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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.