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Newsline 1999 investments of approx. 30 million marks in Pierburg’s Hartha plant Operational performance upgraded Hartha. Anyone driving along route No. 175 – from Döbeln to Rochlitz – to Hartha in Saxony in the late hours of the evening will see immediately that three of the four floors of Pierburg’s plant about a kilometer and a half away from the road are still fully illuminated. At first sight, this light has a simple explanation and pleasing commercial background: owing to an excellent order situation, production is being carried out in three shifts and partly even six days a week (e.g. intake manifold, shaft manufacture, electrical motors for the secondary air pumps) to cope with all the work required in connection with the automatic assembly of electrical water circulation pumps, intake manifold assembly, shaft production, rotor manufacture for the electrical fuel pumps and electrical valve control systems and the manufacture of electrical motors for the secondary air pumps – making up for eighty percent of the production. Yet the bright lights also symbolize something else: in the opinion of district administrator Dr. Manfred Graetz, this plant belonging to the Kolbenschmidt Pierburg group is one of the few major plants in the district to have successfully managed its commercial re-orientation after the German reunification. Very modern production lines for a number of different products (which have to be produced in large quantities to meet market demands) have been implemented since Pierburg took over in spring 1992 with investments of some 47 million marks and the creation of (currently) about 210 new jobs. Hartha’s plant manager Dr.-Ing. Thomas Mielke with the most recent series-produced product from the site: the value-optimized secondary air pump. The screen shows resource management for pump assembly. In the words of Graetz: “From the outset, Pierburg GmbH has been a source of hope for economic reconstruction in the town of Hartha and the neighboring region. The plant now has more than 200 employees and many millions of marks have been spent on modern machines and systems.” According to the 52 year-old administrator, the Kolbenschmidt Pierburg group is the largest single employer in Hartha; furthermore, it is one of the five most important plants in the district. Production of the water circulation pump: electromechanic Veronika Hedrich assembling a pump housing including the stator package with the related printed circuit board and simultaneously checking (on the monitor) the soldering robot which is also part of the production line. Thanks to its growing reputation in the automotive industry and thus also the greater demand on the market, operational performance at this plant in Hartha has naturally also improved: after approx. 66 million marks in 1997, the operational performance rose to 143 million marks in 1998, while profit is also satisfactory. And this improved even further in 1999. Dr.-Ing. Michael Mielke, manager of the Pierburg plant in Saxony since November 1998 remarks that “operational performance will be increased to approximately 190 million marks – with a good contribution margin – which bears comparison with the three other Pierburg sites in Germany.” In view of this pleasing situation, further investments were launched in 1999 to secure the medium to long term position of this Pierburg plant situated in the hilly countryside of central Saxony. To quote plant manager Mielke: “As to the development of this plant since the Neuss-based automotive supplier joined us in the spring of 27 1992, the main accents have naturally shifted slightly. Whereas the initial aim was primarily to establish and consolidate the site we are now focussing on the further development of the plant from a pure motor production site (mono-structure) to a supplier with a broad range of products.” This goal is in the process of being reached: today, Hartha already manufactures large quantities of plastic intake manifolds, vacuum and water circulation pumps as well as electrical motors for various applications. The most recent series-product is the value-optimized secondary air pump that is to be manufactured completely in Hartha in future; in the past, only the related electrical motors were produced for the predecessor system. Customers include renowned companies like VW/Audi, Webasto, Eberspächer, Peugeot, Saab, Nedcar/Volvo and General Motors. The mentioned expansion of its range of products which can benefit from the know-how and enthusiasm of a highly qualified and motivated workforce forms the strategic background for a number of investments, with 30 million German marks spent in 1999 alone. In the words of Mielke: “Our main focus in the coming years will be the utilization of the new assembly lines, including the advanced facilities for the production of water circulation pumps and the value-optimized secondary air pumps, as well as the expansion of our position as a supplier on the market. We naturally attach importance to a well-balanced mixture in regard to our product spectrum and customer structure in order to be able to react sufficiently flexibly on the market.” Related measures include the cost improvement program launched at Hartha in 1999, widespread use of flexible production facilities with shorter set-up times and selective process optimization in the fields of technology and information.
Newsline Pierburg develops AMA 4000 – BMW orders new system generation Central intelligence, modular design Neuss/Munich. Pierburg’s measurement technology product group has ranked among the leading international suppliers of modern measurement systems and equipment for many years. Increasingly stringent requirements for emission standards in Europe and the USA have led to a drastic reduction of pollutant concentrations in exhaust gas. Measurement experts at the Neuss-based company have accepted the challenge and have managed to secure their hold on the market for measurement systems. The team headed by the product group’s manager Georg Maul has developed a new generation of exhaust gas measurement systems (AMA in short) to be launched under the name of AMA 4000 in March this year. The first order for the new exhaust gas measurement system has already been booked from BMW (Bayerische Motorenwerke AG). In line with legislation in different countries, the AMA systems can be used to perform exhaust gas emission tests for certificati- on and to monitor series production of vehicles on engine and chassis dynamometers. Apart from systems delivered to the automobile industry, Pierburg’s measurement technology product group also supplies custommade systems to automotive suppliers, advanced technical colleges and institutes concerned with measurement technology. Dilution unit with multiple venturi jets The advanced, trend-setting technology used in the AMA 2000 analysis unit will also be employed for the latest generation of exhaust gas measurement systems. However, one essential difference is that the AMA 4000 has a central intelligence which controls the components via a bus system. The decentralized structure (where the individual elements all Air blower intergral modal Heated Elements approx. 40°C Lines 40°C had their own computer systems) has been abandoned in favor of the consistent use of modular constructions. Jochen Böning from the sales department points out that “these modifications have produced a compact, cost-effective design. Systems which had to be accommodated in two AMA cabinets in the past can now easily be housed in one”. Sales manager Günter Maassen adds that “internal communication and also control of the AMA have changed decisively as a result of the innovations.” To achieve a user-friendly and aesthetic design, the product group commissioned the Design and Ergonomics faculty of the University of Essen to design the cabinet and central control panel. In the words of Rainer Ballik, manager of preliminary development activities: “In designing the AMA 4000, particular consideration was given to the specific wishes of the customers. About two years ago, we started Air Heater Filter Mixer PIERBURG PIERBURG PIERBURG PIERBURG CVS control unit bags air exhaust diluted AMA diluted AMA undiluted The exhaust gas values of vehicles are tested on a chassis dynamometer. Our diagram shows the system structure: the vehicle under test is positioned on the dynamometer. A test driver drives the specified curve, with the system simulating the resistance exerted on the vehicle when driving along a road. A certain quantity of exhaust gas is filled into bags during the test and is then analyzed by the AMA. asking customers what they wanted. The results of this campaign were then used to specify the requirements for the hardware and software of our latest generation of exhaust gas measurement systems.” The achievements of the highly motivated development team are worth 28 Ambient Air Air dryer after cat pre cat Optional Driver’s Aid seeing. The order placed by BMW even before the AMA 4000 is actually launched on the market is clear proof of the quality of the work carried out by Pierburg’s measurement experts. Although the system will not be available on the market before March 2000, BMW has already ordered the AMA 4000 to modernize its exhaust gas testing centers. Pierburg is to install twelve test facilities in Germany, Austria and the USA. This is the biggest single order ever booked by the product group. And the prospects for the successful team are good – as an official World-Wide Selected Supplier of BMW, the measurement experts will continue to work as a reliable partner for the Munich-based car maker in future, too. Yet the excellent kick-off for the AMA 4000 with the order from BMW is by no means the only success story for Pierburg’s measurement technology team. Other measurement systems have e.g. been sold to BMW, Audi, Degussa, Siemens and Aral. Measurement facilities are also being delivered to Ellring Klinger, a manufacturer of engine seals and sealing systems in Idstein/ Taunus, to the engine manufacturer MAN and to Hatz, a fan diesel engine developer in Rurstorf a. d. Rott near Passau. Interesting projects have likewise been secured on the international market: contracts have, for instance, been concluded with the car maker KIA and the Katech Institute (Korean Automotive Technology Institute) in Korea. In addition, complete measurement systems have been ordered by India – where a major order was placed by the company Mico – and China despite harsh competition there.
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