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ISSUE 04/2011<br />

THE <strong>MAN</strong> GROUP MAGAZINEforum<br />

MARINE dREAMS<br />

How <strong>MAN</strong> diesel engines<br />

speed up luxury<br />

yachts and pleasure crafts<br />

lONG lIfEcyclE<br />

The routes of used trucks<br />

upon export from Western<br />

Europe<br />

fERTIlE NETwORkS<br />

Why <strong>MAN</strong> <strong>Diesel</strong> & <strong>Turbo</strong>’s<br />

license business forms the<br />

basis for business success


Luxury camping on truck wheeLs<br />

clammy sleeping bags, stuffy quarters, a shared toilet and a garden hose for a shower. Just a few of the less compelling images when<br />

thinking of a camping holiday. yet it is not necessarily so, for camping can be done in style. the continental 11250 from germany’s<br />

special truck maker ketterer can certainly bear comparison with a five-star hotel. the basic vehicle is an man tgx with 360 hp, with the<br />

luxury furnishings distributed over a length of 11.25 meters. at the front of the vehicle, a giant seating area in white leather offers lovely<br />

lounging. meals are prepared adjacently, in a kitchen with white-sanded varnished cupboards. and the shower cabin holds its own<br />

dreamy allure, with an artificial starry sky.


Photos: Ketterer Spezialfahrzeuge AG/pr<br />

Masthead<br />

<strong>MAN</strong> <strong>ForuM</strong> – the <strong>MAN</strong> Group magazine<br />

is published four times a year in German and English.<br />

published by <strong>MAN</strong> SE,<br />

Andreas Lampersbach, Corporate Communications,<br />

Ungererstrasse 69, 80805 Munich, Germany<br />

www.man.eu<br />

editors iN chieF Inés Gutiérrez, Claudia Weber<br />

Tel.: +49. 89. 36098-384, Fax: +49. 89. 36098-382,<br />

E-mail: forum@man.eu<br />

publishers Burda Creative Group GmbH/<br />

BurdaYukom Publishing,<br />

Konrad-Zuse-Platz 11, 81829 Munich, Germany<br />

Tel.: +49. 89. 30620-0, Fax: +49. 89. 30620-100,<br />

www.burdayukom.com<br />

editors Klaus-Peter Hilger (resp.), Kirti Letsch<br />

iNterNAtioNAl editors Patricia Preston,<br />

Asa C. Tomash<br />

<strong>MAN</strong>AgiNg editor Marlies Viktorin<br />

Authors Katharina Becker, Dr. Wolfgang Hörner,<br />

Dr. Martin Kaluza, Barbara Rott, Marcus Schick,<br />

David Selbach<br />

creAtive director Anita Mrusek<br />

Art director Robert Neuhauser<br />

grAphics: Kathrin von Eye<br />

grAphics editors: Michelle Otto (resp.),<br />

Elke Latinovic<br />

cover <strong>MAN</strong><br />

epp Silvana Mayrthaler<br />

productioN Wolfram Götz (resp.),<br />

Franz Kantner, Cornelia Sauer<br />

priNtiNg Pinsker Druck und Medien GmbH,<br />

84048 Mainburg, Germany<br />

Printed on Galaxi Supermat<br />

reproductioN permitted with reference.<br />

Any changes must be coordinated with the editors.<br />

copyright ©2011 by <strong>MAN</strong> SE<br />

and Burda Creative Group GmbH<br />

forum 04/2011 03<br />

contributors<br />

>>> WAshiNg, teNdiNg, sustAiNiNg vAlue<br />

The image of smarmy used-car dealers loitering on street corners<br />

does not bode well with the commercial vehicles market of today.<br />

While researching his story on “the five lives of a truck,” our<br />

author Marcus Schick encountered business people who make it<br />

a professional point of considering their used vehicles a valuable<br />

investment asset, bestowing the necessary maintenance and<br />

cleaning them up for the next user—no matter whether based in<br />

Austria, Saudi Arabia or the most remote corners of Siberia. Thus,<br />

Schick’s journey with <strong>MAN</strong> trucks also became a discovery tour of the globalized world,<br />

where second-hand vehicles are not merely scrappy survivors, but rather traveling companions<br />

and pioneers in rising new markets (page 38).<br />

>>> the right NetWork<br />

It is commonplace to assume that connecting with students<br />

today requires the services of social media channels<br />

such as Facebook, LinkedIn or Xing. Yet sometimes<br />

face-to-face contact is actually the better way to achieve<br />

concrete results. Our author Wolfgang Hörner could see<br />

for himself while looking behind the scenes of a partnership<br />

between <strong>MAN</strong> and eight young students. Created by<br />

the Technical University of Munich, the globalDrive<br />

project offers new perspectives for specific issues both to the company and the students.<br />

Even though the project’s ultimate outcome—the prototype of a truck cockpit—was tangible<br />

enough, the greater part of communications between the students was still conducted<br />

via e-mail, as four of them worked at the University of São Paulo in Brazil (page 28).<br />

>>> the suM oF All pArts<br />

The fascination of a mosaic emanates from the dialogue<br />

between its individual parts. The greater the distance between<br />

the viewer and the image, the fewer details can be<br />

made out—while the object as a whole becomes ever<br />

more conspicuous. Greek illustrator Charis Tsevis uses<br />

this optical effect to create truly fascinating pictures. He<br />

created an image of Facebook founder Mark Zuckerberg,<br />

for example, that merely consisted of social network logos.<br />

Tsevis also followed the same leitmotif for <strong>MAN</strong> Forum—the whole being more than<br />

the sum of its parts—and wove together 100 years of <strong>MAN</strong>-licensed engines in Japan to<br />

show us a remarkable photographic mosaic (page 34).


04<br />

10<br />

standards<br />

02 PersPective<br />

03 contributors<br />

03 masthead<br />

43 forum quiz<br />

30<br />

24<br />

28<br />

38


news<br />

06 New majority shareholder Volkswagen; opening<br />

of kindergarten in Augsburg; major order from<br />

Russia; <strong>MAN</strong> Latin America’s investment plans;<br />

fanmobile for Borussia Dortmund; Ferrostaal be-<br />

comes part of the MPC Group.<br />

interview<br />

10 ‘power stations will be a huge topic’<br />

René Umlauft, CEO of <strong>MAN</strong> <strong>Diesel</strong> & <strong>Turbo</strong> and<br />

a member of the <strong>MAN</strong> SE Executive Board, talks<br />

about his beginnings at the company—and about<br />

his strategies and plans.<br />

feature<br />

14 crown jewels of the sea<br />

For many years, <strong>MAN</strong> has built engines for plea-<br />

sure crafts and motor yachts. The latest highlights<br />

of the boat builders were presented at the PSP<br />

Southampton Boat Show. A tour of the trade fair.<br />

34 tomorrow’s transport<br />

<strong>MAN</strong>’s engineers are working at full speed on a<br />

hybrid drive for distribution trucks. Just recently,<br />

the TGL passed a daily stress test during<br />

delivery operations in Munich.<br />

technology<br />

24 mission possible<br />

Mid-2014 witnesses the launch of four special<br />

ships powered by <strong>MAN</strong> engines. Details about the<br />

offshore ships destined for transport and supply<br />

services for drilling platforms on the high seas.<br />

28 through different eyes<br />

Supported by <strong>MAN</strong> Truck & Bus, an interna-<br />

tional student project of Munich’s Technical<br />

University developed innovative ideas for<br />

commercial vehicles. <strong>MAN</strong> Forum reports.<br />

company<br />

20 paramount patterns<br />

Although product variety can be an advertise-<br />

ment for any company, offering many variants<br />

entails the risk of excessive costs. How <strong>MAN</strong><br />

works to solve this complex equation.<br />

30 building a century on diesel patents<br />

In Japan, <strong>MAN</strong> diesel engines have been suc-<br />

cessfully produced under license for all of 100<br />

years. Why the worldwide issue of licenses is<br />

an important business model for <strong>MAN</strong>.<br />

38 the five lives of a truck<br />

forum 04/2011 05<br />

contents<br />

Thousands of excellently maintained <strong>MAN</strong> trucks<br />

set off every year for their new leases on life<br />

in Russia, Africa or the Near East. A closer look<br />

at their journeys.<br />

42 closing words<br />

Volkswagen AG is <strong>MAN</strong>’s new majority shareholder.<br />

Dr. Georg Pachta-Reyhofen, CEO of<br />

<strong>MAN</strong> SE, explains the benefits that arise from<br />

the relationship.


06<br />

news<br />

At a company meeting, chairpersons of the Group Works Council as well as<br />

representatives of the <strong>MAN</strong> and VW executive boards informed employees<br />

about the joint plans for the future.<br />

> PartnershiP<br />

Volkswagen is the new majority shareholder<br />

Upon clearance issued by the Chinese merger control authorities on november 3<br />

and the closing on november 9, 2011, the majority takeover of Man se by Volkswagen<br />

aG has been completed. the transaction had already been approved by the<br />

european Commission and numerous other authorities. Volkswagen now holds a total<br />

of 55.9 percent of the voting rights in Man and 53.71 percent of its share capital.<br />

no personnel cuts are planned in the merger process. Man’s headquarters will remain<br />

in Munich, all the company’s sites should stay unchanged and the independence<br />

of its brands preserved. “We are opening up a new chapter in our 253-yearold<br />

company history, which is set to continue. at the same time, we shall retain our<br />

special Man identity,” emphasized Georg Pachta-reyhofen, CeO of Man se.


Photo: <strong>MAN</strong><br />

The mAn <strong>Diesel</strong> & <strong>Turbo</strong> day<br />

care center can accommodate<br />

> WOrLD cLASS<br />

Record-breaking compressors<br />

up to 76 children.<br />

With an order value amounting to about €50 million,<br />

mAn <strong>Diesel</strong> & <strong>Turbo</strong> has received its largest<br />

order to date in the field of screw compressors.<br />

in all, 24 compressor systems were ordered for<br />

a chemical complex in chongqing, china, designated<br />

for the production of industrial gases and<br />

chemical raw materials. While the systems will be<br />

designed and manufactured at the mAn <strong>Diesel</strong> &<br />

<strong>Turbo</strong> works in Oberhausen, germany, a part of<br />

the units will be assembled at mAn’s site in<br />

changzhou, china. With a motor power of 8,500<br />

kW, eight of the total of 24 screw compressors<br />

are currently the largest and most powerful units<br />

of their kind in the world. “This large-scale order<br />

is an important strategic reference for mAn in the<br />

rapidly growing chinese chemicals industry,” according<br />

to rené Umlauft, ceO of mAn <strong>Diesel</strong> &<br />

<strong>Turbo</strong>.<br />

Screw compressors<br />

with an output of up<br />

to 8,500 kW<br />

> Opening ceremOny<br />

Kindergarten inaugurated in Augsburg<br />

forum 04/2011 07<br />

mAn <strong>Diesel</strong> & <strong>Turbo</strong> has just opened a new children’s day care center at<br />

its headquarters in Augsburg. Speaking at the opening ceremony, Bavaria’s<br />

Family minister christine Haderthauer said: “These days, qualified job<br />

applicants increasingly judge potential employers on the basis of their<br />

family-friendliness. i am delighted to see companies such as mAn <strong>Diesel</strong><br />

& <strong>Turbo</strong> meeting their wishes.” The new kindergarten will not, however,<br />

be restricted to the children of employees. Some slots will be allotted to<br />

Augsburg families and to socially disadvantaged families from the region.<br />

> mAjOr OrDer<br />

Drive power for cities<br />

mAn Truck & Bus has received a large<br />

order for 2,188 engines from its longtime<br />

business partner, the russian bus manufacturer<br />

LiAZ. The order is valued in<br />

the high double-digit millions of<br />

euros. These engines will operate mainly<br />

in city buses in the metropolises of<br />

moscow and St. petersburg, as well as<br />

in other russian cities.<br />

nikolay Odintsov, ceO of gAZ, the parent<br />

company of russian bus manufacturing<br />

firm LiAZ, and Heinz Brunmayr of mAn<br />

Truck & Bus (from left to right).


08<br />

news<br />

Due for expansion:<br />

the Man’s plant at<br />

resende in Brazil<br />

> Market opportunities<br />

More growth through investments<br />

Man Latin america is planning the largest investment program in its<br />

30 years of company history. this was announced by roberto Cortes,<br />

president of Man Latin america, at a meeting with Brazil’s<br />

president Dilma rousseff. Georg pachta-reyhofen, Ceo of Man<br />

se’s executive Board, welcomed this decision: “the investments<br />

are a logical continuation of the excellent business performance<br />

in Brazil and will prove worthwhile in a market that offers further<br />

potential for growth.” Between 2012 and 2016, Man Latin america<br />

plans to invest more than €400 million in production facilities as<br />

well as in research and development. to mark the introduction<br />

of the Man brand to Latin america as of next year, a dedicated<br />

assembly line for heavy-duty trucks will also be set up at the<br />

Brazilian works in resende.<br />

> aGreeMent<br />

New beginning for Ferrostaal<br />

in their dispute over essen-based industrial services provider<br />

Ferrostaal, the two owners Man and the abu Dhabigovernment<br />

owned international petroleum investment<br />

Company (ipiC) have reached an agreement. Back in<br />

2009, ipiC had purchased an equity stake of 70 percent in<br />

Ferrostaal from Man. Man agreed to repurchase all<br />

shares under the current settlement, but Ferrostaal will not<br />

remain part of the Man Group, subject to clearance by<br />

relevant antitrust authorities. immediately thereafter, the<br />

company will be acquired by the Hamburg-based MpC<br />

Group for up to €160 million. the MpC Group is engaged<br />

in financial services, shipping and shipbuilding, as well as<br />

commodity trading and machinery business.<br />

Handover of keys<br />

to uli Hoeness (r.),<br />

president of FC<br />

Bayern München<br />

> sports partners<br />

At home in the top league<br />

Man’s sponsoring activities have been expanded to include<br />

basketball. in the future, a Lion’s Coach from Man<br />

with exclusive features and fittings will comfortably carry<br />

the basketball team of the FC Bayern München sports club<br />

through the season. this means that all of Munich’s top<br />

league teams in soccer (FC Bayern, 1860 München), basketball<br />

(FC Bayern) and ice hockey (eHC München) are<br />

now using team coaches supplied by Man.


Photo: <strong>MAN</strong><br />

Heading Public affairs at MaN se,<br />

stefan Klatt and his department<br />

are in direct communication with<br />

decision-makers in politics.<br />

> a CaLL to...<br />

Stefan Klatt<br />

<strong>MAN</strong> Forum: Good morning, Mr. Klatt. We’re not<br />

interrupting your champagne breakfast, are we?<br />

Stefan Klatt: (laughs) No worries. I’m just sitting<br />

here at my desk, working like always.<br />

Quite a few people imagine that lobbyists merely<br />

do a little small talk, bubbly in hand …<br />

Yes, perhaps it was like that 20 years ago. Lobbying<br />

work has become very professional since then, however.<br />

If you don’t have anything important to say,<br />

nobody will listen to you.<br />

So what is working in your Public Affairs department<br />

really like?<br />

Well, we’re first and foremost an information service.<br />

Before instituting any policies, politicians are<br />

obligated to glean a reliable representation of the<br />

facts. As we have specialized expertise in our area,<br />

we offer possible solutions to economic, technical<br />

and legal issues. In the end, this also improves the<br />

quality of legislation.<br />

Yet surely the interests of <strong>MAN</strong> are always going<br />

to be front and center?<br />

That is correct. And this must be our primary goal,<br />

of course. But we are not the only ones providing information<br />

to the political landscape. You could regard<br />

it as a matter of competing for the best argument.<br />

Actually, that is why it’s essential that our<br />

work should be legitimate and reliable. Otherwise,<br />

we would lose our credibility.<br />

So you are constantly sparring with rivaling<br />

companies?<br />

Not necessarily. When we pursue the same interests<br />

as our competitors, there is no reason why we<br />

shouldn’t form an alliance.<br />

Your office is in Munich. Wouldn’t you be closer to<br />

the action if you were in Berlin?<br />

While I visit Berlin and Brussels on a regular basis,<br />

my base remains in Munich. Lobbyists who don’t<br />

set foot outside of Berlin can easily lose touch with<br />

the company they represent.<br />

> CUstoM-Made<br />

New fanmobile for Borussia Dortmund<br />

Unmistakably BVB: MaN trailer truck<br />

in the club colors, black and yellow<br />

> BRIC stRategy<br />

Buses a winner in Russia<br />

forum 04/2011 09<br />

In the future, germany’s soccer league champions Borussia<br />

dortmund will be accompanied by a new fanmobile. a specially<br />

adapted MaN semitrailer tractor, the fan shop on wheels houses a<br />

comprehensive collection of fan articles and will be used at Borussia<br />

dortmund’s matches and other events. MaN’s partnership with the<br />

soccer club goes back a long way. For the last decade, the league<br />

players have been traveling to all games in an exclusive MaN team<br />

coach. Matthias Zerber, managing director of BVB Merchandising: “It<br />

makes sense that not just our professional players but also our merchandising<br />

articles aimed at the fans should be transported by MaN.<br />

We are delighted to have MaN on board as a partner and to see the<br />

company strengthening its involvement with Borussia dortmund.”<br />

two awards are highlighting MaN’s success story in Russia. at the<br />

international commercial vehicles trade fair Comtrans 2011 in Moscow,<br />

MaN’s Neoplan Cityliner coach was voted “Bus of the year.” With its striking<br />

design, this vehicle is the best-selling Neoplan model in Russia. another jury<br />

singled out the Lion’s Regio as the winner in the category “lowest running<br />

costs for buses.” Frank Hiller, managing director responsible for Marketing,<br />

sales & services at MaN truck & Bus, was very pleased by the awards: “as<br />

an important growth market, Russia plays a major part in our BRIC strategy.<br />

these distinctions confirm the successful activities of MaN truck & Bus on<br />

the Russian market.”


10<br />

interview<br />

‘Power stations will be a huge toPic’<br />

In early September 2011, René Umlauft became CEO of <strong>MAN</strong> <strong>Diesel</strong> & <strong>Turbo</strong> and a<br />

Member of the <strong>MAN</strong> SE Executive Board. A conversation about <strong>MAN</strong>’s global orientation,<br />

the next generation of specialists and green technologies of the future.<br />

<strong>MAN</strong> Forum: Mr. Umlauft, you have been in office at <strong>MAN</strong> for<br />

100 days. Have you seen a lot of the company in this time?<br />

Umlauft: I have certainly been traveling a lot, primarily to <strong>MAN</strong><br />

<strong>Diesel</strong> & <strong>Turbo</strong> sites in Europe. I have already been to Hamburg,<br />

Berlin, Frederikshavn and Copenhagen. And paid customer visits<br />

to Brazil, Abu Dhabi and Turkey. I haven’t spent a lot of time at<br />

<strong>MAN</strong> <strong>Diesel</strong> & <strong>Turbo</strong>’s headquarters in Augsburg so far.<br />

Why did you choose to move to a different company, after more<br />

than 20 years with the Siemens Group?<br />

Although I was principally concerned with renewable energy in<br />

my last position at Siemens, my background is actually oriented<br />

towards fossil fuel power plant technology, with steam turbines,<br />

gas turbines and compressors. This is proving useful at <strong>MAN</strong>.<br />

Moreover, <strong>MAN</strong> is in a particularly exciting phase. There’s much<br />

to do and to contribute. I’m also able to get involved in a new field<br />

of great technological interest for me: the large-bore diesel engine.<br />

This is a completely new group of customers and a new line<br />

of work. The diesel engine offers highly interesting prospects,<br />

especially in the power station sector.<br />

In the context of the energy turnaround, are diesel power stations<br />

actually still relevant?<br />

Absolutely, and above all in combination with wind and solar<br />

energy. Imagine a village somewhere in the midst of India or Africa<br />

that is not hooked to the grid. There may be plenty of wind and<br />

sun available to allow for the installation of wind turbines or<br />

photovoltaic systems—but what do you do at night? Or during a<br />

lull? Batteries are very expensive. A diesel power station that can<br />

be easily integrated with your wind power and solar facilities is<br />

simpler and cheaper. The diesel engine runs at night and you<br />

switch it off at sunrise. We already have such systems in place for<br />

the wind power sector, set up by <strong>MAN</strong> in partnership with the<br />

wind power specialist Enercon.<br />

<strong>MAN</strong> <strong>Diesel</strong> & <strong>Turbo</strong> also supplies steam turbines to solar thermal<br />

power stations that produce heat through the sun …<br />

That is correct: In Spain, the United Arab Emirates and Thailand.<br />

We have already sold a few turbines in this sector. And our Hamburg<br />

site is also busy manufacturing for small biomass power<br />

plants with an output of five to 10 megawatts that we supply components<br />

for. All in all, renewable energy is developing into a highly<br />

interesting business area.<br />

Is this also the result of the energy turnaround away from fossil<br />

fuels and nuclear power?<br />

Only to a limited extent. For we’re mainly talking about the energy<br />

turnaround in Germany. Other countries have a rather different<br />

perspective. There will certainly be other industrial countries,<br />

like Japan, which will rethink their power sourcing after the nuclear<br />

catastrophe in Fukushima. Otherwise, although I can detect<br />

a general trend in the direction of renewable energy, that is not<br />

necessarily equal to a turnaround.<br />

You are a pioneer yourself, having used a Lexus hybrid model<br />

as your company car for a long time …<br />

Yes, that’s right. I was the first head of division at Siemens to be<br />

using a car like that. It stirred up some debate, because there I was,<br />

a German executive driving a Japanese car. At the time, however,<br />

there simply weren’t any German hybrid vehicles available on the<br />

market.<br />

“<strong>Diesel</strong> engines make an excellent<br />

combination with wind and solar parks.”<br />

rené umlauft, ceo of Man <strong>Diesel</strong> & turbo and<br />

Member of the Man se executive board<br />

Photo: Regina Recht


Power plant specialist René<br />

Umlauft wants to tap the market<br />

for renewable energy.


12<br />

“We will have a much stronger<br />

presence in the emerging<br />

nations than we do today.”<br />

René Umlauft, CEO of <strong>MAN</strong> <strong>Diesel</strong> & <strong>Turbo</strong> and<br />

Member of the <strong>MAN</strong> SE Executive Board


Photos: Regina Recht<br />

So what was the car like to drive?<br />

The purely electric drive makes it extremely exciting. There’s<br />

enormous acceleration, especially when the hybrid has both engines<br />

running simultaneously. A purely electric car wouldn’t suit<br />

me yet, however. I make long trips fairly often, and it will be<br />

a while before there’s sufficient range.<br />

Going back to <strong>MAN</strong>: Will energy production become even more<br />

important for the company in the future?<br />

This area already plays an important role today, and we shall be<br />

expanding it further. I see major opportunities worldwide—especially<br />

in the developing nations, such as in Africa. We have greatly<br />

grown our business there recently. There is also tremendous market<br />

potential in Brazil. We’re just starting in China and the US and<br />

also are still not doing enough in Russia and Turkey. At the moment,<br />

we are pretty heavily focused on Europe. But the European<br />

markets are hardly growing anymore.<br />

Where will <strong>MAN</strong> <strong>Diesel</strong> & <strong>Turbo</strong> be in 10 years’ time?<br />

I haven’t been on board for all that long, so I am inclined to be<br />

cautious in my judgment. But it is conceivable that by then the<br />

company could have tripled its turnover to about €10 billion. We<br />

will be much more strongly represented in the emerging countries<br />

than we are today. Overall, there are many more opportunities<br />

for <strong>MAN</strong> <strong>Diesel</strong> & <strong>Turbo</strong> than we are even aware of. We don’t<br />

yet have sufficient knowledge of the market, nor of many competitors.<br />

This situation needs to be improved. Just look at a Brazilian<br />

or Chinese steam turbine producer, for example. We could assume<br />

that these companies don’t represent competition as long<br />

as they stick to their own market. But this could change rapidly.<br />

And then I want to be properly prepared.<br />

How will <strong>MAN</strong> <strong>Diesel</strong> & <strong>Turbo</strong> continue to develop from a components<br />

manufacturer to a full-service supplier?<br />

It might be a little too early to answer that question. To handle<br />

that particular line of business, we have indeed set up a dedicated<br />

strategic business unit, Power Plants, for which I am also<br />

responsible. We will certainly continue to develop this area in<br />

the future. In that regard though, we need to carefully reflect<br />

whether that growth is possible with just the existing components<br />

and whether our steam turbines are fit for the use in<br />

biomass plants after all. This is an extremely interesting, yet<br />

also very complex area. One thing we can be sure of, however,<br />

is that power plant technology will become a huge topic in the<br />

future.<br />

> PERSONAL PROfiLE<br />

René Umlauft<br />

forum 04/2011 13<br />

interview<br />

Born in Berlin, Umlauft studied machine tool building and<br />

factory planning at the Technical University of Dresden. He<br />

began his professional career in 1991 in gas turbine maintenance,<br />

working for Siemens in Mülheim an der Ruhr. His<br />

work included the analysis of major damage to power<br />

stations. in 2002, he became head of the Siemens works in<br />

Görlitz, where he was responsible for the company’s<br />

worldwide business with industrial steam turbines. After<br />

moving to the Siemens Erlangen site in 2007, he became<br />

responsible for the business with large-scale components<br />

for power stations and head of Siemens’ new Renewable<br />

Energy division soon thereafter. After two decades at<br />

Siemens, he moved to <strong>MAN</strong>, where he was appointed CEO<br />

of <strong>MAN</strong> <strong>Diesel</strong> & <strong>Turbo</strong> and Deputy Member of the <strong>MAN</strong> SE<br />

Executive Board on September 1, 2011. Umlauft, 47, is a<br />

passionate long-distance runner and has finished several<br />

half-marathons. He is married and has two children.<br />

You need top specialists to meet such technological challenges.<br />

Can you find the staff you need?<br />

Naturally, we are affected by the lack of specialists. That goes for all<br />

companies engaged in strongly growing sectors—not just in Germany,<br />

but in other countries as well. We must ensure that we create<br />

an attractive brand for applicants. At times, university graduates<br />

and other specialists are not sufficiently aware that <strong>MAN</strong><br />

actually has a major line for power station components and largebore<br />

diesel engines, such as for seagoing vessels. I myself had been<br />

an insider and considered <strong>MAN</strong> <strong>Diesel</strong> & <strong>Turbo</strong> a competitor. And<br />

yet, I still wasn’t actually aware of the size of this business area. We<br />

are thinking about a communications concept to change that.<br />

The signs are pointing to a slowing economy. To what extent<br />

will <strong>MAN</strong> be affected—and particularly your sector?<br />

We can already foresee difficult times ahead. Yet, we have put<br />

flexible structures into place, so we can work around possible<br />

dents and challenges for capacity utilization in individual departments.<br />

In the mid- to long-term time frame, however, the opportunities<br />

are much more numerous than the risks.


14<br />

reportage<br />

Sparkling stainless<br />

steel, gleaming curves<br />

of wood: Built by the<br />

Hardy company, the<br />

yacht Lysithea is a real<br />

eye-catcher. Below<br />

deck, two 800-hp <strong>MAN</strong><br />

engines supply power.


crown jewels of the sea<br />

Every year in September, the Southampton Boat Show is the center of<br />

attention for luxury shipyards and their clientele. During the event, the basin<br />

on the Mayflower Park quay turns into the world’s most expensive harbor.<br />

forum 04/2011 15<br />

feature<br />

Photo: Jiri Rezak


16<br />

feature<br />

01<br />

1. Lined up like a string of pearls: Sunseeker<br />

presents its floating wonders in Southampton.<br />

2. Characterized by powerful acceleration and<br />

smooth and comfortable operation, <strong>MAN</strong>’s<br />

diesel engines keep yachts and sports boats<br />

moving around the world.<br />

02<br />

>>> The landing stages at the Southampton<br />

yacht marina bustle with visitors. Sailboats,<br />

pleasure crafts and massive sleek yachts are<br />

moored close together. Hostesses wearing<br />

dark glasses and white windbreakers smile<br />

from the afterdecks. As Great Britain’s most<br />

important exhibition for boats, the Southampton<br />

Boat Show takes place every year in<br />

September. More than 580 exhibitors have<br />

signed up, and by the end of the 10-day<br />

event, the number of visitors will have surpassed<br />

the mark of 110,000. Naturally, the<br />

number of people seriously interested in<br />

making a purchase is rather low. “You don’t<br />

sell a boat overnight as if it were a TV set,”<br />

says Mark Funnell from the deck of the<br />

Lysithea, a yacht of the Hardy 50 class and<br />

tethered to one of the jetties. Sporting a blue<br />

polo shirt and shortly cropped hair, Funnell<br />

owns the Hardy company, which is based in<br />

North Walsham, in the east of England, and<br />

employs a staff of 24.<br />

The three boats moored at the jetty<br />

were personally sailed here by Funnell, his<br />

daughter and an employee. “We’ve come<br />

round from Norfolk, in rough weather with<br />

a wind of 30 knots,” says Funnell. Hardy<br />

yachts enjoy the reputation of being no less<br />

seaworthy than a coast guard cutter and<br />

precisely what his customers—most of<br />

whom are their own skippers—expect.<br />

Mark Funnell does not sell cookie-cutter<br />

boats. His customers are first queried about<br />

their home port. “It makes a difference<br />

whether they come from a sheltered port<br />

like Southampton or a small port in the<br />

north of England or on the coast of Scotland,”<br />

he says. “If somebody plans to spend<br />

time in the waters up there, I advise against<br />

putting too many structures onto the roof.<br />

The heavy weather could just blow it all<br />

away.” Most of Funnell’s customers come<br />

from England and Scotland, with a buyer<br />

from Russia joining the roster last year.<br />

The Lysithea is 50 feet long. Built in<br />

2007, she is used as a demonstration model<br />

and looks solid—with the design reminiscent<br />

of a houseboat. Funnell smiles roguishly:<br />

“You don’t want to underestimate her,”<br />

he says. “We have two 800-hp <strong>MAN</strong> engines<br />

on board, which gives her a maximum<br />

speed of 30 knots.” As Funnell is well aware,<br />

this is more than the highest speeds<br />

reached by some of the sporty looking<br />

boats on the jetty opposite. He has been using<br />

<strong>MAN</strong> engines for eight years now. “I<br />

didn’t even know that <strong>MAN</strong> made engines<br />

of this size at all, until I saw them displayed<br />

here,” he says. “They are the most reliable<br />

that I have ever installed on a ship.”<br />

<strong>MAN</strong> has set up its booth less than a<br />

hundred meters from the mooring station<br />

of the Hardy yachts. The only exhibit is a<br />

gleaming white V12 engine with gold-plated<br />

cylinder head caps. “This is not a special<br />

paint for the event, but rather what the engines<br />

look like when they leave the factory<br />

“You don’t want to<br />

underestimate the boat.<br />

We have two 800-hp <strong>MAN</strong><br />

engines on board.”<br />

Mark Funnell, owner of yacht manufacturer Hardy<br />

Photos: Jiri Rezak


From a distance, visitors to the Boat<br />

Show can also admire large vessels:<br />

Southampton is Europe’s most<br />

important starting point for cruises.<br />

forum 04/2011 17<br />

reportage


18<br />

reportage<br />

Opportunity for valuable contacts: An <strong>MAN</strong><br />

Truck & Bus staff member is discussing<br />

technical details with an interested visitor.<br />

in Nuremberg,” explains Peter Schedel,<br />

head of Marine Sales at <strong>MAN</strong> Truck & Bus.<br />

The engine certainly attracts attention. Today,<br />

on a weekend with typically changeable<br />

English weather, entire families in fleece<br />

jackets are strolling along the stands and<br />

taking pictures. “Our market is the 50- to<br />

80-foot yacht sector,” says Schedel. The engines<br />

are known for being light and compact,<br />

with a powerful torque. Such specifica-<br />

tions are also in demand for other applications:<br />

They are used by English coast guard<br />

cutters, in fishing vessels off the coast of<br />

Alaska and in inland vessels of the river police—though<br />

in a more modest design. “For<br />

such purposes, we supply the same engine<br />

in a gray paint version,” explains Schedel.<br />

British yacht manufacturer Sunseeker<br />

is one of <strong>MAN</strong>’s most important regular<br />

customers. The company can afford what is<br />

by far the most spectacular stand at the<br />

boat show and a real crowd puller. Covered<br />

by black carpeting, a broad stairway is<br />

flanked on both sides by three large yachts.<br />

A queue of 15 visitors has formed to view the<br />

Predator 64, the numerics symbolizing the<br />

boat’s length of 64 feet, just short of 20 meters.<br />

A sign outside begs for understanding<br />

that priority is accorded to trade visitors<br />

and customers. “I’m not even all that interested<br />

in boats,” says a man from London in<br />

a pink polo shirt, who is here with his sons<br />

and a friend. “But this is a display of top<br />

British products and we didn’t want to miss<br />

The <strong>MAN</strong> V12 flagship can<br />

supply up to 1,800 hp. The<br />

gold plated cylinder head<br />

caps are a standard feature.<br />

the show.” The group dons protective covers<br />

on its shoes before boarding. Two of the<br />

gleaming white <strong>MAN</strong> engines are installed<br />

in the engine room below deck, with not a<br />

speck of oil in view.<br />

Receiving visitors at the top of the<br />

stairway is Robert Braithwaite, founder,<br />

CEO and majority shareholder of Sunseeker.<br />

He looks down at the boats lined up below<br />

him. Braithwaite built his first boat in 1968.<br />

“Sunseeker first began installing engines<br />

made by <strong>MAN</strong> in the late 1970s and the early<br />

1980s. In those days, I was still delivering<br />

the boats in person—as far away as Greece.”<br />

“Sunseeker first began<br />

installing engines<br />

made by <strong>MAN</strong> in the late<br />

1970s and early 1980s.”<br />

Robert Braithwaite, founder and CEO of Sunseeker


Photos: Jiri Rezak, Sunseeker, Royal National Lifeboat Institution UK, <strong>MAN</strong><br />

Today, he employs 2,400 people. Over the<br />

years, the company has ordered more than<br />

2,000 engines from <strong>MAN</strong>. For a long time<br />

now, Sunseeker has no longer been purchasing<br />

merely an isolated engine. Deliveries<br />

nowadays consist of complete drive systems,<br />

including not just the engine, but also<br />

the gears and the operating units.<br />

Braithwaite invites us into the conference<br />

room, which forms part of the stand,<br />

along with a café. He speaks rapidly and eloquently,<br />

his arm loosely leaning on the back<br />

of a chair. His dream, he says, is to make<br />

Sunseeker a household name for yachts one<br />

day—just as the Hoover brand name has become<br />

synonymous with vacuum cleaners<br />

in Great Britain. He has tried his hand at<br />

product placement too. Donning a red<br />

smartphone, he asks his secretary to bring<br />

him a listing of the James Bond movies featuring<br />

Sunseeker yachts. There have been<br />

four of them, so far. He has even made a<br />

brief personal appearance in one of the<br />

films and earned a mention in the credits. “I<br />

wanted a love scene, but they would only let<br />

me drive the boat,” he smiles.<br />

Yet Braithwaite knows that ultimately,<br />

other factors will determine whether his<br />

boats find buyers. These days, he says, customers<br />

from Europe are less common, while<br />

the Far East, Russia, Brazil and Mexico have<br />

become increasingly represented. As it has<br />

become more challenging to predict which<br />

boats will be in demand, Sunseeker is in the<br />

process of expanding its range, while simultaneously<br />

developing smaller and larger<br />

boats than in the past. “People want new<br />

boats!” exclaims Braithwaite. “That is why<br />

we are passionate about what we do, continuing<br />

to invest money in new products,<br />

just as we always have done.” With <strong>MAN</strong>, he<br />

has found a supplier who keeps pace with<br />

his company. As Braithwaite comments:<br />

“Clearly, they recognize how to deliver just<br />

the packages that we need.” <<br />

1903<br />

2011 1993<br />

> Marine drive with a future<br />

The diesel engine: Not just running in container giants<br />

forum 04/2011 19<br />

feature<br />

1903: the inland waterway vessel Petit Pierre becomes the world’s first dieselpowered<br />

ship. the 25-hp engine was developed by the french engineer frédéric<br />

dyckhoff with a license from rudolf diesel.<br />

1972: a dedicated Marine sector is set up at Man’s engine works in nuremberg.<br />

Since then, nearly 50,000 engines have been produced and sold for use in yachts<br />

and in the shipping industry.<br />

1993: the first of 50 coast guard cutters of the royal national Lifeboat institution<br />

is launched. Powered by two Man v10 engines with 860 hp each, the engines<br />

are specially designed to continue running without a hitch even if the boat was to<br />

capsize in heavy seas. Before service entry, all coast guard cutters must pass<br />

a rollover test.<br />

2000: the 41-meter yacht Fortuna III breaks the speed record for large motorized<br />

yachts. with its two diesel engines from Man, backed up by three gas turbines,<br />

it reaches a speed of 68 knots, or 126 kilometers per hour. Part of Spain’s national<br />

cultural heritage, the Fortuna is used by the royal family.<br />

2011: the Monte Carlo 76 model wins the european Power Boat award. the luxury<br />

yacht is powered by two of Man’s v8 or v12 engines.


F<br />

A<br />

B<br />

C<br />

D<br />

E<br />

20<br />

company<br />

1 2 3 4<br />

pArAMouNT pATTerNs<br />

Offering a multitude of products and variants bears<br />

the risk of high costs—due to additional design,<br />

purchasing, manufacturing and logistics. in order to<br />

reduce this level of complexity without forgoing<br />

variety, MAn relies on a variant management system.<br />

>>> Many customers will favor a supplier<br />

with a very varied range of products. After<br />

all, who would frequent a bakery with only<br />

one kind of bread? Similarly, industrial customers<br />

are forever looking for new and<br />

more individual solutions nowadays. Yet offering<br />

a lot of products and product variants<br />

also carries the risk of high costs, as it<br />

results in more design work, small batch sizes,<br />

high levels of stock or confusing marketing<br />

structures. Every new variant is costly—<br />

be it in R&D, purchasing, logistics and production,<br />

or customer service. Failing to<br />

provide the desired diversity with as much<br />

efficiency as possible could result in demise<br />

due to complexity. Providing no exception<br />

from the rule, at <strong>MAN</strong> hardly any truck or<br />

bus, marine engine, or power station engine<br />

currently looks the same. Built for container<br />

transport in Western Europe or as an allwheel<br />

drive construction vehicles in the<br />

Near East, the trucks alone vary in workload<br />

capacity; the number of axles; length;<br />

drive; engine performance; statutory requirements,<br />

such as exhaust emission standards;<br />

or fixtures and features. Even the<br />

driver cabs must meet a very wide range of<br />

specifications.<br />

Complex Customer demands<br />

“Long-distance drivers practically live in<br />

their cabins. That’s where they eat, drink<br />

and sleep,” explains Wilhelm Heintze, who<br />

manages the Product Architecture depart-<br />

F<br />

> DrivEr’s CABin<br />

<strong>MAN</strong> TGX XL<br />

Compact size:<br />

ideal for domestic<br />

long-distance transport<br />

with just one driver<br />

ment at <strong>MAN</strong> Truck & Bus in Munich. To accommodate<br />

features such as a bed, preheating<br />

system, fridge, coffee machine and microwave,<br />

and a radio or television, the<br />

driver’s cabin needs to have a certain size,<br />

he says. “When it comes to urban distribution<br />

runs, on the other hand, a small cab is<br />

sufficient,” acknowledges Heintze.<br />

“Customer requirements do vary<br />

widely,” agrees Petar Pelemis, responsible<br />

for product strategy at <strong>MAN</strong> <strong>Diesel</strong> & <strong>Turbo</strong><br />

in Augsburg. Four-stroke marine engines<br />

are one example: “We have a huge spectrum.<br />

There are enormous differences, after<br />

all, in the requirements associated with<br />

output, consumption, weight or acceleration,<br />

depending on the engine application—


Drawings: <strong>MAN</strong><br />

5 6 7 8<br />

> drIver’s cAb<br />

<strong>MAN</strong> TGX XLX<br />

Plenty of standing<br />

room: the spacious XLX<br />

driver’s cab for<br />

long-distance trucking<br />

be it a commercial vessel, a cruiser, a supply<br />

ship, a dredger, a naval ship or a ferry.” Variety<br />

can actually become a problem for<br />

many company areas. All variants must<br />

meet consistently high standards in quality<br />

terms, and customers demand thoroughly<br />

tested products. “That is why every engine<br />

we develop from scratch must first spend<br />

about a year on the test bed and then prove<br />

its worthiness once more during roughly 12<br />

months of field trials,” explains Pelemis.<br />

“That process is quite expensive and timeconsuming.”<br />

Yet not just the developers get<br />

headaches over the diversity of product<br />

variants: Purchasing has to procure many<br />

different components in small unit quantities.<br />

And getting them to the right place at<br />

In the shell construction stage, <strong>MAN</strong>’s TGX<br />

driver cabs only vary by the height of the roof.<br />

> drIver’s cAb<br />

<strong>MAN</strong> TGX XXL<br />

domestic comfort: a<br />

generous interior with<br />

large resting surfaces<br />

for multi-day trips<br />

F<br />

<strong>MAN</strong> TGX driver’s cabin: dimensions<br />

forum 04/2011 21<br />

“Long-distance drivers practically live<br />

in their cabins. When it comes to urban<br />

distribution runs, on the other hand, a<br />

small cab is sufficient.”<br />

Wilhelm Heintze, head of Product Architecture at <strong>MAN</strong> Truck & Bus<br />

<strong>MAN</strong> TGX XL Length: 2,280 mm. Width: 2,440 mm. Height: 1,660 mm.<br />

<strong>MAN</strong> TGX XLX Length: 2,280 mm. Width: 2,440 mm. Height: 1,975 mm.<br />

<strong>MAN</strong> TGX XXL Length: 2,280 mm. Width: 2,440 mm. Height: 2,200 mm.<br />

F


F<br />

A<br />

B<br />

C<br />

D<br />

E<br />

1 2 3 4<br />

22 > EnginE<br />

V51/60DF<br />

Powerful 12- to<br />

18-cylinder engines in<br />

V-design for gas power<br />

stations or Lng tankers<br />

the right time is a challenge for logistics. In<br />

addition, each and every variant calls for a<br />

supply of replacement parts. Not exactly an<br />

easy task in the case of ship engines that are<br />

in service for 30 years or more. Wilhelm<br />

Heintze points out a challenge in the truck<br />

world: Every variant of driver cabs needs to<br />

be compatible with every kind of engine.<br />

“Product variety also makes considerable<br />

demands in terms of staff qualifications,”<br />

explains Christoph Rimpau, “as you have<br />

different tasks to perform at an assembly<br />

station depending on the particular vehicle.”<br />

Rimpau coordinates dialogue on optimized<br />

solutions among <strong>MAN</strong>’s international<br />

business locations via the worldwide production<br />

network ProNet.<br />

<strong>MAN</strong> relies on a sophisticated variant management<br />

system to ensure that the company<br />

remains master of its products and not<br />

the other way around. This involves more<br />

than merely managing the range of offered<br />

products and services. The objective is to<br />

reduce complexity without diminishing<br />

variety. And even though <strong>MAN</strong>’s developers<br />

have probably outgrown their inclination<br />

to play with building blocks, they have still<br />

borrowed inspiration from colorful Lego<br />

sets when tackling the problem. The system<br />

offers an impressive demonstration, after<br />

all, of how many different products can be<br />

developed and produced with just one set<br />

of parts. So rather than designing a new<br />

product in response to every customer in-<br />

F<br />

quiry, the developers resort to their building<br />

set. Heintze offers an example: To make<br />

the different driver cabs of a truck, <strong>MAN</strong><br />

uses a combination of three different front<br />

walls, four floor panels, three side walls, five<br />

roofs and two back walls to build cabs sized<br />

small and narrow to XXL. A similar tool kit<br />

system provides the basis for assembling<br />

the longitudinal beams and cross beams for<br />

the frame in such a way that the vehicle can<br />

operate on construction sites or in local or<br />

long-distance transport.<br />

Mastering variety<br />

Another benefit of variant management: It<br />

creates transparency for product and cost<br />

structures, thus pinpointing submarginal


Drawings: <strong>MAN</strong><br />

5 6 7 8<br />

> EnginE<br />

L51/60DF<br />

in-line engine for cargo<br />

vessels: many components<br />

are identical (gray<br />

area), piston rod below.<br />

slow sellers. Every variant is closely scrutinized<br />

in all phases of the process—from<br />

the first customer inquiry through to delivery—to<br />

uncover which products are<br />

profitable for <strong>MAN</strong> and which aren’t. Thus,<br />

the system identifies variants that are still<br />

on the books, but no longer in demand.<br />

“Then we can ask ourselves whether we<br />

really need to retain all these products,”<br />

says Heintze. A similar question was faced<br />

by Petar Pelemis and his staff in Augsburg,<br />

with regard to high-output power-station<br />

engines. In the past, these had been supplied<br />

in a range including 12, 14, 16, 18 and<br />

20 cylinders. The Augsburg team uncovered,<br />

however, that between 80 and 90 percent<br />

of customers were able to meet their<br />

With the same ratio between the lift and the drill hole,<br />

the 12-cylinder engine is much more powerful.<br />

needs with a combination of the largest<br />

and smallest engine of the range. Hence,<br />

the intermediate varieties in size are no<br />

longer available, without inconveniencing<br />

any customers.<br />

Production processes are another area<br />

where complexity can be pared down. Petra<br />

Peterhänsel, senior manager of the truck assembly<br />

floor in Munich, explains: In the<br />

past, all individual components for the daily<br />

planned production had been stored<br />

“We have a huge spectrum when<br />

it comes to four-stroke marine<br />

engines. After all, customer<br />

requirements differ enormously.”<br />

Petar Pelemis, head of Product Strategy at <strong>MAN</strong> <strong>Diesel</strong> & <strong>Turbo</strong><br />

forum 04/2011 23<br />

company<br />

right along the assembly line. Today, production<br />

steps that require a large volume of<br />

different variants—such as frame building—will<br />

be accompanied by material trolleys<br />

loaded with precisely the needed parts,<br />

which are moving right along with the<br />

vehicle during the course of assembly. In<br />

addition, transparency is provided by the<br />

so-called Assembly Information System, indicating<br />

on a screen which parts need to be<br />

installed at any given position. <<br />

Large-bore diesel engines: performance and dimensions<br />

12V51/60DF * Drill hole: 510 mm. Lift: 600 mm. number of cylinders: 12<br />

Output: 16,316 hp. Engine length: 10,254 mm<br />

Width: 4,713 mm. Height: 5,517 mm<br />

6L51/60DF * Drill hole: 510 mm. Lift: 600 mm. number of cylinders: 6<br />

Output: 8,158 hp. Engine length: 8,494 mm,<br />

Width: 3,165 mm. Height: 5340 mm<br />

*DF = dual-fuel engine, which can run on liquid fuel as well as natural gas<br />

F<br />

F


Infographics: Horst Kolodziejczyk / Hokolo 3D<br />

coMMand bridge<br />

With control monitors on the bridge,<br />

Captain and First Officer have an<br />

immediate overview of all proceedings<br />

aboard. State-of-the-art electronic<br />

systems support the<br />

37-strong crew in carrying out the<br />

tasks at hand.<br />

Positioning<br />

GPS antennae supply data for<br />

dynamic positioning. This<br />

computer-controlled system allows<br />

for maintaining the ship’s<br />

heading and location automatically.<br />

engine rooM<br />

The <strong>MAN</strong> engines are located<br />

on the lowest deck, the<br />

so-called double bottom.<br />

There are seven decks overall.<br />

control systeM<br />

The control system sends the crew<br />

real-time pictures of all operations<br />

currently under way—such as the<br />

winch hauling in the towing cable.<br />

Main crane<br />

It can lift loads up to 15 tons,<br />

and can be used within a<br />

working radius of a minimum<br />

3.2 meters up to a<br />

maximum of 14.3 meters.<br />

Winches<br />

The three hydraulic winches have a load<br />

capacity of 400 to 500 tons. The drum of<br />

the 500-ton winch can be fitted with up to<br />

13,500 meters of steel cable, as needed.


loading area<br />

On the external loading area, loads<br />

with a maximum weight of 1,500<br />

tons can be lifted and stacked. The<br />

ship’s maximum payload extends to<br />

4,300 tons.<br />

Cranes<br />

Mounted on rails, the two safe deck<br />

anchor handling cranes are<br />

equipped with gripping arms that<br />

serve to couple and release cables,<br />

chains or shackles.<br />

shark Jaw<br />

The so-called shark jaw unit exerts a<br />

hydraulic grip on the towing cable.<br />

With a maximum permissible load<br />

of 700 tons, the two steel pins serve<br />

to fasten the load and also to<br />

provide additional safety backup.<br />

mission possible<br />

towing Cable<br />

A massive steel cable connects the<br />

tug with the mobile platform, as<br />

it moves to its next operating site.<br />

A tough job awaits in the oil industry: As of mid-2014, four ultra-modern<br />

special ships will be towing, positioning and supplying mobile drilling platforms<br />

on the high seas. <strong>MAN</strong> engines provide the drive for these operations.<br />

Platform<br />

Floating platforms drill for oil<br />

and gas from great depths.<br />

Steel cables anchor them to<br />

the sea bed.


26<br />

01<br />

> Special offShore veSSelS<br />

Professional engine tuning for the high seas<br />

02<br />

01 The four 9l27/38Go-type MaN diesel engines aboard the anchor-handling<br />

and supply ships have an output of 4,599 hp (3,285 kilowatt) each. at the<br />

customer’s specification, their power was increased by 200 hp over the original<br />

design. This ensures that they will have the required flexibility for handling all<br />

full-load curves—thus covering the energy requirements for any assignment,<br />

increasing the maximum vessel speed and also ensuring the high bollard pull of<br />

220 tons. This bollard pull is a significant factor for ships of this class, as it<br />

describes the degree of traction that the propellers can reach if the ship,<br />

theoretically speaking, were attached to a bollard.<br />

02<br />

Elastic coupling<br />

The elastic couplings absorb the knocks on the crankshaft that occur every time<br />

the diesel engine fires up.<br />

03 Gears<br />

The single-phase reduction gear unit is equipped with integrated switching<br />

clutches and allows for various operating modes. it is possible to clutch out the<br />

propeller, for example, and merely have the engines drive the shaft generator to<br />

supply power when anchoring at sea.<br />

04 Propellers<br />

The pitch angle of the propeller blades can be adjusted to every load range of<br />

the engines. This way, the propeller always delivers full power, whether at<br />

maximum speed or when towing and maneuvering heavy loads. in addition,<br />

the propeller blades are ducted in a propeller nozzle. The effect of the nozzle is to<br />

boost the efficiency of the propeller, thus facilitating the high bollard pull requested<br />

by the customer.<br />

03<br />

>>> Waves are whipping against the stern,<br />

with ocean spray moistening the faces of<br />

the crew. The men aboard the ship remain<br />

as unfazed as their vessel. It keeps plowing<br />

through the inhospitable seas with an exceedingly<br />

expensive piece of equipment in<br />

tow: a mobile oil platform on the move to<br />

its next assignment site. Up to 40,000 tons<br />

of steel and equipment—the equivalent of<br />

roughly 30,000 passenger cars—must be<br />

pulled with absolute precision and reliability<br />

through waves that loom meters high.<br />

Taking place far offshore and on the<br />

high seas, such transports are becoming<br />

more frequent: In the polar seas for example,<br />

which are thought to be rich in still undiscovered<br />

and unexploited natural resources.<br />

Driving this trend is the globally<br />

growing demand for energy. Rising prices<br />

make it worthwhile to exploit reserves that<br />

would not have been deemed lucrative in<br />

the past. “Stationary oil platforms are increasingly<br />

looking like dinosaurs,” explains<br />

Wolfgang Dullinger of the Medium Speed<br />

business unit at <strong>MAN</strong> <strong>Diesel</strong> & <strong>Turbo</strong> in<br />

Augsburg. This also represents a trend that<br />

04


Infographics: Horst Kolodziejczyk / Hokolo 3D<br />

the large-bore diesel engines manufacturer<br />

recognized early on: Its portfolio meets the<br />

different requirements of the offshore industry<br />

by providing specially customized<br />

propulsion solutions.<br />

And successfully so, as confirmed<br />

once more by the latest order, with a value<br />

of nearly €22 million: Swire Pacific Offshore<br />

Operations Pte Ltd (SPO), based in Singapore,<br />

has just placed an order for 16 fourstroke<br />

diesel engines with gear systems and<br />

electronically controlled adjustable propellers.<br />

These are designated for four new special-purpose<br />

ships capable of navigating the<br />

high seas, namely anchor-handling and<br />

supply ships. The present order included,<br />

the Asian company will then have a total of<br />

52 <strong>MAN</strong> engines powering its fleet.<br />

simulator training<br />

For more than 30 years, SPO and its anchorhandling<br />

and supply ships have been a<br />

well-known name in the oil industry, as<br />

well as a valued partner of large energy operations,<br />

due to the efficiency of its ships in<br />

offshore operations. In order to maintain<br />

its high reputation, SPO focuses on the long<br />

service life, reliability and ease of maintenance<br />

of the engines when equipping its<br />

vessels. <strong>MAN</strong> <strong>Diesel</strong> & <strong>Turbo</strong> has been living<br />

up to these parameters since 1983, the<br />

year when it supplied its first two engines<br />

to the company.<br />

The many years of partnership between<br />

the engine manufacturer and SPO<br />

are also emphasized by the facilities of<br />

SPO’s training center in Loyang, Singapore,<br />

where ship crews receive special training<br />

for these machines on an <strong>MAN</strong> simulator.<br />

For the staff must be just as familiar with<br />

the engines as with the rest of the equipment<br />

aboard these high-tech special ships,<br />

in order to rectify the smallest failure as<br />

quickly as possible. The very expensive offshore<br />

industry will not forgive any errors.<br />

“Whenever an offshore vessel becomes inoperative<br />

for even one single day, the real<br />

losses can amount to $50,000 or more,”<br />

says Poul Knudsgaard, site manager of<br />

<strong>MAN</strong> <strong>Diesel</strong> & <strong>Turbo</strong> in Frederikshavn and<br />

head of PrimeServ Four Stroke Denmark.<br />

In just a few years, when the 92-meterlong<br />

and 22-meter-wide special ships go<br />

into service, they will do so as members of<br />

a very select circle: Even though about 3,500<br />

special ships of this kind are operating<br />

worldwide, just some 200 come in this size<br />

and with comparable fixtures and features.<br />

Each ship features four engines, two propellers<br />

and gear systems to match, with a maximum<br />

output of 13 megawatts. This allows<br />

forum 04/2011 27<br />

technology<br />

puter-controlled dynamic positioning system.<br />

This system enables the crew on board<br />

to keep the ship steady at a fixed point with<br />

an accuracy of just a few meters. The computer<br />

receives data on the vessel type, wind<br />

and sea conditions and operates the engines<br />

and the drives accordingly.<br />

promising market<br />

At the same time, the dynamic positioning<br />

system improves the versatility of the special<br />

ships. It supports the transfer of Remote<br />

Operated Vehicles to the sea bed, for example.<br />

These unmanned stations are either<br />

used to monitor already installed facilities,<br />

or else actively deployed in subsea work—as<br />

“Whenever an offshore industry vessel becomes<br />

inoperative for even one single day, the real losses can<br />

amount to $ 50,000 or more.”<br />

Poul Knudsgaard, site manager, <strong>MAN</strong> <strong>Diesel</strong> & <strong>Turbo</strong> in Frederikshavn<br />

for a top speed of 16.7 knots, the equivalent<br />

of 31 kilometers per hour: sufficient power<br />

to shift drilling platforms and secure them<br />

at the location specified by the customer.<br />

The process of anchor handling can<br />

easily last 10 hours or more, depending on<br />

the weather conditions and the facilities already<br />

installed on the sea floor. For depending<br />

on how far the exploitation of the oil<br />

well has progressed, large quantities of<br />

highly sensitive subsea equipment may already<br />

be present on the sea floor upon the<br />

arrival time of the mobile drilling well. This<br />

includes pumps, pipelines and electrical cables,<br />

which must all be protected against<br />

damage. During this time period, the ship<br />

must hold its position and remain capable<br />

of immediately responding to any changes<br />

caused by heavy seas—facilitated by a com-<br />

a power supplier, for instance—and once<br />

again hoisted back up on board once their<br />

mission is completed. With their large decks<br />

and tank reserves, the ships also supply the<br />

platforms with fuel, fresh water, special alkaline<br />

solutions and cables, and deliver<br />

fresh provisions to the rig galley.<br />

With the rising price of oil and the ensuing<br />

heavy investments in the exploration<br />

of yet untapped resources by the multinational<br />

oil companies, the offshore shipping<br />

industry also stands to benefit in the<br />

long term. It is a rather simple equation:<br />

The higher the price of oil, the more platforms<br />

will be built, thus increasing the<br />

number of vessels needed to supply these<br />

platforms. This offers promising future<br />

prospects—and an outlook that <strong>MAN</strong> is<br />

also likely to benefit from.


28<br />

>>> As new ideas form the engine of progress,<br />

a large team of specialists from a wide<br />

range of disciplines are working at <strong>MAN</strong><br />

Truck & Bus to master current and future<br />

challenges—and the primary focus is ensuring<br />

that the continuous optimization of<br />

vehicles in terms of economy, environmental<br />

friendliness, safety and comfort will<br />

never slow down. It can also prove helpful<br />

to occasionally look at products and tech-<br />

through different eyes<br />

Technology does not exist in a vacuum, but is always influenced by<br />

cultural habits and patterns. In partnership with <strong>MAN</strong>, the globalDrive<br />

initiative of Munich’s Technical University explored the details.<br />

nologies from a different perspective, rather<br />

than merely viewing them in the context<br />

of <strong>MAN</strong>’s familiar working processes. Precisely<br />

this approach caused <strong>MAN</strong> to respond<br />

with interest to an offer from the<br />

Technical University of Munich (TUM) in<br />

early 2010. The Faculty of Vehicle Technology<br />

had just introduced the project concept<br />

globalDrive and was looking for internationally<br />

engaged industrial partners. Pro-<br />

Initial chalk lines turn into ideas for interaction<br />

between driver and machine in commercial vehicles.<br />

fessor Markus Lienkamp’s idea immediately<br />

appealed to <strong>MAN</strong>. Four students from TUM<br />

would work together with a matching set<br />

from a freely selectable partner university<br />

abroad to study a future-related matter of<br />

relevance to the industrial partner. “One<br />

important requirement,” explains Britta<br />

Michel, who coordinated globalDrive on the<br />

<strong>MAN</strong> side, “was that this shouldn’t be about<br />

a specific early development, but rather


Photos: Lehrstuhl für Fahrzeugtechnik TUM (3)<br />

move a step beyond.” Upon the conclusion<br />

of the six-month partnership, something<br />

concrete, ideally a prototype, would have<br />

originated. Considering the project’s global<br />

orientation, <strong>MAN</strong> decided to pick a partner<br />

university in a country where the company<br />

has its own production base. The choice was<br />

Brazil and the University of São Paulo.<br />

InterdIscIplInary work<br />

Out of the three topics proposed by <strong>MAN</strong><br />

Truck & Bus, the Human Machine Interface<br />

project—namely the operating and display<br />

system for drivers—sparked the interest of<br />

faculty and students alike.<br />

In concrete terms, the task was to determine<br />

the utilization habits of truck drivers<br />

in South America in comparison with<br />

those in Germany, to analyze culture-specific<br />

operating patterns and work out ideas<br />

for an adaptable strategy. To this end, the<br />

student team from São Paulo included two<br />

electro-technical engineers, as well as a design<br />

student and a marketing student.<br />

As it turned out, the students involved<br />

in the project did succeed in identifying<br />

significant differences. One example<br />

is the practice of adjusting the truck’s tire<br />

pressure, due to the often rather poor condition<br />

of South American roads—which<br />

represents a relatively insignificant issue<br />

for European drivers. Another difference<br />

pinpointed by the students was the South<br />

American truckers’ desire for a panic button<br />

that could immediately summon help<br />

via the mobile phone network in case of accidents<br />

or criminal attacks. Naturally, the<br />

students also noted many similarities<br />

shared by European and South American<br />

truck drivers, such as their enthusiasm for<br />

personalizing their environment, for example.<br />

Michel underlines the autonomy of the<br />

globalDrive project: “It was a decisive factor<br />

that while <strong>MAN</strong> indeed supported these<br />

students in their research, we didn’t pre-<br />

scribe any specific approach or predetermined<br />

targets.”<br />

Assisted by video conferencing, lively<br />

e-mail exchanges and one visit per team,<br />

the eight students found a solution that<br />

highlights the potential of such projects:<br />

Raised on any imaginable kind of consumer<br />

electronics, this new generation of technicians<br />

came up with an unconventional possibility<br />

for adapting market customs. Their<br />

prototype of a driver’s workstation, presented<br />

at the conclusion of the project in June<br />

2011, uses three Tablet PCs for the display<br />

and controls. The functions of the vehicle<br />

can be rearranged to suit personal preferences.<br />

In Brazil, for example, tire pressure<br />

monitoring can be moved to the most<br />

prominent display level.<br />

Whether implemented in real life or<br />

not, this approach to a solution proves technical<br />

creativity—and competency much<br />

coveted by <strong>MAN</strong>. It should not come as a<br />

surprise, therefore, that <strong>MAN</strong> plans to continue<br />

its commitment to globalDrive—with<br />

a project in China coming up in 2011/2012. <<br />

forum 04/2011 29<br />

technology<br />

1. Students on the globalDrive project present the<br />

prototype of a truck cockpit.<br />

2. Modern and unconventional: Three Tablet PCs make<br />

up a display and control system for the truck driver.<br />

01<br />

02


30<br />

01 oSAKA<br />

Hitachi Zosen Corporation<br />

> Licensee for two-stroke engines<br />

building a century<br />

on diesel patents<br />

Shipyards all over the world utilize <strong>MAN</strong>’s licenses to<br />

independently build and market two-stroke and four-stroke<br />

engines. Issuing licenses for the construction of ship<br />

engines has a long tradition: It has been a hundred years since<br />

<strong>MAN</strong> first acquired a foothold in the Japanese market.<br />

03 Hyogo<br />

<strong>Diesel</strong> United, Ltd.<br />

02 Kobe<br />

Kawasaki Heavy Industries Ltd.<br />

> Licensee for two- and four-stroke engines<br />

04<br />

> Licensee for two- and four-stroke engines<br />

03<br />

02<br />

01<br />

04 KAgAwA<br />

Makita Corporation<br />

> Licensee for two-stroke engines


Illustration: Charis Tsevis<br />

06<br />

05<br />

06 TokYo<br />

05 YokohAMA<br />

> Licensee for four-stroke engines<br />

niigata power Systems Co., Ltd.<br />

> Licensee for four-stroke engines<br />

JFe engineering Corporation<br />

mitsubishi Heavy industries Ltd.<br />

mitsui engineering & Shipbuilding Co., Ltd.<br />

>Licensee for two-stroke engines<br />

forum 04/2011 31<br />

company<br />

License to build: Engines developed by<br />

<strong>MAN</strong> <strong>Diesel</strong> & <strong>Turbo</strong> are manufactured<br />

at six locations in Japan.<br />

>>> In October 2011, Kawasaki and <strong>MAN</strong> celebrated<br />

a special anniversary in Kobe. One<br />

hundred years ago, the Japanese company<br />

received a license from <strong>MAN</strong>’s predecessor<br />

Maschinenfabrik Augsburg for building diesel<br />

engines. As diesel technology was just<br />

emerging—the Augsburg company had<br />

only gotten its first unit up and running 14<br />

years earlier—this agreement marked an<br />

important station in its triumphal march<br />

around the world.<br />

pioneering market<br />

Japan soon developed into an important<br />

market for ship diesel licenses. In 1926, the<br />

mechanical engineering company Mitsui<br />

acquired licenses for building <strong>MAN</strong> diesel<br />

engines, later joined by Hitachi in 1951. “All<br />

three enterprises have remained <strong>MAN</strong> licensees<br />

to the present day,” reports Ko<br />

Sasaki, president of <strong>MAN</strong> <strong>Diesel</strong> & <strong>Turbo</strong><br />

Japan. Just last year, the companies signed<br />

agreements to extend their licenses for another<br />

10 years. Kawasaki, for example, currently<br />

features the entire range of <strong>MAN</strong>’s<br />

two-stroke engines in its program. The


32<br />

licenses enable mechanical engineering<br />

companies to utilize <strong>MAN</strong>’s patents, designs<br />

and manufacturing expertise, building and<br />

marketing the two- and four-stroke engines<br />

in their own name. The formidable success<br />

of this business model is primarily owed to<br />

the fact that it would be hardly effective to<br />

build engines the size of a house in Europe<br />

and then sail them across global distances<br />

to the shipyards. “This was already the correct<br />

perspective back in the early 20th century,”<br />

explains Klaus Engberg, senior vice<br />

president responsible for Two-Stroke Licensing<br />

at <strong>MAN</strong> <strong>Diesel</strong> & <strong>Turbo</strong>.<br />

In issuing a license to Kawasaki a century<br />

ago, Maschinenfabrik Augsburg continued<br />

a business model that had already<br />

proven successful for Rudolf <strong>Diesel</strong>—who<br />

had developed his engine as an independent<br />

engineer. The reputation of his machine<br />

spread so rapidly that as early as 1898,<br />

he had concluded license agreements with<br />

a total of 22 companies in nine different<br />

countries. Beside the Maschinenfabrik<br />

Augsburg, these included Ludwig and<br />

Emanuel in St. Petersburg and the New York-<br />

Massive dimensions<br />

> A two-stroke engine can weigh up to 2,400 tons,<br />

with a height of 14 meters and a length of 28 meters.<br />

Worldwide manufacture under license<br />

> <strong>MAN</strong> <strong>Diesel</strong> & <strong>Turbo</strong> engines are made by 39 licensees—primarily<br />

in the big shipbuilding nations China, South Korea and Japan.<br />

based <strong>Diesel</strong> Motor Company of America.<br />

The contracts granted <strong>Diesel</strong> the financial<br />

latitude he needed to perfect his discovery.<br />

“<strong>Diesel</strong> did particularly well out of the licenses<br />

he issued in France,” explains the<br />

business historian Johannes Bähr, co-author<br />

of <strong>MAN</strong>, The History of a German Industrial<br />

Enterprise. <strong>Diesel</strong>’s issuing of licenses<br />

was abreast of the times. “The patent law enabling<br />

him to pursue that strategy had not


Illustration: Charis Tsevis<br />

been passed in Germany until 1877, so it was<br />

still quite young,” says Bähr.<br />

Manufacturing diesel engines rapidly<br />

became the most important business area<br />

of Maschinenfabrik Augsburg and its successor<br />

company M.A.N. In 1903/04, sales in<br />

this sector already exceeded that of printing<br />

machines, refrigeration equipment and general<br />

mechanical engineering. When Rudolf<br />

<strong>Diesel</strong> turned over the rights associated<br />

with his invention in the fall of 1910, it was to<br />

only take a few months until M.A.N. converted<br />

from license holder to license issuer<br />

and signed the agreement with Kawasaki.<br />

Short development cycleS<br />

Since then, the shipyard industry has experienced<br />

boom times and upheavals. In the<br />

1950s, when Europe still boasted a great<br />

many shipyards and engine manufacturers,<br />

<strong>MAN</strong> was among them. Nowadays,<br />

shipbuilding has almost completely relocated<br />

to Asia, primarily China and South<br />

Korea. At the same time, the licensing business<br />

has become so very significant for<br />

<strong>MAN</strong> that it ultimately displaced the manufacturing<br />

of two-stroke ship diesel engines<br />

altogether. “We haven’t made a twostroke<br />

engine since 2008 and are merely<br />

granting licenses,” says Klaus Engberg. Currently,<br />

22 licensees are building the twostroke<br />

engines developed in Copenhagen,<br />

most of them based in South Korea, Japan<br />

and China. In China, <strong>MAN</strong>’s partnership<br />

with its licensees dates back to the year<br />

1980. The most recent license agreement<br />

signed by <strong>MAN</strong> was with the Chinese manufacturer<br />

GMD, a subsidiary of the government-owned<br />

CSSC Group.<br />

In contrast to Europe, Japan has remained<br />

an important market for the licensing<br />

business. “The shipping industry has<br />

been systematically subsidized by the Japanese<br />

government,” says Sasaki. “Both in the<br />

period after WW II and following the oil crisis<br />

of 1974, it experienced a tremendous development<br />

boost.” At the same time, the island<br />

nation grew to become one of the<br />

world’s most successful exporting countries.<br />

Over the decades, Japan’s industry always<br />

needed more new ships. Although the<br />

majority of the world’s commercial trading<br />

vessels are built in China and South Korea<br />

today, companies such as Kawasaki, Mitsui<br />

and Hitachi were able to maintain their position<br />

as manufacturers of ship engines. Last<br />

but not least, believes <strong>MAN</strong>’s Ko Sasaki, this<br />

is due to the high manufacturing quality<br />

powerful engine output<br />

> The two-stroke and four-stroke engines made by the<br />

licensees deliver an output of up to 115,000 hp.<br />

and excellent qualifications of their engineers.<br />

With the complete shift of two-stroke<br />

engine building to a licensing business, this<br />

sector has experienced a renewal. Engberg<br />

explains: “The shipbuilding industry moves<br />

around the world and we are investing not<br />

in production sites but rather in people, innovations<br />

and new technology.” He also considers<br />

this the best possible way to guard<br />

against a brain drain. While the high costs of<br />

research and development as well as short<br />

development cycles represent significant<br />

barriers when it comes to market entry<br />

forum 04/2011 33<br />

company<br />

efforts, these are precisely the areas where<br />

<strong>MAN</strong> would place its own strengths. “We<br />

support our customers,” continues Engberg,<br />

“by picking up the market signals early on<br />

by continuously developing new engines<br />

with new features.” The engines must be designed<br />

in such a way that licensees can produce<br />

them cost-efficiently. In recent years,<br />

environmental friendliness and low fuel<br />

consumption have become an increasingly<br />

important factor for the end customer. “In<br />

addition, license holders and their customers<br />

benefit from our worldwide PrimeServ<br />

service network,” says Engberg. <strong>MAN</strong> has<br />

more than a hundred PrimeServ support<br />

centers, all of them staffed around the clock.<br />

Most recently, <strong>MAN</strong> developed the first twostroke<br />

diesel engine already complying with<br />

the strict criteria of the Tier III guidelines of<br />

the International Maritime Organization<br />

(IMO). To become effective in 2016, the new<br />

requirements mandate a reduction of nitrous<br />

oxide emissions by 80 percent compared<br />

with levels in the year 2000 for operating<br />

in certain regions. Incidentally, the<br />

first of these low-emission engines was built<br />

by Hitachi – in southern Japan.


34<br />

feature<br />

Tomorrow’s<br />

TransporT<br />

Modern hybrid technology is gaining<br />

a foothold in trucks. In cooperation<br />

with a wholesaler in Munich,<br />

<strong>MAN</strong> is currently testing two of its<br />

TGL trucks with an electrical and<br />

diesel engine in daily operations.<br />

The vehicles are serving as pioneers<br />

for alternative drives in distribution<br />

transport.<br />

>>> They can be sure of attracting attention<br />

these days—especially when steering their<br />

truck through a pedestrian zone. Throughout<br />

the Bavarian region, Michael Dieroff<br />

and Jens Pömitz provide deliveries for<br />

Arndt, a wholesaler in hygienic and cleaning<br />

supplies. Yet while moving through<br />

Munich’s central Stachus Square pedestrian<br />

area, where they are servicing a number of<br />

shops, bystanders look at the two drivers in<br />

an astonished, rather than irritated fashion.<br />

For their transport truck almost glides over<br />

the pavement, emitting hardly a sound nor<br />

are any puffs of smoke emerging from the<br />

exhaust. Dieroff and Pömitz are conducting<br />

trial tests of <strong>MAN</strong> hybrid TGL prototypes,<br />

equipped with an innovative diesel-electric<br />

drive system.<br />

high market potential<br />

Back in 2010, <strong>MAN</strong>’s hybrid municipal buses<br />

completed their testing phase and went<br />

into serial production. Now the TGL, a truck<br />

designed for regional and local distribution<br />

transport, will also be equipped with a hybrid<br />

drive. And for good reason: In light of<br />

progressing climate change and the resulting<br />

necessity to reduce greenhouse gas<br />

emissions, there is mounting political pressure<br />

on road users around the world. Environmental<br />

zones, such as those in Munich,<br />

are increasingly banning vehicles with an<br />

obnoxious output of diesel fumes and soot.<br />

In addition, transport companies like<br />

wholesaler Arndt, with a fleet of around 50<br />

commercial vehicles, are looking for economical<br />

technologies with tax benefits.<br />

“The crucial driver of hybridization won’t<br />

be statutory provisions, but customer demand<br />

for economical vehicles,” believes<br />

Götz Klink, head of the automotive sector<br />

at management consultancy A.T. Kearney.<br />

The main pace-setters of this development,<br />

says Klink, will most likely be Europe, the<br />

US and Japan. In a current study, the experts<br />

predict that the market share of alternative<br />

drives for commercial vehicles will<br />

increase significantly by 2020 and could<br />

grow to between 15 and 50 percent in many<br />

segments and regions. Against this back-


Photos: <strong>MAN</strong> Truck & Bus<br />

ground, they anticipate an annual increase<br />

of more than a million light, medium and<br />

heavy hybrid trucks every year until 2020.<br />

This amounts to a potential market with a<br />

value of up to €10 billion.<br />

Seeking to develop hybrid drives in a<br />

systematic way and bring them to serial<br />

production, <strong>MAN</strong> Truck & Bus has pooled<br />

all its research and development activities<br />

at a new Competence Center. “We are certain<br />

that hybrid technology will play a crucial<br />

role in all commercial vehicle sectors, in<br />

order to save resources, boost efficiency<br />

forum 04/2011 35<br />

reportage<br />

“This new drive solution<br />

offers great potential<br />

savings, especially when<br />

it comes to our short-range<br />

distributors. Indeed,<br />

hybrid vehicles will rule<br />

the future.”<br />

Thomas Wölflein, managing director at Arndt<br />

A delivery run in the<br />

heart of Munich—the<br />

hybrid TGL undergoing<br />

practical trials.


36<br />

feature<br />

> <strong>MAN</strong> TGL 12.220 Hybrid<br />

How electric engines<br />

supplement the diesel<br />

The hybrid principle is based on sophisticated<br />

interaction: The diesel supplies<br />

the basic drive, the electric engine<br />

draws its power from the stored brake<br />

energy—and moves the TGL almost<br />

soundlessly when in low gear. Known<br />

as a parallel hybrid drive, the TGL system<br />

combines the 220-hp of the d08<br />

four-cylinder diesel engine with an integrated<br />

electrical machine, whereby the<br />

engine output is either jointly or individually<br />

passed on to an automated<br />

6-gear transmission system. While the<br />

diesel engine primarily drives the TGL,<br />

the electrical engine works like a generator<br />

in overrun mode. The braking<br />

energy is converted as a result and<br />

stored in the lithium battery, a process<br />

also known as recuperation. The battery’s<br />

capacity is two kilowatt hours,<br />

with a stop-start system switching the<br />

engine off at red lights. When starting<br />

up, the electric engine accelerates first,<br />

while the diesel runs idle. With increasing<br />

power needs, the diesel engine<br />

kicks in and takes over at full speed.<br />

Thus, the hybrid TGL is quiet, economical<br />

and environmentally friendly.<br />

and pave the way to e-mobility,” explains<br />

Bernd Maierhofer, managing director for<br />

R&D and Purchasing at <strong>MAN</strong> Truck & Bus.<br />

Concepts for electromobility have<br />

been on the agenda of the commercial vehicles<br />

sector for more than two decades—and<br />

covering all vehicle types. “This is about<br />

mastering the technical challenges with regard<br />

to size, weight, load, service life and reliability,”<br />

says Götz von Esebeck, head of the<br />

<strong>MAN</strong> Truck & Bus Hybrid Competence Center.<br />

Especially for distribution transport vehicles—as<br />

represented by the prototypes<br />

currently under way for the Munich wholesaler<br />

on urban and overland routes—varying<br />

load conditions must always be taken<br />

into account. Constant loading and unloading<br />

operations, stop-and-go driving, turning<br />

on and off all make continuous demands<br />

on the systems and their reliability.<br />

OngOing imprOvement<br />

The engineers at the Hybrid Competence<br />

Center are well aware that when deciding on<br />

a vehicle concept, the entire cost structure<br />

is the decisive factor for transport entrepreneurs.<br />

On this list of Total Cost of Ownership,<br />

they consider their truck’s fuel savings<br />

and efficiency a top priority. This should allow<br />

for the unification of economic and ecological<br />

targets. The concept is simple: The<br />

less fuel a vehicle consumes, the lower its<br />

level of toxic emissions. And as the hybrid<br />

drive operates close to soundlessly, noise<br />

level also approaches zero once the electric<br />

drive takes over.<br />

During the months of practical testing<br />

the TGL hybrid prototypes are loaded<br />

with measurement technology. The data<br />

from driving operations flows straight into<br />

the Competence Center, where project director<br />

Stefan Kerschl and his team conduct<br />

minute evaluations. “This way, we intend to<br />

optimize the interplay between the drive<br />

components and the overall system,” says<br />

Kerschl. The two test trucks with a dieselelectric<br />

drive incorporate a 220-hp combustion<br />

engine as well as a connectable 82-hp<br />

electric engine, high voltage batteries included.<br />

The system of these two test vehicles<br />

utilizes the braking energy and intermittently<br />

stores it in lithium ion batteries,<br />

to reconvert the energy into forward movement<br />

once the electric engine starts up.<br />

“Consumption peaks are therefore capped<br />

upon startup,” says Kerschl, explaining the<br />

benefits of the system.<br />

After more than 10,000 kilometers of<br />

travel in urban and local transport, the preliminary<br />

conclusions look good for the hybrid<br />

transporter. “The prototypes are all<br />

proving themselves as suitable for daily<br />

use,” Kerschl sums up. “Despite the extended<br />

functionality and the complex energy<br />

management system, the vehicles have delivered<br />

a highly stable performance.” First<br />

demonstrated in simulations and yielded<br />

by testing procedures on the dynamometer,<br />

the fuel savings rates of between 5 and 15<br />

percent were also confirmed by the practical<br />

results. The economic benefits of the<br />

new drive particularly impressed Thomas<br />

Wölflein, managing director at Arndt: “This<br />

new drive solution offers great potential<br />

savings, especially when it comes to our<br />

short-range distributors. Indeed, hybrid vehicles<br />

will rule the future.” These are also<br />

good prospects for others besides the<br />

wholesaler: Soon, our city centers could become<br />

a lot quieter and cleaner. <<br />

1. A display in the cockpit shows data about the flow<br />

of energy in the vehicle.<br />

2. Michael dieroff, a driver for the wholesaler Arndt, is<br />

testing <strong>MAN</strong>’s hybrid system in daily operations.<br />

Bus<br />

&<br />

3. Underway in the stop-and-go traffic of a city<br />

center, with many loading and unloading cycles.<br />

Truck<br />

4. The additional hybrid components are installed in a<br />

compact way on the side of the truck.<br />

<strong>MAN</strong><br />

5. The braking process generates energy, which is<br />

stored in the battery—available on demand. Photos:


01<br />

03<br />

04<br />

02<br />

05<br />

“Due to battery operation,<br />

the soundless acceleration<br />

feels almost like gliding.”<br />

Michael Dieroff, driver for wholesaler Arndt


38<br />

Over Alpine passes and on<br />

desert trails—over their life<br />

cycles, most trucks are<br />

covering a lot of ground.


Photos: Rainer Jahns, Pascal Malamas<br />

The five<br />

lives of a Truck<br />

Every year, thousands of well-maintained<br />

<strong>MAN</strong> trucks leave Western European roads to<br />

enter their next stage of life—be it as the pride<br />

and joy of a haulage contractor in the Near<br />

East or to provide transport in an African<br />

metropolis. <strong>MAN</strong> Forum set out to track<br />

them down.<br />

forum 04/2011 39<br />

company


Lambach/austria<br />

Starting point<br />

after about three years<br />

of service, the trucks of<br />

the Gartner company find<br />

new ownership, brokered<br />

by maN topused.<br />

48° 4' N, 13° 52' O<br />

>>> They’re traveling piggyback—with the<br />

driver’s cabin tilted forward, the rear axle<br />

jacked up and a sparkling green paint job.<br />

Looking as good as new, actually. <strong>MAN</strong>’s motor<br />

tractors were thoroughly spruced up for<br />

their long journey by special truck transporter,<br />

heading for Saudi Arabia. They will<br />

travel some 950 kilometers from Lambach,<br />

Austria, to Bremerhaven, Germany, before<br />

being loaded onto a ship in their transit to a<br />

new life, having lived a good part of their<br />

service history already. Formerly owned by<br />

the large Austrian trucking company Gartner<br />

KG, the well-maintained trucks have<br />

clocked more than 300,000 kilometers and<br />

are now being passed on to a new owner after<br />

some three years of service.<br />

<strong>MAN</strong> TopUsed, the international used<br />

vehicles brand of <strong>MAN</strong> Truck & Bus, ensures<br />

that the Al Rajhi transport company, based<br />

in Alkhobar, Saudi Arabia, receives high-end<br />

vehicles for its logistics services in the Gulf<br />

States, Jordan, Syria and Lebanon. <strong>MAN</strong><br />

TopUsed markets used trucks and buses of<br />

all types and brands from <strong>MAN</strong> TopUsed<br />

centers in more than 30 countries. “Primarily,<br />

our vehicles are moved from Western to<br />

Eastern Europe, the Near East and the African<br />

markets,” explains Holger Hahn, head of<br />

<strong>MAN</strong> TopUsed Sales Management at <strong>MAN</strong><br />

Truck & Bus. For a<br />

long time, he says,<br />

the used-vehicles<br />

business held little<br />

interest for manufacturers.<br />

“In the past, used<br />

car dealers often evoked<br />

the rather unflattering image<br />

of characters attired in string vests,<br />

peddling goods of dubious quality in dusty<br />

back alleys. All that has changed.” Since the<br />

manufacturers themselves became active in<br />

this market, the quality of both product and<br />

consulting services has decidedly improved.<br />

And this is something that customers expect<br />

today. “A strong brand such as <strong>MAN</strong> retains<br />

its value for the entire life cycle of the<br />

vehicle. Even in its second, third or even<br />

fourth incarnation,” states Hahn. At least<br />

this holds to be true when <strong>MAN</strong> service ensures<br />

the quality, economy and top functionality<br />

of the trucks and buses in their new<br />

lease of life.<br />

“We purchase nothing but technologically<br />

impeccable vehicles that are thoroughly<br />

tested by experts,” says transport entrepreneur<br />

Abdulla Al Rajhi. The automotive<br />

fleet of the Saudi Arabian company compris-<br />

es 700 commercial vehicles of all types.<br />

“Quality, length of service life, easy maintenance<br />

and a minimum of operating interruptions<br />

are our criteria when making purchasing<br />

decisions.” Al Rajhi is also very<br />

pleased that the new shipment from Bremerhaven<br />

already comes in the matching colors<br />

of his own company. “We have the same color<br />

branding as the Austrian company that<br />

owned them before. That means additional<br />

savings, as we don’t need to paint them.”<br />

HIgH lIfe expectancy<br />

Al Rajhi started working with <strong>MAN</strong> TopUsed<br />

to tap its used vehicle range in 2009. “The<br />

cost-benefit ratio is right,” says the 45-yearold<br />

businessman, who does not believe that<br />

buying second-hand trucks on the open<br />

market would be a viable alternative. “<strong>MAN</strong><br />

services are an essential part of our business<br />

success,” says Al Rajhi. “Well-maintained<br />

vehicles simply have a much lower<br />

breakdown rate.” And precisely that is a key<br />

element in the transport business. He merely<br />

expects his pre-owned newcomers to run<br />

another 300,000 kilometers or so. “Quality<br />

and efficient service are the decisive factors<br />

when it comes to reselling with value. The<br />

53° 33' N, 8° 34' O<br />

bremerhaveN/GermaNy<br />

Interim stop<br />

having arrived in bremerhaven,<br />

the pre-owned maN trucks<br />

from austria are shipped off<br />

to saudi arabia.


Photos: shutterstock, Gartner KG, Jesco Denzel/Visum, alrajhicorp.com<br />

<strong>MAN</strong> brand enjoys a very good reputation<br />

in the Near East. Our vehicles are therefore<br />

very popular in the market.”<br />

As for the entire life cycle and its overall<br />

value retention of trucks and buses, such<br />

high expectations are increasingly impacting<br />

the markets. “Commercial vehicles are<br />

not an emotional asset but rather an investment.<br />

We must produce used vehicles in a<br />

systematic fashion,” says Holger Hahn,<br />

summarizing this broadened way of looking<br />

at the Total Cost of Ownership. “We<br />

don’t just want to enhance the confidence<br />

in our top-quality used vehicles, but pursue<br />

a targeted strategy of offering premium vehicles<br />

that deliver top-notch reliability to<br />

our customers.” And no matter where their<br />

destination—be it on the streets of an African<br />

metropolis, or as the pride and joy of a<br />

trucker in Mongolia who has been saving<br />

for years to acquire the vehicle: The second<br />

part of a truck’s life history may well last<br />

longer than the first, knows Hahn. As <strong>MAN</strong><br />

TopUsed vehicles have been so well serviced<br />

and maintained, he says, trucks that are 10<br />

or even 15 years old could continue to run<br />

for just as many years, such as in Africa.<br />

Provided that they are adapted to the conditions<br />

of their operational region. “A hightech<br />

engine based on Euro V standards and<br />

equipped with AdBlue technology is not an<br />

option in the Central Asian Hindu Kush.<br />

There simply isn’t any fuel for it,” observes<br />

Hahn. For that very reason, second-hand vehicles<br />

that do not meet the latest Euro exhaust<br />

standards are much in demand in<br />

many parts of the world.<br />

“Usually, every step of the sales process<br />

will be accompanied by an adaptation<br />

to current conditions.” Which does not imply,<br />

emphasizes Hahn, that quality ever becomes<br />

optional at some point. On the contrary:<br />

“We want to keep professionalizing<br />

used-vehicle channels around the world.<br />

That also entails that we increase the aware-<br />

ness of the <strong>MAN</strong> brand among customers<br />

in the developing markets—depending on<br />

their particular needs. Dumping inferior<br />

polluters that hold no value for their owners<br />

would hardly be the right way to go<br />

about it,” concludes Hahn.<br />

Against this background, the overall<br />

life cycle of a vehicle can become a fixed<br />

variable for the owner—as the authorized<br />

representative Marcus Schwarzbauer is<br />

well aware of. He is responsible for vehicle<br />

fleet management and workshop planning<br />

at the Lambach site of Gartner KG. The Austrian<br />

freight forwarding firm has a fleet of<br />

1,600 vehicles, serving customers from 21<br />

bases in eight different European countries.<br />

The company maintains repurchasing<br />

agreements with <strong>MAN</strong> for the new vehicles<br />

it acquires. “The guaranteed return<br />

policy through <strong>MAN</strong> TopUsed plays a major<br />

role in how we manage our fleet strategy,”<br />

says Schwarzbauer. “On this basis we can<br />

plan our investments in new vehicles in<br />

the long term.” After about three or four<br />

years of service, the condition and residual<br />

value of the vehicle will be assessed by independent<br />

experts—followed by any repairs<br />

deemed necessary, as well as technical<br />

maintenance.<br />

Constant quality Control<br />

While reliability and continuously conducted<br />

quality checks carried out at <strong>MAN</strong><br />

workshops are essential factors when it<br />

comes to the resales market, used vehicle<br />

prices must also be calculable in the mid-<br />

and long term. Steering sale prices and residual<br />

value with the greatest possible accuracy<br />

is among the demanding responsibilities<br />

facing <strong>MAN</strong> TopUsed expert Holger<br />

Hahn and his team. About every three<br />

months, they meet with specialists from<br />

the new and used automotive sectors, with<br />

representatives from banking and credit<br />

institutions, with controllers and car rental<br />

AlkhobAR/SAudi ARAbiA<br />

The Al Rajhi transport company<br />

takes delivery of the trucks in<br />

Alkhobar: The vehicles will now<br />

serve in the Gulf States.<br />

forum 04/2011 41<br />

Destination<br />

specialists to discuss individual market developments<br />

in regional markets.<br />

As far as both the Gartner KG and Al<br />

Rajhi companies are concerned, <strong>MAN</strong>’s<br />

TopUsed concept has been highly successful<br />

so far. “Remaining focused on the entire<br />

service life of the vehicle is very helpful in<br />

optimizing our fleet cost management in<br />

strategic terms,” outlines Schwarzbauer. In<br />

the end, all vehicle owners stand to benefit.<br />

“As does the environment also,” points out<br />

Hahn. For when the used vehicles have finally<br />

returned from their last journey upon<br />

their third or even fourth incarnation, they<br />

will be professionally disassembled and<br />

split up into their component parts. These<br />

valuable replacement parts will then be returned<br />

to “circulation,” thus perhaps granting<br />

what amounts to a fifth existence in<br />

the cycle of service life. <<br />

26° 17' N, 50° 12' O


42<br />

closing words<br />

Georg Pachta-Reyhofen,<br />

CEO of <strong>MAN</strong> SE<br />

>>> This is a special moment in the history of <strong>MAN</strong>:<br />

The last remaining approval of a competition authority<br />

required for completion of the compulsory offer for<br />

the majority takeover of <strong>MAN</strong> by Volkswagen AG was<br />

granted in November 2011. Thus, we now officially have<br />

a new majority shareholder, with close to 56 percent of<br />

the voting rights and almost 54 percent of <strong>MAN</strong>’s equity<br />

shares: Volkswagen AG.<br />

The approval renders <strong>MAN</strong> a member of the<br />

Volkswagen family. We intend to become not merely a<br />

strong, but a sustaining pillar of the Volkswagen<br />

Group—a powerful brand in the Volkswagen network<br />

and a strong partner in a new and close association<br />

with Volkswagen, as well as with Scania.<br />

<strong>MAN</strong> has been writing industrial history for 253<br />

years. From the initial St. Antony ironworks to the development<br />

of the first diesel engine, to hybrid buses<br />

and 100,000-hp ship diesel engines—we can look back<br />

on a long and proud corporate history rooted in tradition.<br />

This marks a new chapter in our story, whereby<br />

we will preserve the special identity that has distinguished<br />

our company for all these years: the art of engineering,<br />

international positioning and innovative<br />

strength, coupled with the readiness to change with<br />

the times.<br />

Even if after this quarter millennium <strong>MAN</strong> won’t<br />

remain quite as independent as it has been in the past,<br />

this new chapter nonetheless represents a secure<br />

> The nexT issue is published in March 2012<br />

A new chApter<br />

Volkswagen has become the new majority shareholder of <strong>MAN</strong>—facilitating<br />

substantial synergy effects in purchasing, production and development.<br />

future. Volkswagen has made a clear commitment to<br />

<strong>MAN</strong>’s business areas, and all of our company’s sites<br />

will be retained. This signifies no personnel reduction<br />

due to the merger. The independence of our brands<br />

will be preserved, with <strong>MAN</strong> <strong>Diesel</strong> & <strong>Turbo</strong> and Renk<br />

remaining integral parts of the Group.<br />

These are all clear indicators of the stability, sustainability<br />

and esteem that Volkswagen brings to its<br />

association with <strong>MAN</strong>. We can enter the new partnership<br />

with Volkswagen and Scania in a spirit of openness<br />

and trust. The partnership also lays the basis for<br />

far-reaching synergy potential, as we and our partners<br />

foresee synergy effects amounting to at least €200<br />

million annually, most of it in purchasing.<br />

Furthermore, there is substantial potential in the<br />

long term, based on intensive cooperation in the areas<br />

of production as well as research and development.<br />

Together with Volkswagen and Scania, we will<br />

continue <strong>MAN</strong>’s successful strategy. Naturally, we shall<br />

retain the values linking our customers and partners<br />

to our company around the world: International profitable<br />

growth, technological leadership and the highest<br />

quality always have been and will remain the standards<br />

we always strive for. The success of <strong>MAN</strong>,<br />

Volkswagen and Scania rests on the same principles.<br />

On this basis, we can benefit from our commonly<br />

shared advantages and make <strong>MAN</strong> a strong member of<br />

the Volkswagen family. <<br />

Photo: <strong>MAN</strong>


<strong>ForuM</strong> QuiZ<br />

experience an action-packed<br />

truck race weekend<br />

Simply provide the correct answer to this question:<br />

How many licensees around the world are currently manufacturing diesel engines developed by <strong>MAN</strong> <strong>Diesel</strong>&<strong>Turbo</strong>?<br />

A) 16 B) 39 C) 52<br />

Already launched as a business model by Rudolf <strong>Diesel</strong>, the granting of licenses is very significant for <strong>MAN</strong> <strong>Diesel</strong> & <strong>Turbo</strong>. Acting as a licensor is especially<br />

advantageous for <strong>MAN</strong> in the case of the huge two-stroke engines that can exceed 2,000 tons—as they can be manufactured in the immediate vicinity of shipyards<br />

that mainly lie in the shipbuilding Asian countries. The oldest still-existing <strong>MAN</strong> licensing partnership is one with Japan: A licensing agreement with the<br />

Kawasaki company was signed as early as 1911. Read more beginning page 30.<br />

Send your answer by e-mail to forum@man.eu by February 29, 2012, providing your name and e-mail address and win an exclusive racing weekend for two<br />

in Misano, Italy. The Adriatic town will host a race of the FIA European Truck Racing Championship 2012 on May 19 and 20, 2012. Expect a thrilling competition<br />

with fast trucks and much action. As a VIP guest, you can take an intensive and emotional look behind the scenes of truck racing and learn more about<br />

the technology of <strong>MAN</strong> race trucks. Your stay includes room and board in a local hotel for one weekend night.


Gleaming like perfectly polished gold bars, these cylinder<br />

head caps adorn <strong>MAN</strong> V12 diesel engines with their up to<br />

1,800 hp. Installed in the engine rooms of racy sports boats<br />

and motor yachts, they are more than just a visual attraction<br />

below deck: Renowned manufacturers of luxury boats have<br />

long relied on <strong>MAN</strong>’s marine engines. Shipyards offered<br />

up the latest in spectacular developments and trends at the<br />

Southampton Boat Show in England.

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