dresden<br />
next summer (2008). This will allow all staff to take<br />
on new responsibilities in the course of their career,<br />
including abroad.<br />
ISSUE DECEMBER 2007
specialists?<br />
: Does <strong>HANSA</strong>-<strong>FLEX</strong> need<br />
Diethelm Kappe: This issue also plays a key role at<br />
the meetings of the regional managers. Further development<br />
of the system provider concept means<br />
that we are on the lookout for specialist staff . After<br />
all, we want to ensure dynamic growth in terms of<br />
personnel. Staff who were at our side from the start<br />
will slowly be retiring and need to be replaced by<br />
competent successors.<br />
: Where will future development<br />
take the Group?<br />
Diethelm Kappe: I too have experienced the<br />
transformation from a supplier of spare hose lines<br />
to a system provider for hydraulics. This concept<br />
opens up new opportunities in the market, something<br />
that can also be seen in the increased sales.<br />
Customers appreciate our focus on service, and we<br />
ISSUE DECEMBER 2007<br />
want to optimise this further. Here it is a question<br />
of opening up new markets and making systematic<br />
use of the available opportunities to off er our existing<br />
customer base reliable support. By making<br />
things easier for them - off ering everything from a<br />
single source. We must actively communicate this<br />
message, for example the planning and manufacture<br />
of units or complete hydraulic systems extending<br />
to fi tting and commissioning at customers’<br />
plants.<br />
I have also noticed a change in the approach of<br />
staff . If they were once satisfi ed with supplying<br />
the relevant spare part to the customer, they now<br />
adopt a strategic approach, drawing the customer’s<br />
attention to our services, including the supply of<br />
components or installation. And they look confi -<br />
dent when doing so as they have been trained and<br />
are thus able to off er customers profi cient advice.<br />
: And there are examples<br />
of this in your group.<br />
IN CONVERSATION<br />
Diethelm Kappe: Our off er of repairing cylinders<br />
in Boff zen means fast help for customers right away.<br />
If minor repairs are involved, for example replacing<br />
seals, this can be done in Boff zen by Andreas<br />
Meyer or Ansgar Block. More complex work is carried<br />
out in cooperation with the specialists based at<br />
<strong>HANSA</strong>-<strong>FLEX</strong>’s cylinder repair centre in Königshofen.<br />
: To what extent has<br />
X-CODE been incorporated here?<br />
Diethelm Kappe: Numerous customers are delighted<br />
about using this service module. For example,<br />
the automotive logistics company E.H. Harms<br />
in Paderborn. In the past a fi tter from Harms turned<br />
up at the branch in the morning, armed with a large<br />
box of old hose lines which needed to be replaced.<br />
Today a fax with the X-CODE numbers arrives fi rst<br />
thing. The spare hose lines are immediately manufactured<br />
to order and are ready for collection by<br />
lunchtime.<br />
Or the example of Benteler Automotive and Benteler<br />
Stahlrohr. There hose lines were subsequently<br />
marked with X-CODE on the production machines.<br />
This allows machine downtimes to be kept to an<br />
absolute minimum in the event of repair. And we<br />
even supply the spare parts to the customer using<br />
our service vehicle without any loss of time. Offering<br />
specifi c benefi t to customers: This is where<br />
<strong>HANSA</strong>-<strong>FLEX</strong> is successful.<br />
<strong>HYDRAULIKPRESSE</strong> 11
MOULDED HOSES<br />
When space is tight in machine construction,<br />
manufacturers will now immediately reach for<br />
<strong>HANSA</strong>-<strong>FLEX</strong> moulded hoses. <strong>HANSA</strong>-<strong>FLEX</strong> is rounding<br />
off its comprehensive product range with this<br />
new line: The fl uid technology system partner is now<br />
off ering moulded hoses that can be manufactured in<br />
any form, geometry and diameter and are an ideal<br />
addition to the tried and tested range of products for<br />
fl uid technology.<br />
Anyone who owns a car will know what we are talking<br />
about here: Moulded hoses are used for example<br />
to connect the radiator and the engine. And this<br />
is only one of many possible applications. Moulded<br />
hoses come in whenever pipes reach their natural<br />
limits. This is above all the case with complex installations<br />
when space is tight, calling for bending radiuses<br />
that are just not possible with pipes. In general<br />
moulded hoses can be used to join two parts<br />
together, for example, the fi lter to the transmission<br />
12<br />
Everything from one source:<br />
Moulded hoses now also available<br />
<strong>HYDRAULIKPRESSE</strong><br />
or the steering gear to the oil cooler, especially<br />
when the installation conditions call for bending<br />
radiuses that can only be achieved with moulded<br />
hoses. Such hoses can be manufactured in all forms,<br />
geometries and diameters and are suitable for use<br />
in very cramped spaces. This means that it is possible<br />
to guarantee a technically perfect installation<br />
even under diffi cult, cramped conditions, so in the<br />
end signifi cantly contributing to the wear resistance<br />
of systems.<br />
At the same time moulded hoses even out tolerances<br />
and as vibration dampers have a decoupling<br />
eff ect. They absorb vibration – for example from<br />
the engine – and so reliably prevents this from<br />
causing leakage or worse still, fractures. For this<br />
reason, such hoses are also fi tted in heavy mining<br />
excavators used at open pits. The powerful engines<br />
of these mighty vehicles, which are in non-stop<br />
operation 365 days a year, make the installation of<br />
moulded hoses absolutely essential as they absorb<br />
vibration and oscillation. <strong>HANSA</strong>-<strong>FLEX</strong> produces<br />
customised hoses to the exact specifi cations of<br />
the manufacturer. The man in charge here is Ralph<br />
Rehberger, who is the specialist responsible at<br />
<strong>HANSA</strong>-<strong>FLEX</strong> for the entire sector of moulded<br />
hoses.<br />
Individually moulded<br />
Moulded hoses can be tailor-made as an individual<br />
solution to the exact specifi cations of the customer.<br />
Something that is of advantage particularly with<br />
new designs, which generally call for individual<br />
solutions. <strong>HANSA</strong>-<strong>FLEX</strong> can off er its customers<br />
full service if required: From development of the<br />
moulded hose to sampling and transfer to serial<br />
production. If the customer does not supply the<br />
necessary space coordinates, <strong>HANSA</strong>-<strong>FLEX</strong> will also<br />
take measurements to determine the XYZ data. A<br />
moulding tool is then needed to manufacture the<br />
hose. With the data that have either been provided<br />
or measured <strong>HANSA</strong>-<strong>FLEX</strong> fi rst produces a so-called<br />
moulding mandrel made of steel or stainless steel,<br />
ISSUE DECEMBER 2007
whose geometry will create the hose geometry<br />
required. Vulcanised metal or rubber components<br />
can be incorporated or attached to realise almost<br />
any conceivable design or mounting alternatives –<br />
another advantage of moulded hoses.<br />
As moulded hoses are subject to particularly high<br />
stresses in terms of vibrations and bending loads, a<br />
long service life depends on lasting quality. For this<br />
reason <strong>HANSA</strong>-<strong>FLEX</strong> moulded hoses are produced<br />
from the material EPDM. Ethylene-propylene rubber<br />
is resistant to aqueous media and is therefore<br />
a popular choice for applications involving cooling<br />
water. This versatile material also off ers excellent<br />
resistance to ageing, weathering and ozone, and<br />
can be used in a temperature range from -50 °C to<br />
+150 °C.<br />
Basic range already in stock<br />
Besides the moulded EPDM hoses available from<br />
stock <strong>HANSA</strong>-<strong>FLEX</strong> also manufactures moulded<br />
hoses made of acrylonitrile butadiene rubber (NBR)<br />
from NBR/PVC cuttings according to the requirements.<br />
They are resistant to oil and traces of oil<br />
and are especially robust, non-ageing and fl exible<br />
as well. Chlorobutadiene rubber (CR) off ers good<br />
resistance to chemicals, ageing and ozone while<br />
acrylic-ethylene rubber (AEM) is characterised by<br />
good resistance to mineral oils, water and coolants.<br />
Epichlorohydrin rubber (ECO) has to be used<br />
for moulded hoses which need to simultaneously<br />
withstand temperatures of over 160 °C and the effect<br />
of fuels.<br />
Moulded hoses made of silicone are the choice if<br />
liquid media are to be conveyed with a high material<br />
or ambient temperature. As a fl exible material<br />
resistant to deformation they ey y w wi with wi with withstand t stand temperatures<br />
of up to 180 °C on n a a<br />
llong-term<br />
ong-term<br />
basis, and even to 250 °C for fo or r<br />
brief periods.<br />
ISSUE DECEMBER 2007<br />
With its wide range of moulded hoses <strong>HANSA</strong>-<br />
<strong>FLEX</strong> can now off er customers everything from one<br />
source. <strong>HANSA</strong>-<strong>FLEX</strong>’s warehouse at the Walldorf<br />
branch contains a basic range of all types of moulded<br />
hoses for standard applications such as coolants,<br />
ready for immediate delivery. From an internal<br />
diameter of 20 millimetres up to 78 millimetres.<br />
These robust long-lasting hoses are available from<br />
stock via all <strong>HANSA</strong>-<strong>FLEX</strong> branches.<br />
MOULDED HOSES<br />
<strong>HYDRAULIKPRESSE</strong> 13
BRANCHES<br />
<strong>HANSA</strong>-<strong>FLEX</strong> Czech Republic was founded in Prague<br />
in 1995 with a branch based on the industrial site<br />
of Prazská strojírna A.G., which initially provided<br />
a hydraulics service for the entire region of Central<br />
Bohemia.<br />
It quickly managed to win over customers with the<br />
level of quality supplied, a well-stocked warehouse<br />
and a 24-hour service. Its clientele soon included<br />
numerous transport companies and building contractors<br />
involved in construction of the new traffi c<br />
routes and lines of Prague’s underground railway.<br />
The company then opened a second branch in<br />
Prague in 1999 with a staff of four. Today this offi<br />
ce is responsible for managing all other branches<br />
based in the Czech Republic. It is headed up by Rudolf<br />
Melc. Since 2002 <strong>HANSA</strong>-<strong>FLEX</strong>’s Czech Republic<br />
Group has also included branches in Ústí nad Labem<br />
and Liberec. The branch in Liberec, which is managed<br />
by Pavel Kovarík, is housed in the building in<br />
which the well-known car designer Porsche was<br />
14<br />
<strong>HANSA</strong>-<strong>FLEX</strong> Czech Republic<br />
Development in fast motion<br />
<strong>HYDRAULIKPRESSE</strong><br />
born. Together with the branch in Ústí nad Labem<br />
managed by Rudolf Reichelt it is responsible for<br />
off ering service to North Bohemia. The Ústí branch<br />
was also involved in the tunnelling work for the<br />
motorway network between Prague and Dresden.<br />
Since 2003 the traditionally dynamic industrial region<br />
of Brno has been home to one of the company’s<br />
most successful branches in the Czech Republic.<br />
Here Marian Bednarík and a team of two devote<br />
themselves to the business of hydraulic components<br />
and operate as an OEM for a major exporter<br />
in the oil rig sector supplying the whole of Europe.<br />
In the region of Pilsen, which specialises in mechanical<br />
engineering, Michal Urban manages a<br />
branch founded in 2004. Besides its hydraulics service,<br />
the branch supports the international Ingersoll-<br />
Rand organisation with compressor production as<br />
original equipment. With the help of Karl- Heinz<br />
Loose from Head Offi ce in Bremen, Pilsen is responsible<br />
for supplying curved pipes, produced by<br />
<strong>HANSA</strong>-<strong>FLEX</strong> Weixdorf.<br />
2005 saw the addition of a branch in Pardubice,<br />
which is managed by Miroslav Vencl. This region<br />
is dominated by chemicals production. Its bestknown<br />
product is Semtex, a plastic explosive for<br />
commercial blasting. The customers of the branch<br />
not only include companies from the chemicals industry<br />
but also agricultural fi rms and building contractors<br />
involved in development of<br />
the Prague - Ostrava ava<br />
rail corridor.<br />
Chodov near<br />
Karlovy Vary<br />
was the site chosen<br />
for the next<br />
branch founded<br />
in 2006. Here<br />
branch manager<br />
Zdenek Kozel<br />
was faced with<br />
the major challenge<br />
of in particuu-<br />
lar winning over customers from the mining sector<br />
in the coal basin of North Bohemia and Most.<br />
The region of Ostrava, once a centre for steel in the<br />
republic, has also shown highly dynamic growth.<br />
The demand for hydraulics services is growing<br />
there, so prompting <strong>HANSA</strong>-<strong>FLEX</strong> to open another<br />
branch there in 2007 under the management of<br />
Jirí Stanovsky. This year also saw inauguration of<br />
the tenth branch in the industrial region of Zlín,<br />
where the machine construction sector is currently<br />
undergoing regeneration. This branch is managed<br />
by Martin Panácek. The dense network of branches<br />
in the Czech Republic headed up by Jaroslav Kratochvil<br />
is now aiming to further improve the quality<br />
of services and add to this range according to the<br />
requirements of customers. The <strong>FLEX</strong>XPRESS vehicle<br />
based in Prague is set to be joined by others<br />
in these regions. New services such as X-CODE,<br />
the ISSO standard and of course constant expansion<br />
of the product range are all communicated by<br />
<strong>HANSA</strong>-<strong>FLEX</strong> Czech Republic at exhibitions and fairs,<br />
in trade journals and - it goes without saying - by<br />
<strong>HYDRAULIKPRESSE</strong>.<br />
ISSUE DECEMBER 2007
From 2008 the night will end at 4.00 am for staff at<br />
<strong>HANSA</strong>-<strong>FLEX</strong>’s Nordhausen branch. Introduction of<br />
a two-shift system will then mean getting up early.<br />
This is the only way to cope with customer requirements.<br />
The upheaval underway in an entire region at<br />
the southern edge of the Harz mountains in the north<br />
of Thuringia is apparent.<br />
In Nordhausen branch manager Bernd Bady and his<br />
team of two staff , who will soon be backed up by<br />
the addition of two other colleagues, not only look<br />
after over 1,000 customers in the agricultural sector<br />
and industrial fi rms in the region both large and<br />
small, but act as an OEM to manufacturers known<br />
throughout Germany. One of these is Schachtbau<br />
Nordhausen GmbH, a specialist contractor with<br />
over 105 years of tradition in the techniques of mining<br />
and underground working, as well as the use of<br />
modern building methods. This company operates<br />
in the mining sector in addition to bridge building<br />
and civil engineering and is also involved in environmental<br />
technology.<br />
For centuries Thuringia has been known for the extraction<br />
of potash salt taking place in the region at<br />
ISSUE DECEMBER 2007<br />
BRANCHES<br />
<strong>HANSA</strong>-<strong>FLEX</strong> Nordhausen branch<br />
A region undergoing upheaval<br />
depths between 600 and 1000 metres. Although in<br />
the past many potash mines have seen retreating<br />
and shutdown, the plan is to once again mine potash<br />
salt from 2009 – not least due to the increasing<br />
salt prices. With this taking place at a deposit<br />
containing at least 200 million tons of potash salt.<br />
This means that additional responsibilities are in<br />
store for <strong>HANSA</strong>-<strong>FLEX</strong> Nordhausen. For Schachtbau<br />
GmbH the branch operates as an OEM in the business<br />
area of undercarriages and upper decks for<br />
construction and mine vehicles, leaders and bodies<br />
on MAN drilling equipment.<br />
Maximator GmbH, a systems supplier for high-pressure<br />
and testing technology, hydraulics and pneumatics,<br />
also relies on support from Nordhausen.<br />
As an OEM, <strong>HANSA</strong>-<strong>FLEX</strong> ensures that the right hydraulic<br />
components go into test rigs for high-pressure<br />
applications used to check pressure, bursting,<br />
tightness and internal pressure, under the responsibility<br />
of fi eld team member Volker Weickert. Such<br />
test rigs are utilised in laboratories or R&D facilities<br />
or for quality control and incoming goods checks.<br />
<strong>HANSA</strong>-<strong>FLEX</strong>’s Nordhausen branch is currently managing<br />
a workshop container at the Höllbergtunnel<br />
building site near Bernterode on the B 80 / A 38.<br />
The customer working there has already relied for<br />
years on support from <strong>HANSA</strong>-<strong>FLEX</strong> and its dense<br />
service network at construction sites elsewhere in<br />
Germany and has benefi ted from good experience<br />
with the company. So it was a matter of course<br />
that the nearest branch at Nordhausen should be<br />
in charge of the workshop container at the tunnel<br />
building site in Thuringia. Works manager Bernd<br />
Bady and Volker Weickert are responsible for ensuring<br />
that this mobile container, which is relocated<br />
along with the tunnel building site, is adequately<br />
stocked with the spare hydraulic parts required on<br />
site at all times.<br />
The customer structure of the Nordhausen<br />
branch means that it has to call on the services of<br />
<strong>HANSA</strong>-<strong>FLEX</strong>’s special centres of competence time<br />
and time again when special hydraulic components<br />
or special pipes and fi ttings are needed. And when<br />
it is a question of sealing technology, unit manufacturing<br />
or plant engineering, the team from Nordhausen<br />
are happy to frequently call on the services<br />
and full range of benefi ts off ered by <strong>HANSA</strong>-<strong>FLEX</strong>’s<br />
numerous centres of competence. For example, the<br />
manufacture of hydraulic units required by Schachtbau<br />
Nordhausen for the off shore sector.<br />
<strong>HYDRAULIKPRESSE</strong> 15
MAGAZINER<br />
The logistics sector is booming, and globalisation is<br />
resulting in cargo handling that is not only showing<br />
continuous growth but also has to take place at<br />
ever-increasing speed. International trade is thriving,<br />
something that mainly benefi ts the stock management<br />
sector. Here acceleration of the processes involved<br />
calls for sophisticated storage systems, which<br />
need to fi t together smoothly in the interaction between<br />
rack and truck.<br />
16<br />
Getting to the top with Magaziner<br />
Adaptation of high-lift trucks<br />
<strong>HYDRAULIKPRESSE</strong><br />
This in particular applies to the latest high-rack<br />
warehouses with picking facilities, making use<br />
of special trucks. Magaziner GmbH, which was<br />
founded in 1975 and is managed by the owners as<br />
a family fi rm, specialises in the development, design<br />
and manufacture of combi narrow-aisle trucks.<br />
Magaziner originally made these industrial trucks<br />
– as they are offi cially known – for the brands<br />
Lansing and Linde: very stable and reliable vehicles<br />
featuring fl exible narrow-aisle technology. These<br />
special industrial trucks are characterised by their<br />
individual manufacture. “This means that we can<br />
specially tailor this equipment to the specifi c features<br />
of the customer’s warehouse”, enthuses Magaziner<br />
sales manager Hans-Jürgen Ebsen. While the<br />
competition frequently only off ers product versions<br />
in four sizes, Magaziner can supply overall widths<br />
ranging from 1,000 to 2,600 millimetres - in other<br />
words, especially narrow or wide vehicles, which<br />
with a length of 2,850 millimetres can also be extremely<br />
short and manoeuvrable. With this size<br />
the industrial trucks can be closely adapted to their<br />
subsequent application in terms of the design in<br />
increments of one centimetre – so allowing them<br />
to work equally well in narrow-aisle warehouses<br />
as in halls with large widths for bulky products.<br />
The adaptability of these trucks is of advantage to<br />
the operators of warehouses in the service sector in<br />
order to optimise quiet running and ensure ergonomic<br />
design for picking.<br />
An ideal combination<br />
Such variable adaptation is a convincing reason for<br />
customers to use this equipment. Magaziner only<br />
recently received a major order from a car manufacturer<br />
which ordered 70 trucks for the company’s<br />
logistics system. The enquiry involved narrow-aisle<br />
combi trucks as the manufacturer was already using<br />
picking equipment manned by a driver who<br />
rides up with the pallet to the storage location and<br />
can remove or transfer the goods to stock by hand<br />
as appropriate. This procedure not only brings ergonomic<br />
benefi ts for staff but also more eff ective utilisation<br />
of the space in the high-rise rack as pallets<br />
can be precisely positioned by operators.<br />
Where once there was often only room for three<br />
pallets because visibility from the ground was no<br />
longer very good at heights from six metres, the<br />
driver riding up with the truck can now store four<br />
pallets, so making better use of the capacities available.<br />
It is also easier to remove individual items<br />
from the pallets, also simplifying picking.<br />
ISSUE DECEMBER 2007
Narrow-aisle technology with so-called man-down<br />
trucks has been around for a long time – here the<br />
truck driver remains on the ground. In 1973 Magaziner<br />
was one of the fi rst manufacturers to combine<br />
the two systems including their respective benefi ts<br />
following joint discussions and planning with the<br />
customer in question. Particularly in the fi eld of<br />
automotive engineering the conveyance of parts of<br />
course needs to function smoothly, both in the case<br />
of complete pallets and individual components.<br />
The combi trucks are equipped as standard with a<br />
spacious and comfortable cab, which makes picking<br />
easier thanks to the narrow front railing.<br />
With annual sales fi gures of 250 narrow-aisle trucks,<br />
Magaziner has a market share of 25 percent in this<br />
sector and has become one of the key manufacturers<br />
of such special-purpose vehicles. Magaziner is<br />
the only company to build such combi trucks with<br />
a lift height of max. 17 metres and capacities of up<br />
to 2 tons. Such narrow-aisle trucks are even used<br />
in refrigerated warehouses storing foodstuff s such<br />
as fi sh, meat and frozen vegetables. Here trucks<br />
not only have to cope with a lift height of 17 metres<br />
- the temperatures of -30 °C also occurring in<br />
cold stores make high demands on the operational<br />
readiness of equipment. A true challenge for every<br />
truck.<br />
Truck masts are optimised by means of computerised<br />
design, so making them very lightweight<br />
with excellent visibility. The truck’s overall centre of<br />
gravity is set low to ensure that the vehicle is characterised<br />
by outstanding stability. Another important<br />
feature is a low mast weight as this is a basic<br />
requirement for high performance and low energy<br />
consumption. This means that complex electrical<br />
systems to stabilise equipment are basically not<br />
required in Magaziner trucks.<br />
Equipped for every application<br />
Magaziner is currently working on a special design<br />
for a combi truck that is to be used at a furniture<br />
logistics warehouse. As exhaust gases are to be<br />
avoided at this facility for reasons of hygiene and<br />
ISSUE DECEMBER 2007<br />
to protect the health of the people working there,<br />
Magaziner is designing its trucks as electric vehicles.<br />
It even off ers special-purpose industrial trucks<br />
in a version designed for explosive gas atmospheres<br />
in the chemicals industry.<br />
As Magaziner only sells to dealers, it receives its<br />
orders from their customers. They give the dealer<br />
specifi cations e.g. for the pallet size and fi lling<br />
height as well as the dimensions of the hall, asking<br />
the dealer to arrange for the maximum number<br />
of storage locations and to ensure they provide for<br />
fast handling. Magaziner then advises dealers according<br />
to these customer specifi cations, helping<br />
them to determine all parameters and translate<br />
them into an optimum design. g<br />
As a subsupplier <strong>HANSA</strong>-<strong>FLEX</strong> <strong>FLEX</strong> is naturally also dependent<br />
on this individual alconstruction procedure for trucks. s. Like its<br />
customers, Magaziner expects pects fast<br />
ability to deliver and makes es special<br />
demands on the hydraulics cs serviceprovider.<br />
With individual machines<br />
this of course also includes s advising<br />
on optimum design of the e line engineering.<br />
The timescales allowed for orproduction from placement of an n order<br />
to commissioning of a material<br />
handling vehicle are becoming coming<br />
ever shorter: A fast response onse is<br />
what is needed in the booming ooming<br />
logistics sector. <strong>HANSA</strong>-<strong>FLEX</strong>’s A-<strong>FLEX</strong>’s<br />
Hanover branch staff ed by y manager<br />
Carsten Daumen and his team eam has been in charge of<br />
Magaziner for almost 30 years ears and are used to providing<br />
the customer with extensive support. They<br />
ensure the immediate delivery ivery of hose lines ready<br />
for installation together with ith mountings. Although<br />
Magaziner has its own machines achines for in-house pro- production<br />
of hoses, <strong>HANSA</strong>-<strong>FLEX</strong> <strong>FLEX</strong> nevertheless also<br />
supplies it with the complete mplete hose material<br />
required.<br />
MAGAZINER<br />
<strong>HYDRAULIKPRESSE</strong> 17
<strong>HANSA</strong>-<strong>FLEX</strong> SWITZERLAND<br />
<strong>Hydraulics</strong> service by helicopter<br />
From a commercial enterprise to a strong partner<br />
The new name now makes plain what was clear to<br />
many customers long ago: <strong>HANSA</strong>-<strong>FLEX</strong> AG has become<br />
a high-powered hydraulics partner – for this<br />
reason it was offi cially named <strong>HANSA</strong>-<strong>FLEX</strong> Hydraulik<br />
AG in August 2007.<br />
Under the committed management of Paul Rentsch<br />
the former <strong>HANSA</strong>-<strong>FLEX</strong> AG has transformed itself<br />
from a commercial enterprise with hose line preassembly<br />
to a global hydraulics supplier. “And we also<br />
18<br />
<strong>HYDRAULIKPRESSE</strong><br />
express this with our change in name”, comments<br />
managing director Paul Rentsch. This transformation<br />
coincides with the off er of additional services.<br />
Here <strong>HANSA</strong>-<strong>FLEX</strong>’s fi tting team has already<br />
proved its worth under the toughest conditions,<br />
managing to successfully install and commission<br />
impressive hydraulic systems. For example, on the<br />
Sedrun site at the Gotthard Base Tunnel, where<br />
<strong>HANSA</strong>-<strong>FLEX</strong> was instructed by Marti-Technik AG to<br />
fi t and start up the hydraulic systems on concrete<br />
formwork carriages. When concreting the two tunnel<br />
sections, each with a diameter of around nine<br />
metres, a nozzle rotates around the longitudinal<br />
axis of the tunnel drilling machine and sprays the<br />
enclosed section with concrete. Here the resulting<br />
inner shell has to be as smooth as possible to allow<br />
the trains to subsequently travel through the<br />
tunnel at high speeds. Work at the Gotthard Tunnel<br />
is by no means an easy matter for <strong>HANSA</strong>-<strong>FLEX</strong>’s fi tters<br />
as the driving points can only be reached via an<br />
ISSUE DECEMBER 2007
access gallery some one kilometre metre<br />
in length. This means that<br />
every single component has to o<br />
be lowered from 1,300 metres es<br />
above sea level down to the he<br />
track height of 500 metres using ing<br />
an enormous lift. It must be possible<br />
to dismantle each machine ne so<br />
it will fi t into the lift. The logistics gistics<br />
have to be right as well. If a tool ool or<br />
screw fi tting has been forgotten, otten,<br />
this means going up to get and d coming<br />
back – something that takes kes up to<br />
two hours each time. And the last lift is<br />
at 10.00 pm.<br />
Our team of fi tters therefore turned up with a<br />
10-foot container and 1,500 metres of KP213 hose<br />
complete with swage nipples and screwed connections.<br />
In the tunnel the hose lines ines were measured<br />
up, preassembled and installed, d, followed by commissioning<br />
of the formwork system. Work that<br />
<strong>HANSA</strong>-<strong>FLEX</strong>’s fi tters have already eady carried out on<br />
several building sites, installing ing in total almost almost<br />
9,000 metres of hose line. Several eral hundred metres<br />
of piping were fi tted to the full ll satisfaction of the<br />
customer when <strong>HANSA</strong>-<strong>FLEX</strong>’s X’s hydraulics service<br />
was asked to modify / replace place the production<br />
equipment at Jansen Röhrenwerke. erke.<br />
When the mountain calls for<br />
<strong>FLEX</strong>XPRESS<br />
<strong>FLEX</strong>XPRESS has also been successfully introduced<br />
as a service in Switzerland, with the mobile hydraulics<br />
service fl ying into the mountains by helicopter if<br />
there is no other alternative. With the mobile workshops<br />
the service technicians have repaired many a<br />
hose line on the spot, so reducing downtimes and<br />
avoiding any loss of production.<br />
ISSUE DECEMBER 2007<br />
Here X-<br />
CODE naturally<br />
also<br />
contributed<br />
to clear identifi<br />
cation of spare<br />
parts. The The benefi ts<br />
of the coding system system<br />
when working in the<br />
Gotthard Tunnel need no<br />
special mention. HAN-<br />
SA-<strong>FLEX</strong> has recently<br />
started off ering its Swiss<br />
customers other services<br />
such as the inspection<br />
and maintenance<br />
of hydraulic systems, including<br />
oil treatment. A<br />
service that is of particular<br />
interest to customers<br />
with decentralised, regional<br />
production sites.<br />
<strong>HANSA</strong>-FLE X SWITZERLAND<br />
<strong>HYDRAULIKPRESSE</strong> 19
TRAINING CENTER<br />
In hydraulic systems the hydraulic fl uid or pressure<br />
medium is a decisive factor in determining whether<br />
a hydraulic system operates reliably and achieves a<br />
long service life. The use of fl uids in hydraulic installations<br />
calls for enormous knowledge and care. With<br />
the course subject “Hydraulic Fluids” <strong>HANSA</strong>-<strong>FLEX</strong> is<br />
helping to make customer customers<br />
more aware of how to<br />
handle hydraulic hydrauli<br />
fl uids.<br />
20<br />
Oil treatment made easy<br />
An ABC: Which hydraulic fl uid is right?<br />
<strong>HYDRAULIKPRESSE</strong><br />
<strong>HANSA</strong>-<strong>FLEX</strong>’s training manager Ulrich Hielscher<br />
points out time and time again how serious the<br />
consequences may be if customers use the wrong<br />
fl uids and mixtures of fl uids, or oils which are of<br />
inferior quality or do not comply with the specifi c<br />
operational requirements. “This may even cause the<br />
hydraulic system to fail.” That is why it is essential to<br />
select the right hydraulic fl uid. “Here it is the fi eld of<br />
application that decides - in other words, whether<br />
the system will be used for example for automotive<br />
engineering, in a press or smelting works and rolling<br />
mill; whether it is special-purpose equipment<br />
or a mobile work machine. The maximum operating<br />
pressure also plays a role, as does the ambient<br />
temperature and installation location.” No hydraulic<br />
fl uid is suitable for every application. These oils are<br />
just as varied as their possible uses. Many manufacturers<br />
of branded products clearly state what specifi<br />
cations an oil has to fulfi l for their equipment. “It<br />
is important to know in practical terms that the DIN<br />
standards for hydraulic fl uids only represent the<br />
minimum requirements for manufacturers and operators<br />
and are no longer suffi cient for most applications.<br />
For many plant and mechanical engineering<br />
companies the standard is merely the lowest<br />
level here”, explains Ulrich Hielscher. If an oil does<br />
not meet the manufacturer’s specifi cations, this<br />
may invalidate the warranty. If oils specifi ed with<br />
key performance data are approved by the manufacturer,<br />
the warranty may extend for two years,<br />
and if oils which are specifi cally named and have<br />
been fi eld-tested by the machine manufacturer are<br />
used, the warranty may even be for three years.<br />
Fluid under pressure<br />
When deciding which oil to use, it is a good idea to<br />
take a look at the technical data sheets provided by<br />
the oil supplier. They give the main characteristics<br />
of the oil, for example, the air release capability or<br />
ageing behaviour and its viscosity level. To play it<br />
safe, these data from the oil supplier and the manufacturer’s<br />
specifi cations should always be compared<br />
when selecting the type of oil.<br />
The viscosity does not characterise the quality of<br />
the hydraulic fl uid but indicates how it will behave<br />
at a certain reference temperature. In order to<br />
observe the limits on the use of a hydraulic fl uid,<br />
it is important to take account of the permitted<br />
minimum and maximum viscosity values given by<br />
the manufacturer of the hydro components. The<br />
viscosity of a hydraulic fl uid should not vary widely<br />
with fl uctuations in temperature or there will be<br />
a change in the volume fl ow rates at the throttle<br />
points. In terms of design it is also necessary to look<br />
at the critical range as on start-up, the oil in a machine<br />
should not be too viscous or there is the risk<br />
of it not reaching certain lubricating points quickly<br />
enough. However, once the operating temperature<br />
is achieved, the oil should not be too thin either or<br />
rubbing wear will not be adequately prevented.<br />
Hydraulic fl uids with a high viscosity index are<br />
mainly required for applications subject to wide<br />
fl uctuations in temperature, such as mobile work<br />
machines, vehicles or aircraft.<br />
ISSUE DECEMBER 2007
Maintenance costs money –<br />
repair costs more<br />
Hydraulic installations require precise lubrication<br />
if all components are to be properly controlled<br />
and to ensure smooth operation. In such systems<br />
large volumes fl ow through small spaces under<br />
high pressure. During this process tiny particles<br />
of dirt form a fi ne “grinding paste”, which causes<br />
wear through abrasion. Friction must be reduced<br />
between cylinders and lift rods. Most hydraulic<br />
components move on a very thin fi lm of oil,<br />
which cannot be seen with the naked eye. This<br />
guarantee smooth functioning of the machine.<br />
But only without friction when the oil is absolutely<br />
clean, something that in practice is virtually impossible<br />
– in Ulrich Hielscher’s experience. “Firstly, oil<br />
is always subject to ageing in service. Temperatures<br />
that are too high and too much air in the system<br />
ISSUE DECEMBER 2007<br />
will w cause it to oxidise. Secondly, water can get in as<br />
condensation, and abrasion on hose lines (elastomers)<br />
and pistons or cylinders does not fail to leave its<br />
mark.” Experience has shown that 75 percent of all<br />
hydraulic fl uids in hydraulic systems are not clean,<br />
with w increasing levels of soiling reducing effi ciency<br />
and a the service life of components. The result is unintentional<br />
stoppages along with high costs.<br />
This T is why the right oil treatment is a decisive<br />
factor. f Here Ulrich Hielscher refers <strong>HANSA</strong>-<strong>FLEX</strong><br />
customers to the <strong>FLEX</strong>XPRESS Fluid Service, which<br />
off ers machine operators the option of putting the<br />
responsible task of oil treatment in the hands of capable<br />
specialists. They can quickly make an accurate<br />
and a informative analysis of the oil status for every<br />
machine and submit individual suggestions for optimisation.<br />
t<br />
Thanks to our cooperation with the oil<br />
laboratory WEARCHECK, which is s not linked to any<br />
manufacturer, the result of an oil l check is available<br />
within w 36 hours. This can then be used to draw up<br />
an a action plan, extending from simple fi ltration of<br />
the t oil using the partial fl ow method thod to a complete<br />
oil change.<br />
Buying oil is a matter r of trust<br />
But things do not just end with selection election of<br />
the right oil and its treatment. “Buying<br />
oil is a matter of trust”, emphasises ses Ulrich<br />
Hielscher in his training courses. rses.<br />
A responsible supplier documents ents<br />
his oil deliveries with a technical cal<br />
data sheet and also provides in- n-<br />
formation about his quality as-<br />
surance procedure between the e<br />
refi nery and oil storage facility.<br />
If an oil has not been stored<br />
properly and has already taken<br />
up water, this will of course immediately<br />
impair its properties,<br />
possibly leading to complete<br />
failure of the machine. “Experience<br />
has shown that even new<br />
oils are often delivered heavily<br />
soiled. “For this reason I can<br />
TRAINING CENTER<br />
only recommend”, comments Ulrich Hielscher, “decontaminating<br />
oil using a partial fl ow fi lter system<br />
before fi lling the installation.” This also forms part<br />
of responsible oil treatment!<br />
The <strong>HANSA</strong>-<strong>FLEX</strong> Fluid Service (Tel. 0800 77 12345)<br />
is the simplest route to eff ective oil treatment. It<br />
consists of specialist services ranging from help<br />
with “water in the oil” to a changeover to bio-oil.<br />
The <strong>FLEX</strong>XPRESS fl eet is being gradually fi tted out<br />
with the mobile equipment for the Fluid Service. 30<br />
vehicles currently have such equipment on board in<br />
order to help customers with analysis of their fl uids<br />
and conditioning using the partial fl ow method.<br />
These systems can also be hired by <strong>HANSA</strong>-<strong>FLEX</strong><br />
customers from an equipment pool if they want to<br />
perform oil decontamination themselves.<br />
<strong>HYDRAULIKPRESSE</strong> 21
WILLMANN<br />
On 1 January 2006 <strong>HANSA</strong>-<strong>FLEX</strong> Hydraulik GmbH<br />
took over the shares of Willmann Steuerungstechnik<br />
GmbH. A change in management is now scheduled<br />
for the beginning of 2008.<br />
With the sale of Willmann Steuerungstechnik<br />
GmbH to <strong>HANSA</strong>-<strong>FLEX</strong> Hydraulik GmbH, Wolfgang<br />
Willmann has taken a strategic decision for the future,<br />
designed to ensure the continuity of his company<br />
and so safeguard service for customers on a<br />
long-term basis.<br />
A long-term approach was at issue here, particularly<br />
as regards hydraulic steel construction, a speciality<br />
of Willmann Steuerungstechnik. This sector<br />
had in recent years already been under the control<br />
of Stephan Kallage, who remains at the company in<br />
a management role. This means that the company<br />
22<br />
20 successful years in the hydraulics sector<br />
Change in management at Willmann<br />
<strong>HYDRAULIKPRESSE</strong><br />
will not have to do without his specialist knowledge,<br />
so safeguarding company operations in terms<br />
of ongoing and new projects. The chances of success<br />
for two forthcoming hydraulic steel construction<br />
projects look very promising at the moment.<br />
Wolfgang Willmann was anxious to maintain direct<br />
contact with customers as fast technical assistance<br />
and personal support remain the bywords of the<br />
company. At the special request of <strong>HANSA</strong>-<strong>FLEX</strong><br />
Hydraulik GmbH he initially continued to act as<br />
managing director in particular to arrange for his<br />
successor at the company and to ensure a smooth<br />
handover.<br />
This has now taken place. The fate of Willmann<br />
Steuerungstechnik GmbH is now in the hands of<br />
Stephan Kallage and Martin Brinkmann. Stephan<br />
Kallage takes over as technical director, while Martin<br />
Brinkmann is in charge of commercial management.<br />
In the fi eld Eilt Poppen will be playing an important<br />
role in account management and customer<br />
acquisition, so rounding off the team at Willmann<br />
Steuerungstechnik GmbH.<br />
“Expertise in <strong>Hydraulics</strong>” – Willmann Steuerungstechnik<br />
is set to live up to this claim in future. This<br />
is the challenge taken on board by the new team.<br />
With the technical know-how and experience of all<br />
staff the company will continue to satisfy the expectations<br />
of its customers to their full satisfaction.<br />
ISSUE DECEMBER 2007
Just answer the question correctly and an iPod nano 8 GB could be yours!<br />
Mail your entries to ma@hansa-fl ex.com or post them<br />
to <strong>HANSA</strong>-<strong>FLEX</strong> Hydraulik GmbH, Marketing Department,<br />
Zum Panrepel 44, 28307 Bremen, Germany. Please include<br />
your name and address. Entry deadline: 23rd of January<br />
2008. Only one entry per participant. Any recourse to legal<br />
action and any liability shall be excluded to the extent<br />
permitted by law. The prize may not be paid out in cash.<br />
Read in the following issue...<br />
02/08<br />
Openings<br />
October<br />
<strong>HANSA</strong>-<strong>FLEX</strong> Sp. z.o.o. Ul. Kwiatkowskiego 1 37-450 Stalowa Wola Poland<br />
<strong>HANSA</strong>-<strong>FLEX</strong> Hidraulika d.o.o. Sarajevska 2 18000 Niš Serbia<br />
<strong>HANSA</strong>-<strong>FLEX</strong> Hydraulic Ltd. 135/2 Moo 7, Bann Krua Road 18240 Amphoe Chaloem Phra Kiat Thailand<br />
November<br />
<strong>HANSA</strong>-<strong>FLEX</strong> Hydraulic Co. Ltd. Unit 3.5/F., Far East Consortium Bui Hongkong Hongkong<br />
<strong>HANSA</strong>-<strong>FLEX</strong> Bulgaria Ltd. Kuklensko Schosse No.21 4004 Plovdiv Bulgaria<br />
<strong>HANSA</strong>-<strong>FLEX</strong> Hydraulik GmbH Havelstr. 12-14 24539 Neumünster Germany<br />
December<br />
<strong>HANSA</strong>-<strong>FLEX</strong> Hydraulik GmbH Am Surbach 10 35625 Hüttenberg-Rechtenbach Germany<br />
ISSUE DECEMBER 2007<br />
Anniversary<br />
iPod Nano, 8 GB (up to 2000 tracks), colour: black or<br />
silver; incl. earbud headphones, USB 2.0 cable, dock<br />
adapter, Software iTunes for Mac & Windows; requirements<br />
PC: USB 2.0, Windows XP Home or Professional<br />
Service Pack 2 (or newer), iTunes 7.4; requirements Mac:<br />
USB 2.0, MAC OS X 10.4.8 or newer; (actual product may<br />
diff er from displayed image)<br />
December 2007: <strong>HANSA</strong>-<strong>FLEX</strong> Elsterweda 10 years<br />
January 2008: <strong>HANSA</strong>-<strong>FLEX</strong> Barleben 10 years<br />
<strong>HANSA</strong>-<strong>FLEX</strong> Zwenkau 10 years<br />
XWORLD ADVENTURE 2008/2009 Preparations for the start in Bremen<br />
In conversation with … Regional manager Thorsten Hellmann<br />
Special vehicle construction Stokota off ers winning new concepts<br />
Training centre All oil is not the same<br />
Industrial hoses A new range for the sea water sector<br />
Oil service Improving machine availability, cutting costs<br />
FACTS & FIGURES | PREVIEW<br />
Win an iPod nano!<br />
After what time is the result of an oil<br />
sample by WEARCHECK available?<br />
A: 24 hrs<br />
B: 36 hrs<br />
C: 48 hrs<br />
Correct answer issue 10/07:<br />
B: Suak Nie, C. Seidel, Dortmund<br />
Facts & Figures<br />
Gesamt<br />
316<br />
165<br />
Preview<br />
Deutschland<br />
175<br />
91<br />
Copy deadline: 25th of January 2008<br />
<strong>HYDRAULIKPRESSE</strong><br />
23