Vaillant Group at a glance
Vaillant Group at a glance
Vaillant Group at a glance
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<strong>Vaillant</strong> <strong>Group</strong><br />
Corpor<strong>at</strong>e present<strong>at</strong>ion<br />
06.11.2008
⎮Corpor<strong>at</strong>e Present<strong>at</strong>ion <strong>Vaillant</strong> <strong>Group</strong><br />
<strong>Vaillant</strong> <strong>Group</strong> <strong>at</strong> a <strong>glance</strong><br />
– <strong>Vaillant</strong> <strong>Group</strong> is an intern<strong>at</strong>ionally successful<br />
company focusing on he<strong>at</strong>ing and air-conditioning<br />
technologies<br />
– As one of the world's market and technology leaders,<br />
the company develops and produces tailor-made<br />
products, systems and services for he<strong>at</strong>ing, cooling<br />
and hot w<strong>at</strong>er<br />
– In 2007 the <strong>Group</strong> achieved sales of about €2.4 billion<br />
with 12,400 employees<br />
– Since its founding 1874, <strong>Vaillant</strong> <strong>Group</strong> has been a<br />
family-owned company<br />
2
⎮Corpor<strong>at</strong>e Present<strong>at</strong>ion <strong>Vaillant</strong> <strong>Group</strong><br />
Development of sales 2003 – 2007<br />
billion Euro<br />
3.000<br />
2.500<br />
2.000<br />
1.500<br />
1.000<br />
500<br />
0<br />
1.571<br />
1.627<br />
1.791<br />
1.997<br />
Continuous sales growth<br />
2.388<br />
2003 2004 2005 2006 2007<br />
3.000<br />
2.500<br />
2.000<br />
1.500<br />
1.000<br />
500<br />
0<br />
3
⎮Corpor<strong>at</strong>e Present<strong>at</strong>ion <strong>Vaillant</strong> <strong>Group</strong><br />
<strong>Vaillant</strong> <strong>Group</strong>: employees in 2007 by country/region<br />
Italy<br />
Spain<br />
4%<br />
10%<br />
17%<br />
10%<br />
UK<br />
Rest of world<br />
Rest of Europe 2%<br />
Emloyees 2007<br />
12,387<br />
13%<br />
France<br />
Germany<br />
28%<br />
16%<br />
Turkey<br />
2006 2007 Change<br />
Employees<br />
Germany 3,365* 3,453 88<br />
Gre<strong>at</strong> Britain 1,175 1,291 116<br />
France 985 1.624 638<br />
Italy 508 479 (29)<br />
Spain 1,126 1,201 75<br />
Turkey 426 2,000 1,574<br />
Others 2,182 2,339 157<br />
10,055 12,387 2,333<br />
* pro forma<br />
At end-2007 <strong>Vaillant</strong> <strong>Group</strong> had 12,387 employees. Th<strong>at</strong> was 2,332<br />
(23%) more than <strong>at</strong> the end of 2006.<br />
4
⎮Corpor<strong>at</strong>e Present<strong>at</strong>ion <strong>Vaillant</strong> <strong>Group</strong><br />
Intern<strong>at</strong>ional presence – production sites (1)<br />
Site Number of Production<br />
employees*<br />
Remscheid (D)<br />
Headquarters<br />
* Number of employees (manufacturing units, R&D, Purchasing) as <strong>at</strong> 31 December 2007<br />
1,257<br />
Wall-hung boilers,<br />
hydraulic pipes,<br />
he<strong>at</strong> exchanger,<br />
burner, electronics<br />
Nantes (F) 636 Wall-hung boilers<br />
and gas w<strong>at</strong>er<br />
he<strong>at</strong>ers<br />
5
⎮Corpor<strong>at</strong>e Present<strong>at</strong>ion <strong>Vaillant</strong> <strong>Group</strong><br />
Intern<strong>at</strong>ional presence – production sites (2)<br />
Site Number of Production<br />
employees*<br />
Skalica (SK) 362<br />
Belper (UK)<br />
Gelsenkirchen (D)<br />
* Number of employees (manufacturing units, R&D, Purchasing) as <strong>at</strong> 31 December 2007<br />
Wall-hung and<br />
floor-standing<br />
boilers, electric<br />
w<strong>at</strong>er he<strong>at</strong>ers<br />
367 Wall-hung boilers<br />
(condensing)<br />
168 Renewable energy<br />
appliances, spare<br />
parts<br />
6
⎮Corpor<strong>at</strong>e Present<strong>at</strong>ion <strong>Vaillant</strong> <strong>Group</strong><br />
Intern<strong>at</strong>ional presence – production sites (3)<br />
Site Number of Production<br />
employees*<br />
Bergheim (D)<br />
Trenčin (SK)<br />
Bad Kreuznach (D)<br />
* Number of employees (manufacturing units, R&D, Purchasing) as <strong>at</strong> 31 December 2007<br />
205 Storage units,<br />
floor-standing oil<br />
boilers<br />
380 Modules<br />
- He<strong>at</strong> engine condensing<br />
- Hydraulics<br />
- Jigs<br />
73 Electric w<strong>at</strong>er<br />
he<strong>at</strong>ers and<br />
storage units<br />
7
⎮Corpor<strong>at</strong>e Present<strong>at</strong>ion <strong>Vaillant</strong> <strong>Group</strong><br />
Intern<strong>at</strong>ional presence – production sites (4)<br />
Site Number of Production<br />
employees*<br />
Roding (D)<br />
Vitoria (ES)<br />
Wuxi (CN)<br />
* Number of employees (manufacturing units, R&D, Purchasing) as <strong>at</strong> 31 December 2007<br />
340 Brass components<br />
(gas valves)<br />
137 Air-conditioning<br />
units<br />
He<strong>at</strong> pumps<br />
96 Wall-hung boilers<br />
8
⎮Corpor<strong>at</strong>e Present<strong>at</strong>ion <strong>Vaillant</strong> <strong>Group</strong><br />
Intern<strong>at</strong>ional presence – production sites (5)<br />
Site Number of Production<br />
employees*<br />
Bozüyük (TR)<br />
Orgiano (IT)<br />
Pontenure (IT)<br />
* Number of employees (manufacturing units, R&D, Purchasing) as <strong>at</strong> 31 December 2007<br />
1,474<br />
140<br />
<strong>Vaillant</strong> <strong>Group</strong> Flues<br />
159<br />
Hermann, Gesamtzahl: 219<br />
Gas w<strong>at</strong>er he<strong>at</strong>ers,<br />
electrical storages<br />
w<strong>at</strong>er he<strong>at</strong>ers,<br />
radi<strong>at</strong>ors, he<strong>at</strong> pump<br />
systems, combi boilers,<br />
air-conditioners (as<br />
from 1 May 2008)<br />
Flues systems<br />
Wall-hung he<strong>at</strong>ing<br />
appliances<br />
9
⎮Corpor<strong>at</strong>e Present<strong>at</strong>ion <strong>Vaillant</strong> <strong>Group</strong><br />
Established brands – brand portfolio<br />
He<strong>at</strong>ing and air-conditioning Household products<br />
Sales: €2,348 million<br />
Employees: 12,152<br />
€40 million<br />
With its eight he<strong>at</strong>ing and air-conditioning technology brands <strong>Vaillant</strong> <strong>Group</strong><br />
is one of the leading intern<strong>at</strong>ional suppliers of products and services in this<br />
sector.<br />
235<br />
10
⎮Corpor<strong>at</strong>e Present<strong>at</strong>ion <strong>Vaillant</strong> <strong>Group</strong><br />
Short introduction: GE facts and figures<br />
Utilised area: 35.000 m²<br />
Total production area: 27.800 m²<br />
Found<strong>at</strong>ion d<strong>at</strong>e: 1987<br />
Divisions/units on site:<br />
Series production: 150 empl.<br />
Spares production: 50 empl.<br />
Call center tecbytel: 70 empl.<br />
plus external enterprises/lessees<br />
GE plants development: from GWH production to WHB products<br />
to Renewables...<br />
11
⎮Corpor<strong>at</strong>e Present<strong>at</strong>ion <strong>Vaillant</strong> <strong>Group</strong><br />
Short introduction: current product portfolio<br />
Condensing<br />
boilers<br />
He<strong>at</strong> pump geoTHERM<br />
B 2008: 10 k pcs.<br />
WHB ecoTEC exclusive FSB ecoCRAFT<br />
B 2008: 24 k pcs. B 2008: 2 k pcs.<br />
Airventil<strong>at</strong>ion recoVAIR/<br />
Airmaster<br />
Solar fl<strong>at</strong> collector<br />
Broad product portfolio with different technologies/<br />
production techniques.<br />
Renewables<br />
products<br />
Start of production:<br />
April 2008<br />
B 2008: 4 k pcs. B 2008: 45 k pcs. (own production)<br />
12
⎮Corpor<strong>at</strong>e Present<strong>at</strong>ion <strong>Vaillant</strong> <strong>Group</strong><br />
Layout Gelsenkirchen plant 2008:<br />
Solar<br />
assembly<br />
Solar absorber<br />
production<br />
Powder<br />
co<strong>at</strong>ing<br />
Spare parts<br />
production<br />
Pipe production<br />
Gas<br />
cond.<br />
WHB<br />
Showroom<br />
He<strong>at</strong> pumps<br />
Logistics/Warehouse<br />
Airventil<strong>at</strong>ion<br />
Gas<br />
cond.<br />
FSB<br />
Maintenance<br />
Spare parts<br />
production<br />
13
⎮Corpor<strong>at</strong>e Present<strong>at</strong>ion <strong>Vaillant</strong> <strong>Group</strong><br />
Solar Thermal Collector Production<br />
Pipe system Absorber welding Collector assembly<br />
Vertical Horizontal Drainback<br />
• Bending of three<br />
serpentine types<br />
• Brazing of collector pipes<br />
• Testing of pipe system<br />
• Fix<strong>at</strong>ion of pipe system<br />
onto absorber sheet<br />
The production concept is structured into three main processes.<br />
Title of Present<strong>at</strong>ion<br />
⎮Structure ⎮ Manufacturing Process Pipe System ⎮ Manufacturing Process Absorber<br />
| Manufacturing Process Assembly ⎮ Lay out | Back up<br />
⎮20-O ct-04 ⎮Title of P res ent<strong>at</strong>ion<br />
Assembly Process “Packaging”<br />
⎮Struct ure ⎮ Manuf ac turing Proc ess P ipe Sy stem ⎮ Manuf act uring Process Absorber<br />
| Manuf ac turing Proc ess A ssem bl y ⎮ Lay out | Back up<br />
Assemb ly Process “Fram e”<br />
1 2<br />
1. P ress 2 corner fittings in the short, black anodised aluminium profiles<br />
2. P lace all profiles into frame press and press the frame<br />
3. A pply type sticker on frame for identific<strong>at</strong>ion in line<br />
The anodised aluminium profiles are connected with corner fittings and<br />
compressed in a frame press<br />
⎮Struct ure ⎮ Manuf ac turing Proc ess P ipe Sy stem ⎮ Manuf act uring Process Absorber<br />
| Manuf ac turing Proc ess A ssem bl y ⎮ Lay out | Back up<br />
⎮20-O ct -04 ⎮Title of Pres ent<strong>at</strong>ion<br />
Assemb ly P rocess “Ab so rber”<br />
Standard Collector Drainback - Collector<br />
For mounting the absorber the two<br />
For mounting the absorber the Ø10mm-pipe ends are manually<br />
collector pipe ends are clicked slotted through the grommets and<br />
manually in the couplings<br />
placed on the insul<strong>at</strong>ion – further<br />
fix<strong>at</strong>ion might be needed<br />
The absorber is m anually clicked in the couplings for the standard collector, and<br />
slotted through gr ommets for the drainback collector<br />
17<br />
3<br />
1<br />
⎮Structure ⎮ Manufact uring Process Pipe Sys tem ⎮ Manufacturing Proc es s A bs orber<br />
| Manufact uring Process Ass em bly ⎮ Lay out | Back up<br />
⎮20-O ct-04 ⎮Title of P res ent<strong>at</strong>ion<br />
Assemb ly P rocess “ Back Pl<strong>at</strong>e”<br />
Primer Plasma<br />
Adhesive<br />
1 2<br />
Prepa r<strong>at</strong>ion of<br />
fram e<br />
Applic <strong>at</strong>ion of<br />
adhesive<br />
3<br />
F ix <strong>at</strong>i on of bac k<br />
pl<strong>at</strong>e<br />
Befor e the back pl<strong>at</strong>e can be fixed, the frame must be cleaned – depending on<br />
the feasibility, a plasma tre<strong>at</strong>ment is pr efer red over primer as it is much ne<strong>at</strong>er<br />
14<br />
⎮Structure ⎮ Manufact uring Process Pipe Sys tem ⎮ Manufacturing Proc es s A bs orber<br />
| Manufact uring Process Ass em bly ⎮ Lay out | Back up<br />
⎮20-O ct -04 ⎮Title of Pres ent<strong>at</strong>ion<br />
Assemb ly P rocess “ G lass”<br />
1<br />
A B<br />
• Glass to be i nspected for damages<br />
• Prepare area for adhesive on glass if needed<br />
• Option A: 1. Place glass on frame<br />
2. Fill space with adhesive<br />
• Option B: 1. Apply adhesive on frame<br />
2. Place glass in adhesive and press<br />
Befor e the glass process is started, the covering foil on the absorber sheet is<br />
peeled off and the pipe system is tested for tightness<br />
18<br />
⎮St ructure ⎮ Manufact uring Process Pipe Sys tem ⎮ Manufacturing Proc es s A bs orber<br />
| Manufact uring Process Ass em bly ⎮ Lay out | Back up<br />
⎮20-O ct-04 ⎮Title of P res ent<strong>at</strong>ion<br />
Assemb ly P rocess “ In su l<strong>at</strong>ion”<br />
Bottom insul<strong>at</strong>ion<br />
i nto casing<br />
Opti on<br />
• One insul<strong>at</strong>ion<br />
As the insul<strong>at</strong>ion layer is lamin<strong>at</strong>ed w ith a black fleece m<strong>at</strong>erial, test w ill show , if<br />
the handling of a one-piece-layer is feasible<br />
⎮St ructure ⎮ Manufact uring Process Pipe Sys tem ⎮ Manufacturing Proc es s A bs orber<br />
| Manufact uring Process Ass em bly ⎮ Lay out | Back up<br />
⎮20-O ct -04 ⎮Title of Pres ent<strong>at</strong>ion<br />
Assemb ly P rocess “ F inishing”<br />
– Quality check of adhesive edge<br />
– Manually finishing if needed<br />
– Applic<strong>at</strong>ion of clamps for defined<br />
pressure on glass corners<br />
– Hardening of adhesive in shelf system<br />
Example for shelf system<br />
Example for p<strong>at</strong>ernoster<br />
A quality check is made before the hardening of the adhesive<br />
15<br />
Rework necessary<br />
19<br />
⎮St ructure ⎮ Manufact uring Process Pipe Sys tem ⎮ Manufacturing Proc es s A bs orber<br />
| Manufact uring Process Ass em bly ⎮ Lay out | Back up<br />
Option<br />
Assemb ly P rocess “Absor ber P repar <strong>at</strong>ion”<br />
• A ir duc ts integr<strong>at</strong>ed in<br />
coupling<br />
⎮20-O ct-04 ⎮Title of P res ent<strong>at</strong>ion<br />
⎮20-O ct -04 ⎮Title of Pres ent<strong>at</strong>ion<br />
Standard Collector Drainback - Collector<br />
• Press in 4 couplings<br />
• Fix with 2 rivets each<br />
• Press in airing ducts<br />
• Press in 3 grommets<br />
• Press in airing ducts<br />
Befor e the absorber is p laced couplings and airing ducts are inser ted manually<br />
Frame Backpl<strong>at</strong>e Insul<strong>at</strong>ion Fixings<br />
⎮S truc ture ⎮ Manufact uri ng P rocess Pipe S ystem ⎮ Manuf ac turing Proc es s Absorber<br />
| Manufacturing P roc ess Assembly ⎮ Lay out | Back up<br />
Assem bly Pr ocess “P ackaging”<br />
• Foil on glass*<br />
• Pr otection against dirt<br />
• Pr otection of collector after<br />
install<strong>at</strong>ion but befor e sys tem<br />
oper<strong>at</strong>ion<br />
• Plac ement of handling and<br />
install<strong>at</strong>ion ins tr uctions<br />
• Cardboard end pieces<br />
• Collector strapped<br />
• Pallet stretched in order to secure<br />
collector pile<br />
* F oi l al ready applie d by gl ass suppl ier<br />
The glass is covered by multi-functional foil, but still noticeable, so th<strong>at</strong> the<br />
collector is handled car efully in w arehouses and on construction sites<br />
Absorber Glass Hardening Packaging<br />
• Assembling of frame<br />
• Fix<strong>at</strong>ion of back pl<strong>at</strong>e,<br />
insul<strong>at</strong>ion and absorber<br />
• Fix<strong>at</strong>ion of glass<br />
• Hardening of adhesive<br />
• Packaging of collector<br />
16<br />
20<br />
14
⎮Corpor<strong>at</strong>e Present<strong>at</strong>ion <strong>Vaillant</strong> <strong>Group</strong><br />
3D layout of the Assembly Line<br />
Framing cell<br />
Manual work<br />
st<strong>at</strong>ions<br />
Gluing cell<br />
Assembly is divided into 5 major areas:<br />
frame pre-assembly, manual st<strong>at</strong>ions, glueing, hardening, packaging.<br />
Hardening<br />
buffer<br />
15
⎮Corpor<strong>at</strong>e Present<strong>at</strong>ion <strong>Vaillant</strong> <strong>Group</strong><br />
16
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