glück­auf 2/2012

The newspaper for employees, customers and friends of the GMH Group

Extracts in English

Editorial Dear Colleagues, Which team has won the European football championships? By the time you read this, you will already know. As this edition of glückauf goes to print, however, the answer is still in the clouds. As far as some issues are concerned, it is quite simply a question of time. This certainly applies with regard to the many optimisation projects within the GMH Group, about which reports are included in this edition. Here also a period of time is required before the extent of the benefits can be realistically assessed. And if there aren’t any? In contrast to the European championships, it is always possible to make a fresh start. Editorial team

»Success needs us all«

Illustration: Lutz Mathesdorf

Merely a question of time GMH Group · The proportion of women employed in the GMH Group is increasing constantly. And the GMH Group creates conditions which support women in their careers and help them achieve success.

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t is meanwhile an established fact that women at work – whether in the industrial or commercial sector – are usually very well qualified and thus provide significant added value for the employer. Women are therefore warmly welcomed by the GMH Group. This already begins in the acquisition of junior employees. By means of participation in Girls’ Day, specific approaches to (prospective) academics, training of women in technical professions or involvement of qualified mothers who are currently not in professional employment, companies of the GMH Group show clearly where they stand. Long-term and reliable integration of women at the workplace can only be successful, however, if the employer knows about the challenges involved in combining work with family life, and also accepts them and provides appropriate working conditions. GMH Group companies are well aware of this. Many of our companies, therefore, already offer flexible working hours, mobile work places (home office), individually tailored possibilities to return to work after maternity leave, care and supervision of schoolchildren during school holidays or even family support periods, to

mention just a few examples. The same fundamental principle applies to all these companies, as it does to Harald Schartau, Managing Director for Human Resources and Personnel Manager of Georgsmarienhütte Holding: “We will never put obstacles in the way of a qualified woman. On the contrary. Should there be any in her way, we will remove them.” The proportion of women employed within the GMH Group is not regulated by quotas, because Harald Schartau does not consider such a measure to be necessary: “Not only because women are welcome here. We also have an equal treatment system with regard to recruitment, pay and career opportunities.” Indeed, Kranbau Köthen is a good example of how other GMH Group companies think and act in a similar way because the crane construction company has recently been awarded the title of “Family-friendly business”. For many decades steel production and processing was considered an exclusively male domain. Well-developed muscles and good stamina were the principle qualities required on the shop floor, whilst rough language and manners prevailed in the office. Today, however, a look into the production facilities and offices shows that times

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have changed. Increasingly frequently jobs in these areas which used to be done by men, also at management level, are now held by women. Statistics prove that this impression is correct. Against such a background, it seems almost superfluous to mention that almost 800 of the approximately 11,000 employees of the GMH Group – in other words almost 7 percent – are meanwhile women. However, the proportion of female trainees is almost twice as high, at 11.6 percent. And in the GMH Group’s current junior trainee programme, seven of the 31 participants are women – representing a proportion of 23 percent. Furthermore, by comparison with other Group companies, the quota of women employed by Georgsmarienhütte Holding is the highest at 47 percent. Nevertheless, despite the increasing proportion of women within the GMH Group, no woman has ever progressed to the management level of a GMH manufacturing company. “But that is about to change. Very soon a leading managerial position is going to be occupied by a woman“, says Harald Schartau, looking confidently to the near future. ikw

That’s us

Security of supply and processing expertise GMH Group · Reliable partner and service provider: The value chain begins with the Raw Materials Recycling business unit. and two gantry cranes. The range of activities of the business unit’s 176 employees goes far beyond processing the secondary raw materials and supplying to the Group companies, however. The international marketing of scrap, photos: Felix Treppschuh of residual iron from the metallurgical and View of the company premises of Rohstoff Recycling Osnabrück GmbH steel industries, of NF metals and of alloyed scrap grades also plays ithout scrap there is “nothing doing” a major role as do, equally, the business of in the melt shops and foundries of the collecting discarded secondary raw materiGMH Group. This secondary raw material, which is fundamental to the steel and found- als, and consulting, disposal, hire crushing and screening, demolition, logistics and slag ry industries, is procured by the companies management services. of the Raw Materials Recycling business unit The Raw Materials Recycling business unit for the production processes of GMH Group thus offers an extensive portfolio relating members and numerous customers nationally and internationally, and is processed using to the supply of scrap materials, including industry-specific services for steel mills and wide-ranging, state-of-the-art technologies. foundries of the GMH Group as well as other Rohstoff Recycling Osnabrück GmbH and Adolf Ellermann GmbH were taken over by national and international customers. GMH Holding GmbH in 1995. Rohstoff Recymk cling Dortmund GmbH was founded in 2001. In Osnabrück, Dortmund, Mülheim/Ruhr and Krefeld, steel scrap and residual iron are processed in special-purpose installations at sites totalling 140,000 m2 in area - large enough to accommodate around 14 football fields. • The harbour-based site in Osnabrück includes a press for the briquetting of grinding swarf and steel turnings, in addition to two alligator shears, a baling press, and an NF separation installation with attached The underground blasting chamber is a float-sink plant. reinforced-concrete monolith that is fed by a • The site at Dortmund harbour processes crane with materials that are to be reduced in heavy, large-volume scrap with the aid size, such as rolls and pig iron skulls. Blasting of two drop-ball crushers, three hoodholes are cut into the materials beforehand in enclosed burning chambers, a underthe hood-enclosed torch-cutting facilities and ground blasting chamber and a scrap shear. packed with explosives and a fuse. The detoTwo rented drop-ball facilities for crushing nation chamber is then closed off by means pig iron skulls and engineered castings are of a traversible cover (weight of the cover: additionally available in Mülheim/Ruhr. 360 t) to prevent any objects from being • In Krefeld a screening plant processes sepahurled unhindered from the chamber. Once rated scrap for its ferrous metal content. the cover is in place, a master blaster electriUsed for handling the scrap prior to its cally triggers the detonation from a remote transportation by road, water and rail are location. Rohstoff Recycling Dortmund GmbH 19 mobile excavators, two slewing cranes uses cartridge explosives for this process.

Special scrap “Special scrap” encompasses materials such as rolls, dies and moulds. Metallurgical byproducts, by comparison, come about in melt shops and comprise either pig iron or steel. Rohstoff Recycling Dortmund GmbH crushes such materials - generally delivered as large, heavy and solid entities - in its own processing installations into sizes suitable for charging. Examples of the wide diversity of materials that are processed include pig iron and steel skulls in various sizes, castings in the form of automotive industry dies, cast metal ingots from the steel industry, and steel rolls.

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Detonation chamber

Torch-cutting chambers. To reduce the size of large-volume scrap, Rohstoff Recycling Dortmund GmbH operates three hood-enclosed torch-cutting chambers facilities equipped with a modern exhaust-air cleaning system. Such a facility comprises a roofed-over and encapsulated area within which heavy scrap is cut up into chargeable sizes using industrial torch-cutting equipment. Holes are burned into the pig iron skulls and rolls by means of oxygen lances in preparation for blasting. During such work the personnel are located outside the enclosures and thus protected from flying sparks and torch-cutting fumes. All the hood enclosures are connected to a modern filter system, with a slightly negative pressure being maintained within the enclosures. Around 770 filter bags ensure that no dust finds its way into the environment. This extraction system uses state-of-the-art filter techology, cleaning approximately 140,000 m3 of exhaust air per hour. The mass flows that develop in the process lie well within the limits stipulated in Germany’s 2002 “TA-Luft” air quality requirements.

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LeAD artiCLE

Proceeding cautiously “Since politicians are not creating reliable underlying conditions for the energy sector, we will have to pursue our corporate philosophy more scrupulously than ever.”

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n the international economic and financial crisis, politicians have often repeated the slogan “We’re proceeding cautiously”, out of uncertainty as to which bad debts would appear next in the banks’ accounts, how the markets would react to this and how the diminishing confidence in the financial world would continue to weaken the real economy. The consequences of these uncertainties are continuing to have effects throughout the world, but in Germany, at least, economic performance has reached pre-crisis levels. We have the highest number of employees paying into Germany’s social insurance programme since reunification. Nevertheless, there are new storm clouds appearing on the horizon, so it is now up to the companies in this country to say “We’re proceeding cautiously”. Not just because we cannot guess how the markets are going to develop but also because underlying political conditions are becoming visibly more incalculable – at German as well as at European level. The national debt crisis within the eurozone, European energy and climate policies and the energy u-turn in Germany are the three main issues on which politicians are failing to demonstrate any resolve or clear perspectives. Thus they are making it extremely difficult for private sector companies – the energy-intensive ones in particular - to make any long-term plans. Whilst we have been talking about a “twospeed Europe” to date – namely the EU member countries using the euro as their common currency and those still using their national currencies, there are now also signs in the euro states of domestic and incalculable dynamics. Governments which are committing themselves rigorously to consolidating their budgets are being voted out of office one after the other – as we have recently seen in France as well as Greece. Or they are watering down their savings targets in anticipatory obedience to their voters’ wishes – for example Mario Monti in Italy, who again cancelled an ambitious debtbrake in April. The – only half-hearted – efforts at saving are now to be supported by a growth pact. However, if it is to be financed with new debt, in other words, if we are not talking about more state-financed economic stimulus packages, only structural reforms will be left to stimulate the weak economies in the coun-

tries affected by crises and reduce government expenditure. In concrete terms, we are talking - for example - about whether the French will keep their state-mandated 35-hour working week, whether the Spanish will adhere to their extreme job-protection legislation and whether the Greeks can continue to afford an inflated state apparatus with massive personnel costs. In Germany some of these questions have already been answered with the employment market reforms of Agenda 2010: unemployment market benefits and social welfare benefits have been combined, the long-term unemployed have had to accept considerable cuts in these benefits, the instrument of minijobs has been created, and employment agency work regulations have been liberalised. The instrument of short-time working came later in order to keep German companies flexible and competitive during the economic crisis as well. It is due far more to the significance of medium-sized companies in Germany’s economy that we are comparatively robust from an economic point of view: small and medium-sized companies are world leaders in many areas with their highly specialised products and they also combine to provide over half of all jobs subject to compulsory social insurance contributions. Businesses such as the GMH Group are firmly integrated into industrial value chains and can act independently of financial markets (and were indeed vilified as “old economy” before the crisis precisely for this reason). This German medium-sized sector is the anchor of stability in the crisis and part of the industrial base for growth and prosperity. In Greece, Italy or Portugal you seek such structures in vain. For this reason in particular it remains to be seen whether the debt-ridden euro-states can succeed in consolidating their economies with ambitious structural reforms or whether they will continue to fall into the downward spiral of new debt, higher taxes and hence sinking competitiveness. In order that we, too, as member companies of the GMH Group, can continue to make use of this stabilising function, a few clarifications are required from politicians, in particular a clear commitment to Germany as an industrial location. The additional gigantic burdens that threaten the German steel industry are a result of emissions trading by the EU, the German Renewable Energies Act levy , higher energy taxes and increased electricity costs due to the

Photo by courtesy of the GMH Group

energy u-turn. These are uncertainties that make “proceeding cautiously” necessary. Major investments must be held back until reliable basic conditions in energy and climate policies prevail. Should all foreseeable burdens actually come about in this manner, investments in Germany as an industrial location could be economically difficult from a business point of view and could only be justified with a very carefully calculated sense of proportion. With a view to European policies, the main issue is emissions trading. The cries to increase the price per tonne of emission rights - which has dropped to less than ten euros at the current time - by having the EU take certificates off the market, are becoming increasingly louder. At the same time it is certain even now that the price will rise considerably from 2013 due to the fact that fewer certificates will be traded when that period begins. In order for German companies – in the energy-intensive steel industry in particular – to remain competitive, we need a rapid implementation of compensation for national electricity prices into national law, as was decided by the EU in May. With compensation restricted to 85 percent of electricity price increases and to 75 percent from 2019, as provided by the EU, we will be able to compensate for our international competitive disadvantage – but not completely. The energy u-turn and its related, ambitious aims are, on the other hand, an exclusively GerContinued on the next page

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q Continued from last page man issue. Even after the phasing-out of nuclear power, the future supply of power is intended to be environmentally friendly, guaranteed and economical. We do not need to worry about the environmentally friendly aspect – the German Renewable Energies Act - an Act for accelerating the expansion of the German electricity grid and an Energy and Climate Fund to finance the energy u-turn - will take care of that. However, the question of secure supply remains open to debate. How can the expansion and stability of the German electricity network be guaranteed if, at the same time, the share of renewable energies – the availability of which fluctuates – is continuously increased and an extensive source of base-load electricity is lost?

The question of economy is equally uncertain. There are no reasonable data on how far the electricity prices may vary by comparison with the international level and from which point they become a competitive disadvantage. Nor is there any consensus on how an affordable energy supply can be guaranteed in practice. Germany needs a plan in which all three aims of national energy policy – environmentally friendliness, secure supply and economy – are treated equally and aimed for in a similar manner. A clean yet insecure energy supply is equally as worthless as a secure supply that is unaffordable for either private households or industry. So far, no solution to these uncertainties is in sight – either at national or at European level. As long as we are unable to rely on clear under-

lying conditions from politicians over the long term, we will be forced to concentrate all the more on our own strengths: producing flexibly and close to customers, not taking any incalculable risks and – instead – pursuing sustainable growth for all the member companies in the GMH Group. Because, even if we are obliged to “proceed cautiously” from a political perspective, this company philosophy still provides us with a proven and reliable compass. Glückauf

THE OWNER’S VIEW

What is required for the championship? Dear GMH Group employees, dear glückauf readers, The Euro 2012 in Poland and the Ukraine is in full swing. There is hardly anyone who does not share the excitement and thrills with their favourite team and generally enjoy the summer spectacle. And even those who normally are not completely “football crazy” may well feel astonished at how such sporting competition brings people together and inspires them with overwhelming enthusiasm for the event. But what does a team need in order to achieve success? What preparations are required in order to compete against the crème de la crème? These are exactly the questions which we also ask ourselves within the GMH Group if we want to play in the highest league. In the European Championship, the teams compete to master the round leather ball at the highest level technically, to combine strategy with fighting spirit and, in doing so, also to project themselves well and with sportsmanlike appeal. The one that invests the greatest effort – mentally as well as physically – in the training camp and then reproduces these efforts on the field in the actual matches will have the best chance of success. On the pitch the line-up must be right, the rules of fair play are to be observed towards opponents as well as fellow players – but each individual’s playing style must also involve a certain assertiveness. Within our group of companies everything revolves around the basic materials of steel, iron and also aluminium. We are exposed to global competition in the manufacture and processing of these materials. You, dear employees,

work every day on making our processes more efficient and our products even better, lighter wherever possible and even more resilient, and putting them to use in even more intelligent applications. Sporting and technical ambition are rather similar in this respect. Instead of the training camp we have our know-how, which has been acquired over many years, and the constant transfer of skills and knowledge. Nevertheless, constant self-criticism is necessary – to look at ourselves carefully and scrutinise how we work, to reflect, and if necessary learn from others about where and how we can become even better. We need a team which covers all the requirements: older members who lead and share their experience and younger persons who are hungry for success and introduce a new approach. In the areas of mobility, energy and mechanical engineering we are already market leaders with a number of our products, in some cases even at global level, and we are able to react quickly and flexibly to the wishes of our customers, whom we support as a reliable partner – all of which is a reflection of the fact that we do our homework well and are well positioned. However, success like this is always only of snapshot value. The business world is dynamic and such success must always be defended anew which means we must re-define ourselves constantly and inspire new confidence. That is the team spirit of the GMH Group: We want to play at the top, become champions in our field.

Photo by courtesy of the GMH Group

We see this not as a one-off target but as a permanent task. In order to accomplish it there must be fair play in our dealings with each other. In contrast to large conglomerates, this means that the employees in our companies must pass the ball on or accept an unexpected ball now and again and always think a step ahead of our “opponents”. But the most important thing is: in the long term no-one is successful alone – the team lays the foundation for success. And we want to share this success fairly with each other whenever it is achieved. Everybody deserves to have a share. Glück auf!

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Strong joint representation GMH Group · Hanover Fair 2012: Nine companies of the Group presented themselves as competent partners for the energy sector in the context of the “Energy” flagship fair.

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resent expertise in “young” as well as “old established” sales fields, strike up customer contacts and further increase the level of awareness of the GMH Group – these were the objectives which nine companies of the GMH Group wanted to achieve at the five-day Hanover Fair. The fair, which is considered to be the most important technology event in the world, took place from 23rd to 27th April and its gates were open not only to trade visitors but also to the general public. This year the fair was divided into eight flagship fairs which all made a convincing impression with their diversity of topics. The most important technologies and innovations from varying fields of industry were displayed over an area of more than 150,000 m2. The GMH Group naturally had to be there too. Nine companies of the Group (see box) presented themselves with numerous impressive and heavy-weight exhibits. Their fair stand was located in Hall 27 on the former Expo site. This building also accommodated the flagship “Energy” fair, one of the core themes of which was “renewable energies“. The GMH Group was thus located in the direct vicinity of sector giants such as GE Energy, Enercon and Vestas and consequently there were large numbers of visitors in this area of the huge fair site – which enabled the GMH companies to present themselves very effectively to potential customers. WeserWind exemplified the GMH Group’s involvement in the “Renewable Energies” sector. The company showed off its capabilities in the development, design, construction and assembly of windproof and weatherproof foundation structures for offshore wind farms. The tripod model, which is 1.5 t in weight and 5 m in height, was a good eye catcher and attracted lots of fair visitors to the fair stand. But expertise in

Facts Date: 23rd to 27th April Number of exhibitors: 5,000 from 69 countries Number of visitors: approx. 195,000 Photos by courtesy of the GMH Group Visitors from abroad: approx. 50,000 Over two levels: the busy fair stand of the GMH Group. This year the Hannover Fair accommodated eight wind power was not everything international flagship fairs: that the GMH companies had Industrial Automation, Energy, MobiliTec, Digital Factory, Into offer the 195,000 visitors to dustrial Supply, CoilTechnica, the 2012 Hanover Fair. Its knowIndustrialGreen Tec and Research how in other areas of energy gen& Technology. eration met with just as much interest. Numerous exhibits provided impressive evidence of During his tour of the fair its wide range of products, inthe Minister of Economics of cluding a cast steel Kaplan blade (Pleissner Guss) for hydroelectric Saxony, Sven Morlok, also visited the GMH Group stand. Hartwig plants and a forged connecting rod (Wildauer Schmiedewerke) Kockläuner Managing Director, weighing 850 kg for large enHolding, Market & Purchasing) gines. and Michael Schiller (Manag-

ing Director, Schmiedewerke Gröditz) used this opportunity to discuss the energy policy in Germany with him as well as the general economic development at the Gröditz location. The Minister of Economics and managing directors were in agreement: energy policy in Germany will have a significant influence on the future competitiveness of the energy-intensive and exportoriented GMH companies . Ultimately, the benefits of the fair extended beyond the numerous talks with current and potential new customers. The joint presence helped, in particular, to provide a stronger perception of the range of capabilities offered by the group of companies as a whole. Thus a lot of stand visitors showed great interest in the numerous companies which are behind the red signet of the GMH Group. A logical consequence was that in many cases Group companies were able to establish contact with other Group companies on behalf of their customers. In this way customers were often able to find further suppliers and product lines from the range on offer within the GMH Group. A further positive image effect ensuing from the constellation at the Hanover Fair was that the group of companies as a whole as well as individual Group companies attracted the attention of many qualified persons, including university graduates. This contributed to an even clearer perception of the GMH Group as an attractive employer. Now that the event is over, the fresh impetus which the Hanover Fair has created must not be allowed to simply ebb away. Our aim must be to revive it again at future trade fairs in order to further improve the positive image of the GMH Group amongst the qualified public. Maren Dependahl

Who all was there?

Exchange of opinions (from left to right): Michael Schiller, Minister of Economics Sven Morlok and Hartwig Kockläuner.

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The following companies of the GMH Group were represented at the Hanover Fair: Schmiedag, Wildauer Schmiedewerke, Walter Hundhausen, Friedrich WilhelmsHütte Eisenguss, Pleissner, Pleissner Guss, Stahlguss Gröditz, IAG MAGNUM and WeserWind.

Bigger stand came at the right time GMH Group · Excellent timing: Wire 2012 in Düsseldorf achieved a new exhibitor and visitor record. The companies of the GMH Group were perfectly prepared for the large number of visitors.

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rom 26th to 30th March, 1,314 companies from all over the world provided information about their latest machines and products. Amongst them were eight companies of the GMH Group: GMH ütte, GMH Blankstahl, Stahl Judenburg, MVO Metallverarbeitung Ostalb, Wista Stahlhandel Witten, Heinrich Geissler, J. A. Bäuerle und ESB . But was this Wire event really appropriate for the GMH companies? At first glance it might seem that it was not because “wire” as such is not one of the GMH products. Nevertheless it is a tradition for producers of rolled bar steel from Germany and Europe to exhibit at this event. Accordingly, in Hall 12, where the GMH companies had their stand, a lot of our competitors were also present. This really was the venue where all the names and faces of the industry congregated. The companies of the GMH Group were optimally prepared for the trade fair. A newly designed stand with a total area of

photo : Oliver Santelli

The second level provided an oasis of calm amidst the bustle of the fair. This was a good place to talk in a relaxed atmosphere.

165 sq m constructed over two levels provided sufficient space for holding detailed discussions with regular customers as well as making new contacts. The “Messe” forum offered the opportunity to discuss current subjects and new market trends or – very popular this time – to exchange information between Group members. It soon became obvious that the expansion of the stand had

been very necessary. Not only because an additional GMH company, ESB , had joined the team of exhibitors. There was also a remarkable increase in the number of visitors to the stand. Thus, particularly around lunchtime, there was not a single space free on the second level. A substantial increase in the number of international fair visitors was also registered. This may well have been due – at least in

part – to the new catering concept. “Food et Event”, a company from Osnabrück, provided an all-round service and was responsible for the culinary delights. ESB , as a first-time exhibitor, had a very successful time according to sales manager Frank Swierzinski: “In our opinion, after the Stahlmesse, the Tube & Wire dual trade fair is the most important and most popular fair in Europe. The principal objective was to offer our customers, project partners and potential future clients a platform for personal contacts.” The response from ESB customers was positive, as was also underlined by the number of redeemed vouchers and appointments on the stand. Frank Swierzinski: “At the meetings, prices were discussed, projects elaborated, or the opportunity was simply used for contact and social exchange. ESB had defined the tube industry as a customer group for round, continuously cast products. Although we, as the GMH Group, were actually exhibiting at the Wire event, within the scope of this dual fair we also wanted to be visible for visitors to the Tube exhibition.” Furthermore, the fact that Engineering Steel Belgium has definitely decided to exhibit again at the Wire event in 2014 is due to the stand team, excellent organisation and a fantastic stand design. Preparations for April 2014 are already in full swing. Then there will be a reunion at Wire 2014 in Düsseldorf. Andrea Busch

Travel tips – presented by Leon Radunovic

Airlines are also in action SAS: Europe’s most punctual airline. Scandinavian Airlines has now been distinguished by Flightstats as the most punctual airline in Europe for the third time in succession. With a punctuality rate of 88.22 percent on all flights, SAS occupies third place worldwide amongst all major scheduled airlines. In fact the punctuality rate has even increased by comparison with 2010 (86.47 percent). The data is based on punctuality statistics recorded by Flightstats which analyses more than 150,000 scheduled airline flights per day. Lufthansa: First Boeing 747-8 Intercontinental. Lufthansa is the first airline in the world to receive the passenger version of the Boeing

747-8 Intercontinental. Back in December 2006 the airline ordered 20 new jumbo jets and secured an option on another 20. The new jumbo is not only 5.60 m longer but also equipped with the latest generation of wings and engines. Fuel consumption is thus significantly lower than in conventional aeroplanes used on long-haul flights. The CO² emission of the new series is approximately 16 percent lower than that of the B 747-400. On 1st June the world’s first passenger version of the Boeing 747-8 will fly from Frankfurt to Washington D.C. Other flights to the USA and to India are planned. United/Continental: Last stage in the merger. The two US airlines United and Continental

actually combined forces back in 2010. Since then the new United has not only become the world’s leading airline, it is also the biggest in the world. Already since spring 2011 passengers have been able to recogphoto: Senator Reisen nise a homogeneous outer appearance and coordinated procedures as well as matching service features on the ground and in the air. In March, the last stage of the merger was completed, and ever since the two airlines have been operating exclusively under the name “United Airlines”, meaning that United flight numbers only are used.

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The cheerful artist After a long professional life extending far beyond normal retirement age, Nikolaus Schuck is devoting himself to painting again. A visit to his atelier in Osnabrück.

The A r t is t

Nikolaus Schuck

photos: mk

Not only productive in his profession, but also in his leisure time: Nikolaus Schuck surrounded by a selection of his paintings.

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professional career as an economist and artist – is it possible to combine both at the same time? Looking at Nikolaus Schuck’s career, it seems that this can only be done to a limited extent. For many years he was only able to pursue his artistic work in small doses to provide some equilibrium in his busy professional life. Nikolaus Schuck painted his first pictures as a child during the Second World War. His motifs, as he remembers very well, were mostly burning houses. This probably helped him to cope with his terrible war-time experiences. A few years later, as an altar boy, he painted the Stations of the Cross. He achieved his first success in a painting competition on the subject of transport

safety. He was awarded first prize for his picture entitled “Berliner Luftbrücke” (Berlin Airlift). After passing his schoolleaving examination, Nikolaus Schuck’s painting activities ceased for a number of years. Following university studies in economics, he began his professional career in the steel industry. It was not until the late 1970s – during this time he was an authorised signatory at Krupp

– that he took part in a painting course at the community college (Volkshochschule) in Bochum. During this course his passion for painting was rekindled. Encouraged by a colleague, he exhibited his pictures for the first time at “Café Zürich” in Bochum, where he immediately sold ten pictures. On the basis of this success further exhibitions followed. When Krupp’s forging works merged with Klöckner in 1984, Nikolaus Schuck moved to Osnabrück as sales manager and later to Georgsmarienhütte, where he became managing director in 1993. From this point onwards at the latest, his professional commitments allowed no more time or leisure for painting. Nikolaus Schuck retired from the board

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1937: born in Berlin 1963: Diplom Volkswirt (degree in economics) Freie Universität Berlin 1963-2000: employment in the steel industry, finally as Managing Director at Georgsmarienhütte GmbH Since 2005: art education at the academies of Bad Reichenhall and Trier Since 2005: chairman of Kunstund Kulturstiftung Georgsmarienhütte Since 2006: chairman of Kunstschule Paletti Georgsmarienhütte Nikolaus Schuck lives and works in Osnabrück. of managing directors in 2000. This was not to be the end of his working life, however. He remained chairman of the supervisory boards of several forging and casting businesses belonging to the GMH Group of companies. Nevertheless, he was able to dedicate more time to his painting. He brushed up his knowledge in courses at the art academies of Bad Reichenhall and Münster. Since 2003 Schuck has held regular exhibitions of his work in Osnabrück and beyond. Continued on the next page

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q Continued from last page His favourite motifs are houses and landscapes. Most of them are located in Tuscany and other southern countries. The light and colours are so wonderfully intensive there. Back at home he recalls the motif and/or the draft of one or more pictures – the structure, the composition, the colours – which he has stored in his mind and creates the actual painting in his Osnabrück atelier. His works oscillate between realism and abstraction. He uses acrylic paint for most of his pictures. Furthermore, he sometimes includes materials such as sand, gravel, cardboard, scale (decades of work in the steel industry become evident here!) or textile fabrics. In former years he used to simply whiten a picture which did not seem

to work out as planned and started anew. Today he often lets excerpts of the “original” shine through, a method which lends additional depth to his pictures.

Like most artists, Nikolaus Schuck also has his role models. Principal personalities here are Lyonel Feininger, Karl Schmidt-

Current exhibition Nikolaus Schuck’s pictures oscillate between abstraction and realism. He has already held numerous exhibitions, not only In Osnabrück and surrounding area but also elsewhere in Germany.

Increase efficiency, decrease requirements GMHütte · Successful application and a special award: steel maker invited to Schloss Bellevue for the “Week of the Environment”. I n t e r view GMH ütte compiled a study entitled “Simulation-based Study on the Use of Existing Waste Heat Sources”, the method of which will probably also be of interest to other companies. An independent jury selected the study for presentation on 5th and 6th June within the scope of the “Week of the Environment” in the park of Schloss Bellevue – with GMHütte being the only steel maker represented. The fact that the project was selected by the jury from so many applications is a special distinction in itself. It confirms it as being one of the best projects demonstrating in a practical way, with innovative approaches, that ecology, economy and social considerations are compatible. The “Deutsche Bundesstiftung Um-

Rottluff and Anselm Kiefer. He is, however, also inspired by other German and French expressionists. In addition to his passion for landscape painting there is another artistic technique of which Nikolaus Schuck has an impressive command: he loves drawing caricatures. He held his first exhibition of caricatures entitled “Rasend dünkt mich, wer am Wein nicht Freude hat – Euripides 480 B.C.” at Bistro Steinwerk Osnabrück in 2004. Much to the pleasure of his friends and former colleagues, who also greatly enjoyed viewing illustrations of their own persons. mk  

welt” (German Foundation for the Environment ) and the “Bundespräsidialamt” (Office of the Federal President) are joint organisers of the “Week of the Environment”. During this week around 200 medium-sized companies and organisations presented their ideas, innovative projects and developments as well as proposals for implementation. In total around 12,000 visitors, including many prestigious representatives from industry, politics, academia and society, were invited to the event. But what exactly did the GMH ütte study deal with? glückauf interviewed Reimund Laermann, GMH ütte’s Director of Energy Management, in order to find out more: glückauf: Mr Laermann, what was the main topic of the study? Reimund Laermann: Being a steel maker, GMH ütte belongs to one

Photo by courtesy of the GMH Group

Reimund Laermann

of the most energy-intensive sectors of industry. It is therefore important to exploit the full energy-saving potential and this is why GMH ütte started a project on the structured assessment of its waste heat potential. The objective was to discover so-called heat sources and heat sinks on the works site and in the works

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Paintings by Nikolaus Schuck are exhibited at Diakoniestift am Westerberg (Osnabrück) from 14th June 2012.

buildings, to assess them and evaluate the possibility of utilising these energy sources. How did you proceed? Laermann: In order to assess this energy potential from a technical and economic point of view, we had to prepare a simulationbased study. But initially we observed the processes in all sections of the company in order to localise heat sources and heat sinks. The particularly difficult part was subsequently to evaluate their potential for use, because this potential is influenced by many factors – the course of time, the quantity of waste heat, the carrier medium, the temperature level as well as spatial conditions and distances between the places in question. So how great is the potential? Laermann: We have more heat sources than heat sinks in our location. But with the present state of technology, the majority of them are still not economical to use. On the basis of the knowledge acquired, we then developed a holistic heat concept. While doing so, different possibilities for use, such as conversion into electricity, cold generation or heating purposes, were investigated. First you simulated and then evaluated these possibilities for use.

Laermann: As far as the “steel production” application is concerned, the simulation-based study can certainly be applied successfully – although it involved the evaluation of a wide variety of process steps. And, of course, it became clear in the course of the project that some concepts, which at the outset promised to be successful, were in fact impossible to implement, either from a technical or an economic point of view, or both.

Photo by courtesy of the GMH Group

The GMH study met with great interest (from left to right): Henning Schliephake, Clemens Lammerskitten (Member of the Regional Parliament of Lower Saxony), Frank Leischner (Limón GmbH), Reimund Laermann and Wolfgang Schmidt

Laermann: That’s right. In this way we were able to simulate all possible process contexts and operating conditions. In this case steam was selected as a carrier medium, along with an electricity generation process and optional steam storage. The mechanisms are applied to the model through the use of physical modelling and by using technical parameters of the real case in question. On the basis of the data provided,

the programmed calculations are carried out as a function of time, continuously, and in real time. The results of the simulation runs can thus be evaluated precisely from a technical as well as an economic point of view.

for generation of electricity with the aid of a suitable conversion technology. However, they must be interconnected intelligently in order to reduce energy loss.

And with regard to the net results, what does this mean in concrete terms for GMH ütte? Laermann: The waste heat potential should be used on a decentralised basis Ingot store

Did the simulation method used prove successful in your investigation?

Furnaces 63

Can other companies in the industry also make use of this simulation method? Laermann: Definitely. In the case of complex production processes and different heat requirement profiles, simulation is a core method for modelling current heat situations, for illustrating potential, and for supporting the development of measures. It is not possible to investigate such intricate relationships on the basis of static observation. Thank you for talking to us.

Would you have known?

Heat sink

A component with high heat conductivity and in most cases also high heat capacity is described as a heat sink. In building services engineering, heat sinks are used as a synonym for heat losses because they lead to a higher heating or cooling requirement.

Media centre

Oxygen plant

Electric furnaces Ladle furnaces 1+2

Rolling mill

Continuous caster Condensation from exhaust gas boilers

source: GMHütte

Vacuum degasser

Slag

District heating North Annealing furnaces 21-24

theoretical waste heat potential heat requirements unused surplus available

District heating East District heating West

Comparison of heat quantities at GMHütte

The plant overview with potential bars illustrates the situation clearly. Here heat sources and heat sinks were identified. The aim of the simulation is to show how these can be used.

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All in the same boat GMHütte workshop promotes mutual understanding and teamwork.

A premiere in safety GMHütte · A woman is now responsible for occupational safety.

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Safety officer Thorsten Biewald and foreman Heiko Jesse from the rolling mill

I n t e r view Safety officers are the foreman’s righthand men as far as industrial safety is concerned. Their job is to detect hazard areas and help to eliminate them, to investigate and process accidents and, above all, to act as a link between superiors and colleagues. In order to support the team building process and promote cooperation on a partnership basis within the sphere of occupational health and safety management, a number of foremen and safety officers have now taken part in a workshop. glückauf spoke to foreman Heiko Jesse and safety officer Thorsten Biewald from the rolling mill. glückauf: A workshop on the subject of team building – that sounds as if in-fighting used to be the order of the day. Heiko Jesse: No, it was never as bad as that! After all, we have known each other since we were at school. There was only one year between us during our apprenticeship and we have also been working together in the rolling mill for quite a long time. Thorsten Biewald: Heiko has been shift supervisor in the rolling mill for five years and six months ago he was also appointed safety officer for this shift. It is a big advantage that we already had a well-established working relationship. So was the workshop superfluous? Jesse: The aim was not only to become a team, but also to evaluate the team, to get to know its structures – and detect the weak

points in our collaboration and eliminate them. Biewald: Within the scope of a so-called team diagnosis we took a careful look at how we work together with one another, how we speak to each other, who plays which role. On the basis of specific exercises we then refined our team work. What did you find particularly difficult? Jesse: The feedback session. To get feedback from the other person, to let them finish what they were saying, not to interrupt with my own point of view – that was difficult for me. Biewald: We like to discuss things in our everyday work, even controversial issues, and at great length. But we always arrive at a solution which suits both parties. You want to jointly implement an occupational safety project. Which one? Jesse: We call it “3 storage locations for stripping plates”. These plates weigh between 20 and 50 kilos. We need them at the roll stands. Unfortunately until now they have just been left lying in different places – a potential accident hazard should anyone stumble over them. Biewald: Going by the motto “Everything in its right place”, we created three locations for our colleagues to put the stripping plates. It already works quite well on our own shift. We now only have to improve the cooperation throughout all the shifts. There are some colleagues whom we very seldom see due to the different shifts and so it is difficult to make arrangements with them. Many thanks for this interview.

atascha Volkmann is GMH ütte’s first female safety officer. She works in the fitter’s section of the finishing shop and is looking forward to her new, additional task: “For a long time now I have wanted to become actively involved in shaping the safety culture in our works. I believe I am capable of addressing my colleagues, drawing their attention to unsafe behaviour or praising them in connection with positive issues.” Hans-Günter Randel, finishing shop manager, shares her opinion: “We have re-defined the role of the safety officer at GMHütte, upgraded the position and given more responsibility to the persons concerned. This development has meant that we have had to appoint some new safety officers. I immediately had the idea of involving a woman.” He is also convinced that Natascha Volkmann will carry out her new role very successfully: “She will establish good contact with her colleagues and thus have a very positive influence on the safety culture. Colleagues will take her comments and instructions seriously.” Natascha Volkmann believes in the positive influence of women on male colleagues: “When I discuss technical problems with my male colleagues, these conversations always take place on a factual and business-like level. I am listened to and my comments are taken seriously. It subsequently becomes obvious that everyone is trying that little bit harder. Why shouldn’t the same apply in the context of occupational safety?” Another advantage is that, as a fitter, Natascha Volkmann gets to see a lot of different workplaces in the finishing shop and meets colleagues on all the shifts there. She thus has a good chance of discovering safety deficiencies and convincing as many colleagues as possible about the benefits of safe behaviour. hgr

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A touch of Hollywood

actors and other members of the crew and take some souvenir photographs. In addition to the beautiful Audrey Tautou (“Amélie”, “The Da Vinci Code”) and Romain Duris (“Dans Paris”, “Heartbreaker”), Omar Sy was involved on the steelworks film set. He should be particularly present in the minds of cinema fans because he starred in the film “The Intouchables”, which has recently been highly acclaimed at international level. Omar Sy has already been awarded several prizes for his role in the film. “L’Ecume des Jours” will run in the cinemas in 2013. And, of course, there will be plenty of ESB colleagues in the audience.

ESB · Computer animation cannot always replace reality: Steelworks served as the impressive setting for a new film.

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n 17th April the steelworks of Engineering Steel Belgium in Seraing were converted into a film set. The reason was the making of “L’Ecume des Jours”, a new film by Michel Gondry. The French director, who won the Oscar for the best original script in 2005 for his film “Eternal sunshine of the spotless mind!”, has worked in the past with top stars from the music industry such as the Rolling Stones, Paul McCartney or Björk. His last film (“The Green Hornet”) with Hollywood stars such as Christoph Walz or Cameron Diaz reached the top of the international cinema charts. “L’Ecume des Jours” is based on the novel of the same name written by Boris Vian in 1946 (English title: “Froth on the Daydream”). It tells the story of Colin (Romain Duris), a wealthy young man, and his financially not so well-off friend Chick (Gad Elmaleh). Despite his own wealth, Colin rather envies his friend on account of his girlfriend, Alise. His desire for love grows. Then he meets Chloé (Audrey Tautou), whom he marries

Michael Schmak

photos: Michael Schmak

Leading actors Audrey Tautou and Romain Duris

shortly afterwards. During the honeymoon, however, it already transpires that Chloé suffers from a rare disease. A water lily is growing in her lungs … During breaks in the shooting, several ESB employees took the opportunity to talk to the

“Green manikins” ensure bizarre scenery: filming in the steelworks.

Good ideas score again GMHütte · IdeenManagement awarded “DeutscherIdeenPreis 2012”.

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or the second time in succession, GMH ütte’s IdeenManagement scheme has been awarded a prize by Deutsches Institut für Betriebswirtschaft GmbH (dib). It achieved third place in the “DeutscherIdeenPreis 2012” in the “iron and metal industry” category, and was thus beaten only by WESO -Aurorahütte GmbH of Gladenbach (Hesse)

 

and Mann + Hummel GmbH of Bensheim (Hesse). “This award is a great success for us because it proves that our IdeenManagement scheme functions very well”, comments Ralf Kübeck who is responsible for GMH ütte’s IdeenManagement.

photo: dib

Ralf Kübeck after receiving the “DeutscherIdeenPreis 2012”

After all, the company was able to maintain the good position it achieved last year. “Now our aim is to progress one step higher

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on the winners’ podium”, said Kübeck with a view to the goal for 2013. dib awards the “ DeutscherIdeenPreis“ to companies and individuals for outstanding commitment and success in connection with creativity, innovation and responsibility. The awards are classified into six categories, one of which is “Best Idea Management” (basis: participation in the dib-Report 2012). They were presented at the annual conference of the dib-Forum Idea Management in Dresden. The jury of high-ranking members included executives from industry, politics and science. Fundamental criteria for the award are the degree of innovation, transferability, as well as added socio-cultural, economic and ecological value. mw  

Lots to do – but also something special GMHütte · Memories of the highlights will still be cherished long after Clean-up Day 2012.

Made a joint “attack” on the greenery: Jianxiong Deng (back row), Axel Stüber (front), Vadim Rembold (back, internee), Heike Witte, Ingo Kolm, Reinhard Frauenheim and Thomas Wurm.

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reen and flourishing, but getting a little out of hand, even at GMH ütte. The annual Clean-up Day again offered the opportunity to bring the fast growing greenery back under control and also to do some of the other jobs for which there is never enough time in everyday business. At the beginning of May around 300 volunteers (employees, pensioners and business partners) came early on a Saturday morning to put the plans into action. A variety of projects were tackled in mixed working groups. All around the car parks, production facilities and office buildings bushes were pruned and weeds removed. On this occasion also rubbish was discovered which was correctly disposed of straightaway. Luckily the rain eased off during the course of the morning – which made the work easier and also lifted the spirits. As always there were some highlights which deserve special

Labour Director Felix Osterheider demonstrates the attractive blue electric scooter, the prize on offer for the next IdeeM draw.

mention. For example, colleagues from the rolling mill paved the area in front of their building – with the GMH logo! And since

that day another large GMH logo has been on display at the bend near the heat treatment facilities. It was created as part of this year’s “women’s project”. The slope there had been basically cleared beforehand so that on Clean-up Day only the remaining stones, branches, roots and other stubborn debris had to be removed before the female colleagues were able to start positioning plants in the form of the GMH logo. Light gravel stones create a background contrast. The managing board was very pleased that so many employees had again come to work voluntarily in their free time. Many business friends of GMH ütte were also a great help, however. They had not only come with their own hard-working hands, but had also brought along lorries, wheel loaders and excavators to deal with the rubbish collected and other heavy transport loads. For some time now GMH ütte has commissioned companies to maintain the grounds and build-

Above – Hung pictures by Angelika Walter to embellish the newly decorated office hallway of BGG (left to right): Jens Melcher, Lukas Brockmeyer and Tom Schöne.

ings throughout the year. The traditional Clean-up Day still makes sense, however. Not only because of the bonding effect it has and the symbol of loyalty to the company. It is also a day when individual ideas can be implemented, such as the paved area in front of the rolling mill. The new paving had become necessary, but the logo was a voluntary addition – an extra touch that gives the place something special. At the end of Clean-up Day everyone was delighted to enjoy some delicious goulash soup. vl   photos: vl

The “women’s project” is one of the highlights of Clean-up Day. They “planted” the GMH logo in natural form on the slope near the heat treatment facilities (from left to right): Thorsten Kurz, Christina Battmer, Birgit Diestelkämper, Cornelia Börger, Claudia Riesenbeck, Christa Krick, Monika Friebe, Marvin Kurz, Katharine Hügelmeyer, Andrea Bruns, Silke Flaspöhler and Andrea Frank.

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Putting systems to the test Bous · Before its quality, environmental and energy management systems were “officially” certified, the steel maker held an “in-house” rehearsal for the real upcoming event. were audited strictly according to the audit plan. The auditors also carried out a precise assessment

INTERVIEW In March, Stahlwerk Bous completed its annual in-house audit with the assistance of consultants proTerra Umweltschutz- und Managementberatung GmbH. On the agenda were its quality, environmental and energy management systems. External auditors Anton Backes and Daniela Jakoby took a really close look at the company’s operating processes and procedures. Only then was the green light given for the official audit, which was conducted by TÜV Saar Cert. Armin Hans (Head of “Industrial Safety, Environmental Protection and Energy Management”) reports on the findings of the audits in an interview with glückauf. glückauf: Bous has also put its faith in external auditors in the past where in-house audits are concerned. Why is that? Armin Hans: Experience has shown that such audits are simply rated more highly by the employees. An audit conducted

Armin Hans Photo by courtesy of the GMH Group

by external personnel is taken more seriously than one done by company employees who are otherwise in charge of instruction and training. Our employees take the presence photo: Armin Hans of the company’s own environmenGerhard Schmitt shows Albert Lucas and Ursula Wolff test reports relating to electrical plant and tal and energy equipment. management officer for granted. of the laboratory, engineering ofAuditing by external auditors fice, purchasing department and breaks with such routine. warehouse. A focal point in this The in-house audit took place at the regard was the documented procedure for “procurement”. This end of March. Did it go smoothly? is important for the purchasing Hans: You could say that. The of charge, raw and indirect mamaintenance shop, vehicle terials as well as fuels, lubricants workshop, electrical workshop, and coolants, and also for the segment workshop, continuous procurement of energy-relevant casting facilities and melt shop

equipment and resources. Training courses, operating instructions and the handling of hazardous materials were also audited. What were the findings? Hans: That we were much better compared with the year before. That was undoubtedly a good basis for the official audit due in April. Who conducted it? Hans: TÜV Saar Cert. Ursula Wolff and Albert Lucas audited the environmental management system, and Herbert Conrad and Manfred Mateiko the energy management system. And what was the outcome? Hans: A differentiation has to be made in this connection: During auditing to DIN EN ISO 9001, the daily schedule was completed without any major incidents and shortcomings. During certification to DIN EN 16001:2009 and DIN EN ISO 5001:2011, the one or other possibility for improvement was found after all. They were mentioned in the audit report. And how would you sum up the audit personally? Hans: All in all, a positive development of our environmental and energy management systems is to be noted. This will also continue – if all employees continue to work motivatedly together and are interested in, and receptive to, new challenges. Thank you for talking to us.

Positive development MA · Continuing demand for rolled colliery sections

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annstaedt is evident in underground mining, too. Trough sections from Troisdorf, for instance, are needed for the extraction of hard coal removed at the face. Mannstaedt has been rolling them in a broad range of types now for several decades. A special role is additionally played by the “TH40 = W 09.006“ section, which is a trough section used for flexible roadway or tunnel supports (also referred to as yielding arch supports). It was re-included in the product catalogue in 2009, and deliveries were made again for the first time in early 2010. The rolled trough profiles are sent to Bochumer Eisenhütte, where they are quenched

and tempered or otherwise heattreated. They are then shaped to the radii that the end user requires. Below ground the curved trough profiles are assembled in overlapping arrangement and Photo by courtesy of the GMH Group joined together by means of fish plates. Depending on the design, Trough sections from Troisdorf: a prime example of roadway supports. the support segments used for yielding arch supports can slide Mannstaedt is also looking to include other into one another, thus allowing the supports to withstand the roof pressure within certain sizes in its product catalogue and is currently holding exploratory discussions with Bolimits without being destroyed. chumer Eisenhütte on the subject. Sales of the trough sections have shown a very positive development since 2011. Dieter Tondar

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International flair

How it all began The first Students’ Day of Metallurgy took place in 1993 – in response to an initiative launched by metallurgy students at the German speaking universities of RWTH Aachen, TU Berlin, TU Clausthal, GMU Duisburg, TU BA Freiberg and MU Leoben. The conference has expanded tremendously over the years as the number of participating universities has increased. In 2012, participants from 19 universities all over the world were welcomed. A platform for ideas and discussions has meanwhile been established, involving a different host university every year.

SWG · 19th International Students’ Day of Metallurgy in Freiberg

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he 19th International Students’ Day of Metallurgy (ISDM ) took place from 15th to 17th March and, after a period of four years, the venue of this event was again TU Bergakademie Freiberg. The conference objective is a scientific exchange between universities. The ISDM programme was correspondingly varied. The event was attended by approximately 250 students and postgraduates of metallurgy and related disciplines from 19 universities who had plenty of opportunities to attend lectures or to present and discuss their own research work. Furthermore, interesting excursions and a variety of opportunities to talk to representatives from companies involved in the sector were offered. The 3-day conference in the silver-mining location of Freiberg

was completed by two successful evening events. They provided an ideal setting for students and company representatives to get to know each other in a relaxed atmosphere. The shortage of skilled personnel is now also noticeable in the metal industry. Within the scope of a 2-day company contact fair, therefore, the Students’ Day offered around 30 companies the chance to present themselves to students as potential employers. The fair was held in the “Neue Mensa” of TU Bergakademie Freiberg. Schmiedewerke Gröditz (SWG ) also had its own stand at the event. Engineers from different SWG departments and colleagues from the human resources department answered a wide range of questions relating to internships, final dis-

photo: Stefanie Hoffmann

Above: SWG colleague Igor Karasevich (quality engineer, ring rolling mill) advises a participant at the ISDM company contact fair. Below: Group picture of ISDM participants

sertations and how to join the company. Employees of Pleissner Guss were also present at the stand. The GMH Group was thus able to present itself from a different aspect – and show prospective metallurgists also other job opportunities and future perspectives. jp  

Source: Verein Metallurgiestudenten zu Freiberg e.V., Marcel Schlenkrich

More pressure for academia SWG · New 10 MN forming press inaugurated at the Institute of Metal Forming.

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t the end of March, MEFORM 2012 took place at the Institute of Metal Forming of TU Bergakademie Freiberg. The focus of the conference, which is held once a year, was this time on materials development and massive forming. Almost 200 national and international forming technology experts, among them four engineers from Schmiedewerke Gröditz (SWG ), spent three days discussing challenges and latest developments in these fields. A highlight of this year’s symposium was the inauguration of a new universal forming press at the host institute. The 10 meganewton press is installed in an experimental facility there. It is capable of carrying out differ-

ent forming processes and of systematically testing new work pieces. It is also designed to provide students of forming technology with greater practical experience and to improve the cooperation between industry and academia. The funding for the investment, costing 2.33 million euros, came from the German Research Foundation (Deutsche Forschungsgemeinschaft), the federal state of Saxony, the Central Innovation Programme for Medium-Sized Companies, TU Bergakademie Freiberg, as well as sponsors and industrial interests. Schmiedewerke Gröditz also contributed toward the new forming press. It produced and machined the base plate in

photo: Stephan Reichelt

The new 10 MN press at the Institute of Metal Forming of TU Bergakademie Freiberg

Gröditz, then donated it. Schmiedewerke thus plays an important part where research in Freiberg is concerned. It will, of course, also benefit from the diverse research possibilities that the new press opens up. Ralf Schreiber

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Thorough structural overhaul SWG · Re-organised Technology activities place even greater emphasis on the customer. INTERVIEW Thursday, 1 March 2012 was a special day for Schmiedewerke Gröditz (SWG ). Since that day, namely, the company has been adopting new approaches. To support its customers even better, SWG has thoroughly re-organised its Technology activities. glückauf interviewed Robert Kühn, Managing Director Technology, and Bernd Kresinsky, head of the newly created Centre of Excellence, on the reasons for this and on how the re-structuring has gone. glückauf: How did you go about the re-organisation? And what was the aim of it? Robert Kühn: Quite generally speaking, it had to do with fulfilling customer and market requirements even better than before. We got started with a preparation project in which we analysed all the in-house processes that a forged product goes through. This meant that the analysis encompassed not only the flow of production but also customer support, cost estimating, order processing, product and process development, processing of complaints, and other aspects. Who took part in this analysis? Bernd Kresinsky: Personnel from the production shops, from marketing and sales, from quality management, and from Application and Process Engineering. After mapping the actual situation, they developed a number of ideas and proposals on how to modify and improve operating procedures to meet the aims in mind.

Photos by courtesy of the GMH Group

Robert Kühn

Bernd Kresinsky

And what was the aim of this analysis or these process studies? What was particularly important? Kühn: We had a whole number of aims that were not only of a technical nature. Firstly, to create procedures and matching structures that are as efficient as possible for the processing of enquiries, orders, as well as customer queries or complaints, and which promptly make it easy for us to realise also new products or comply with unusual customer requirements. Secondly, we want lessons learned from ongoing production – both positive and negative – to help our processes to develop further as smoothly as possible. A self-learning production establishment, if you so wish. Kresinsky: This also means putting technology faultlessly into practice. We’re looking to adopt a double-check principle throughout the process chain. To us, fulfilling orders means being good, fast, and punctual, and that we cannot afford any unplanned delays. Kühn: And ultimately there was the important question of how do we identify the products and technology trends on our markets of tomorrow at an earlier

stage, prepare better for them, and help shape them more actively? Did you also touch upon personnel issues with these proposals? Kühn: Once the new procedures were clear, suitable re-structuring then followed. And it is in this regard we also made very important personnel-related decisions, of course. There are now, for instance, technical customer advisors for individual product fields. The main focus of their work will be direct contact with the customer and technical advice on individual applications. They will also identify what customers expect of products from Gröditz in future. They will work in close cooperation with our marketing and sales people. Kresinsky: Occupying ourselves so intensively with these optimisation proposals and with the analysis of weak points led to yet a further fundamental decision: to create a Technology Centre of Excellence, where the Order Centre, Process Engineering and Application Engineering will now be concentrated. Who will be in charge of matters there?

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Kühn: Bernd Kresinsky, previously manager of forging and machining activities. He will have overall responsibility for the Centre of Excellence. Within the Centre he will also be head of Application Engineering. The Order Centre will be managed by Birgit Salega, and Process Engineering by Stefan Lachmann. Congratulations on your new position, Mr. Kresinsky. What functions will the Centre of Excellence have? Kresinsky: A large number of activities will be concentrated there. The Order Centre will be responsible in future for the onestop processing of all technical enquiries and orders and ensure a smooth flow of information, also during production. Process Engineering will be responsible for setting and developing the technological parameters for the melt shop and ESR unit, for the forging and heat treatment facilities, and for the machine shop. And the focus of Application Engineering’s work will be on product development and support for new products. Kühn: The Centre of Excellence will thus be, so to speak – as the name also implies – the technological core for the strategic development of the company. But we haven’t stopped there. The forging/machining activities have also been re-organised. There is now Forging/Heat Treatment, headed by Ralf Schreiber, and the Machine Shop, headed by Torsten Ulrich. How do the personnel concerned stand with regard to the re-organisation? Kresinsky: They all want to improve upon the positive results we have achieved so far. And they want to minimise any weak points that might come to light when realising customers’ steadily more exacting requirements. Kühn: In which respect, one thing is absolutely clear: Only if we continue to improve our products – and have an optimum cost structure and competitive delivery times – will we be able to take Schmiedewerke Gröditz forward on a sustained and positive basis. Thank you for talking to us. 

Multi-tasking talent Schmiedag · New FARO measurement arm efficiently performs a multitude of tasks. INTERVIEW

photo: Uwe Dannen

In March, Schmiedag was able to put a 3D measurement arm and laser scanner manufactured by FARO Europe GmbH & Co. KG into service. It will enable the company to pursue new production routes. In an interview with glückauf, Uwe Dannen (Head of Tool Engineering) explains which ones.

Are there any other areas of use? Dannen: We are also planning to use it for the geometry scanning and CAD reverse engineering of old dies.

glückauf: What capabilities does the new measurement arm offer, Mr. Dannen? Uwe Dannen: More than you would expect at first glance. First and foremost, we are able to carry out all tool and die geometry measurements with the new measuring system, which is of portable design! Who is responsible for operating it? Dannen: The personnel from the Quality Assurance, Tool Engineering and Finishing departments. They have completed a three-day training course so as to familiarise themselves with how to operate the measurement arm and use the software.

However, we derive a much greater benefit from it in tool engineering and in the regeneration of tools and dies because, by scanning the used die cavities, we are immediately able to identify the worn cavity areas – which will significantly reduce the amount of corrective maintenance work we have to do in terms of partial repairs. Together with the reduction in workintensive manual engraving after milling, this will lead to a considerable cost benefit in tool engineering. We are already using the measurement arm to assess dies. When doing a tool calculation we are thus able to calculate precisely, taking the tolerances into account, what number of pieces per die we can expect.

The new measurement arm in operation: Emir Ribic (left) and Thorsten Thurn measuring a die half for a pump casing.

transmitted wirelessly by WLAN from photo: the measureThomas Irmscher ment arm to the data Uwe Dannen (Head of Tool Engineering) analyser. How does the new There they technology work? are processed further by a softDannen: The measuring points ware tool. The software is able to are recorded by tactile means – in generate a polygonal model from other words, by touch – or the the measurement data and do a component surface is scanned. comparison with the 3D CAD These measurement data are then geometry.

And what is done with this target/ actual comparison of the geometries? Dannen: The data can then be output in the form of a first-piece inspection report or as a false colour photo. What was the reason for Schmiedag deciding on this new technology? Dannen: Our primary aim has been to reduce, by 50 percent, the time required to produce first-piece inspection reports.

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How will that be done, and what benefits will that yield? Dannen: We will scan-in the old copy models or die cavities and, using the software module, generate a 3D reverse-engineered image. Once the surface data have been transferred to the CAD programme, it will be possible to generate a volume model that can also be modified in design if necessary. There are also plans, though, to digitalise all old as well as hand-produced dies using the new technology. The amount of work involved will probably be enormous. Will it also be worthwhile? Dannen: The effort involved will be justified and worthwhile, of course, for our customers. Why is that? Dannen: We could then also supply them with constantly high quality where spare parts are concerned. Thank you for talking to us. 



Clamps and jaws

photo: Karin Kriebel

Schmiedag · KAIZEN optimises new forging line a step further. Approved.

Representatives from the French State Railways (SNCF) have visited and audited Schmiedag in Hagen on several occasions. Recently SNCF issued the company their approval to supply forged components. The entire process took more than twelve months, the reason being the customer’s stringent requirements with regard to non-destructive testing and the documentation of all the test steps undergone by the components. During this period the additional requirements of the SNCF were also incorporated into Schmiedag’s existing quality management system. The customer also satisfied itself directly on site in Hagen just how effectively the arrangements are implemented. Besides approval by the SNCF, incidentally,Schmiedag successfully completed its re-certification for German rail carrier Deutsche Bahn at the start of the year. It is also in the process of completing such an approval process for Trenitalia (successor company of the Italian state railways). Through these approvals and certifications, Schmiedag is systematically extending its qualifications as a specialist in railway technology products on the European market. The photo shows one of the products to which the diverse approvals relate: wheel-mounted brake disks. Andreas Studinski

photo: Karin Kriebel

Technical data

The new “jaw rack“

In glückauf 4/2011, Schmiedag in Hagen reported on the upgrading of its H16 forging line, involving a new method of heating, full automation and longer tool life. There have been further modifications in the meantime. KarlGünter Kruska (foreman in the closed-die forging shop) gives details: One outcome of upgrading our forging line has been that automation has led to the use of two KUKA robots. They handle the forgings, which are around 1,250 °C in temperature and up to 120 kg in weight. The initial programming was provided by Lasco and is based on reference components. The foreman and shop personnel adapt the programming for items that are to be forged by hammer for the first time. In this way, experience is gained that is then fed into the workflow. In line H16, forgings pass through the following stations: Robot #1 transfers the heated block of material from the induction furnace for it to undergo the pre-forming operation (up-

setting or hot working). The material is then placed precisely in the hammer die. After forging, robot #2 picks up the part and takes it to the deflashing press, where it undergoes trimming and/or piercing. Robot #2 then places the part and the flash into suitable boxes. The robot thus takes up a reformed part after each work step. So that a maximum of working precision is achieved despite the variety of products, we require many clamps, jaws, grippers and pincer arms for each robot. A “jaw rack” is situated in proximity to the hammer for these tools. It was developed as part of a KAIZEN project. Each tool now has its own assigned place and is quickly available for changeovers in production. The rack hence guarantees a high level of efficiency and reproduction accuracy.

KAIZEN The term “Kaizen” comes from the Japanese and means “change (KAI ) for the better (ZEN )“.

Width: 1,400 mm Length: 4,000 mm Height: 1,800 mm Coil interior: 500 x 800 mm

photo: Christian Dinter

Worthwhile. Wildauer Schmiedewerke has a new magnaflux (MF) crack detection system. The Wildau-based company is now able, as a result, to inspect connecting rods weighing as much as 1,000 kg. The installed coil is also capable of inspecting round components measuring up to 300 x 700 mm with minimum effort. The new MF system additionally offers greater reliability in the event of disruptions caused by power or compressed air outages. Designed by company Karl Deutsch, it ensures that the forgings remain safely in their fixture. With “old” MF systems it happens at least once a month that a component undergoing inspection falls into the testing-medium collecting tray and suffers considerable deformation in the process. These deformations greatly impair the off-flow of the testing medium and make cleaning more difficult. The new crack detection system not only replaces an older system (UNI 260 ) but also lightens the work load of a larger, still installed system (UNI 500 ). The bottom line is that the investment is proving worthwhile in several ways: it eliminates bottlenecks in the finishing shop, increases flexibility, and shortens the throughput times for forged components. The photo shows “fluxer” Karsten Krüger checking the field intensity at the new crack detection system. Harald Dröge and Frank Ledderbohm  

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Audit confirms: A sustainable energy policy increases energy efficiency ETE · An energy management system was introduced in 2010 – certified by Det Norske Veritas (DNV) in accordance with DIN EN 16001. The positive result of the audit was posted on the DNV website.

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nergietechnik Essen GmbH has been a company of the Georgsmarienhütte Group since 2003, but it can look back on a company tradition stretching over several decades. The company manufactures cap rings for generators in processes which are particularly energy-intensive. The rings manufactured from non-magnetic special steel are used to fix the copper windings which protrude at rotor ends against centrifugal forces. Energietechnik Essen also produces nitrogen-alloyed steels, which are used, for example, in ball screws for adjusting elevators in aeroplanes. Quality assurance is absolutely paramount in the case of these specialised and safety-relevant high-tech products and for this reason the company has been certified by DNV according to ISO 9001 since 1993. In the course of the years, certifications according to OHSAS 18001 and ISO 14001 have been added and summarised in an integrated management system. Since 2010 the company has also been certified according to DIN EN 16001 and has been improving the system continuously. But it is not always easy to introduce and implement measures. In particular, the structural fabric of the production buildings represents a major challenge because, for instance, of a lack of heat insulation in buildings constructed in the first half of the 20th century. Employees must be integrated Nevertheless, even a company with these difficulties can fulfil its claim to be a sustainable company – as described in the

Interview with Hermann Skotz Energietechnik Essen has had a certified quality management system since 1993. In 2006 the integrated management system (IMS ) was certified for the first time by certification company DNV (Det Norske Veritas) (Quality, Environmental and Safety at Work Management Systems are interlinked at IMS ). This IMS was supplemented in 2010 by the Energy Management System (EnMS) and the company had it audited by DNV according to DIN EN 16001 . In December 2011 the periodical audit of the Energy Management System was carried out. In this audit it became clear that ETE provides a good example of how small measures can have a great effect and energy consumption can be reduced. For this reason DNV interviewed EnMS Officer Hermann Skotz with the aim of presenting ETE as a DNV -certified company on its website. glückauf has printed the original of the article here. More information about Norske Veritas can be found at www.dnv.de.

mission statement of Energietechnik Essen. The company would like to “meet the challenges of a rapidly growing energy machinery market by developing further from an adaptable organisation to a sustainable one. This objective will be implemented by managers and employees together, at both strategic and operative levels.“ To come a step closer to being a sustainable company, energy management must be organised systematically. At Energietechnik Essen GmbH this is achieved by a committee composed of different company members, the so-called “Energy Circle”. In addition to Hermann Skotz, the Officer for Quality, Environmental and Energy Management, members include external consultants, company engineers and the company management. The great support provided by the management – expressed, for example, by their participation in the Energy Circle – makes it much easier to enforce the required energy saving measures. However, the energy goals which have been set can only be

achieved throughout the company if the whole workforce is convinced about them. “The employees should always be integrated into the resolution to save energy because, in addition to static measures, such as the insulation of heating pipes, they must also discover further potential for saving energy in their daily working schedules and implement appropriate measures”, says Hermann Skotz. For if, for example, the residual heat from heat treatment furnaces can be used for heating other production parts, instead of heating these separately, there is quite a lot of potential here for reducing costs. But in order for this procedure also to be used in practice, the workforce must be convinced of the positive aspects. Here it is helpful to involve them in conceiving the measures in order for them to be able to assess whether, in addition to the theoretical potential, such measures can actually be implemented in practice. Different media are used to inform the employees at Energietechnik Essen GmbH. Posters

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have been hung up throughout the company, for example, drawing attention to the potential for saving energy. Furthermore, extensive information can be found on the intranet, and notices are clearly displayed in show cases for employees who do not have access to personal computers. Young employees are specifically addressed by means of interactive information on monitors. Customers are also informed about the measures which have been introduced in the context of customer audits. Here the company’s experience has been that the energy-saving measures often meet with astonishment. Specific demands for an energy management system are not yet common practice amongst customers. Sustainable company policy The motives for the company to introduce an energy management system and have it certified by DNV were above all to depict the sustainable company policy as credible to the outside world and respond to the public discussion relating to the topic of “saving energy“. It is particularly important for the management to avoid waste because it is not only expensive but also damaging to the environment. Since then, different measures have been introduced with the aim of achieving a sustainable reduction in energy consumption. In an initial analysis, the cause of the greatest electricity consumption within the company was quickly identified – the electro-slag remelt facilities. There, however, a major investment is required in order to make any significant impact.

The Energy Circle therefore focused on other areas and began, for example, with the insulation of approx. one kilometre of heating pipes in the production buildings. This measure could be implemented relatively cheaply and, according to the company’s calculations, it will pay off within just a few years. The same applies with regard to installing photoelectric lighting controllers and time switches in buildings where there is natural daylight. Thus during the day, only some of the lighting is switched on and the remainder is switched on additionally at dusk. Other measures included optimisation of the treatment temperature of products or saving gas in burners. In addition to these small measures, complete production processes were examined and reorganised. Previously, for exam-

ple, hot steel ingots were subjected to controlled cooling before undergoing downstream processing at another company, where they would then be re-heated by a service provider. Today, special transporters are used to transport the ingots in hot condition and thus to save energy. Only time will tell what results these rather small measures can actually achieve. Members of the Energy Circle, however, are certain that “there is still considerable room for Improvement”. In comparison with other management systems the energy management system has the advantage that its effectiveness becomes visible very quickly. By contrast, an Environmental Management System according to ISO 14001 – for example – is based rather on legal certainty. Investments in keeping the air pure are

often too high and the results cannot be directly measured from a financial point of view, whereas an energy management system has a direct influence on the monthly costs. Parts of both standards are very similar, however, and companies which are certified according to ISO 14001 can therefore introduce an energy management system according to DIN EN 16001 or DIN EN ISO 50001 more easily and have it certified. Improvements can be made regularly by certifying and continuously checking the system. “Up to now, every DNV audit has led to measures which have a high added value for our company”, states Hermann Skotz. The auditor often detects process weaknesses which the company itself fails to identify. However, the Officer for Quality, Environmental and Energy Management

also views certain aspects of the audits more critically and sums up: “In addition to the core stock of measures with a high added value which must be implemented after an audit, there are always specifications which are less relevant for the company.“ A lot has changed in the field of energy management at Energietechnik Essen GmbH as a result of the certification. Success has become measureable through the introduction and certification of the energy management system and Hermann Skotz is convinced of the future success: “In future, a few things can also be achieved through the fact that the employees are becoming increasingly open to change, that they bring in their own ideas and that they simply feel that they also have a responsibility.”

Cooperation at the highest level BVV · Experts from eleven manufacturers in nine countries got together at the ERWA Spring Meeting in May for technical discussions.

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his time, Bochumer Verein Verkehrstechnik (BVV ) hosted the ERWA Spring Meeting, which takes place once a year. The Meet-

ing ranks as the consultation forum for the Technical and Development Committees of the “European Railway Wheels Association“.

photo: Andreas Dal Canton

The Association was founded in 2004 under the umbrella of the UNIFE (European Rail Industry). Its members are the eleven renowned European manufacturers of railway wheels and wheelsets from nine nations, namely Bonatrans, CAF (Construcciones y Auxiliar de Ferrocarriles, S.A.), Gutehoffnungshütte Radsatz, Lucchini Italy, Lucchini Sweden, Lucchini UK, Lucchini Poland, Valdunes SAS and Valdunes Belux, as well as Bochumer Verein Verkehrstechnik and Radsatzfabrik Ilsenburg. All these different companies with their experience embody the core expertise of this branch of industry – ranging from the corresponding research and development of suitable steels to the finished and certified product. The aim of the committee work is to support the international rail vehicle manufacturers in the development of the most efficient wheelset systems possible for their various vehicles. Besides information and discussions at the meeting, culture also featured on the agenda. Completely in keeping with the tradition between coal and steel, the programme included a visit to two extraordinary sightseeing venues in Essen: the UNESCO World Heritage site of “Zeche Zollverein“, and Villa Hügel. em

Impressive setting: Participants of the ERWA Spring Meeting on a visit to Zeche Zollverein in Essen.

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Moscow Metro wants greater energy efficiency RAFIL · Ilsenburg-based company to supply first broad-gauge wheelsets for new Moscow Metro cars. Manufacturing quality convinces rail vehicle builder and operator.

photo: em

Dimensional inspection on a driven Metro wheelset

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ho is not familiar with the opulent edifices of the Moscow Metro – at least from TV reports or photos? Its first line, connecting 13 stations between Sokolniki and Park Kultury, went into service as early as 1935 and was nevertheless 11.5 km in length. Today the Metro has grown to become a route network extending over 305 km and including 185 stations. Not all, of course, are able to exude the great splendour of small palaces in the style of Stalinist classicism, such as Komsomolskaja or Majakowskaja Station.

But it does boast other superlatives. At some locations, Moscow’s underground railway runs 84 m below the earth’s surface, making it the deepest metro system in the world. And passengers reach the subterranean platforms via gigantic escalators 126 m in length and comprising as many as 740 steps. Some nine million passengers daily are carried on the route network in different, mainly Russian-built vehicles: all in all 4,500 cars. Depending on their year of manufacture and technical standard, the vehicles travel at speeds of up to 100 km/h.

They were, and still are, built at the engineering works of “Metrowagonmasch“ in Mytischtschi, near the Russian capital (the only exception being 120 cars that were brought from occupied Berlin in 1945 as reparation payments and adapted to the Russian broad-gauge network). After the war, numerous indigenous vehicles were developed and produced in Mytischtschi. The most modern trains currently in service belong to the 81-760/761 series. They have been in production since 2012 and use less power than their predecessors. So much regarding

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the history and current state of the Moscow Metro. Further vehicles of the 81760/761 series are to be built in future. For their production, RAFIL was awarded a contract only last year to supply 128 driven wheelsets, including gear units from ZF Friedrichshafen. This contract came at an ideal point in time, incidentally, the Ilsenburg company having just completed a retrofit programme involving 3,000 wheelsets for Berlin’s rapid transit “S-Bahn” system. Although assembly tracks in the Russian gauge of 1,168 mm were needed for the contract, this proved to be the least of the problems, as such tracks were still available in Ilsenburg from the time of working together with Deutsche Waggonbau AG. Up to the early 1990s, RAFIL had produced huge numbers of wheelsets for passenger coaches and special-purpose refrigeration vans designed for Russia’s broad-gauge network. The first-piece inspection for the new driven wheelsets took place in Ilsenburg in April successfully, RAFIL’s manufacturing quality convincing the representatives of both “Metrowagonmasch“ (vehicle builder) and the Moscow Metro (train operator). RAFIL thereby qualified as an approved wheelset manufacturer for the Moscow Metro. What remains to be hoped is that this good impression can also help to win further contracts. As is generally known, Moscow has a major goal in mind: the 2018 football world championship. By then the intention is to invest 4 billion euros in the Metro system in order to expand the route network by 82.5 km, and, in particular, to procure new vehicles. em  

Prototype undergoing trials

design. RAFIL ’s proposal to the customer is therefore to fit the 5M2A trains with a new wheelset generation based on the tried and proven Ilsenburg lightweight wheel. The development of the prototype has taken account of the many lessons learned from the operation of metro systems in Berlin, Helsinki and also Moscow. The proposal put to the PRASA was a convincing one. According to Matthias Schwartze,

“Given the changed design loads, the customer also agreed to now apply European Standards to the design of the wheelsets, in variance from the previous AAR requirements.” What will then “move” people at the Cape in future will become evident after the three-month phase of testing undergone by the first wheelsets. At the present time the production work being undertaken in Ilsenburg comprises 12 non-driven and 24 driven wheelsets. One prototype of both will, because time is of the essence, be sent by air freight to Africa, where the testing will take place. If everything turns out to the customer’s satisfaction, the first 5M2A type vehicles will, probably, be retrofitted soon in the well-equipped workshops in Koedoespoort. RAFIL will then send individual components, lightweight wheels and wheelset axles by sea to South Africa for assembly locally. According to information from the relevant ministry, South Africa intends, within the next 20 years, to invest as much as 30 billion euros in the modernisation of the country’s rail infrastructure. The programme will include not only rail tracks, stations and halts, but also the procurement of new Electrical Multiple Units (EMU ) – and the retrofitting of many of the more than 4,000 rail vehicles in the Republic of South Africa. em

BED’s maintenance department, which had the task of coordinating all the external contractors technically and organisationally on this major job site. A total of 203 individual activities carried out by five teams had to be managed. No easy task, given that one “old hand” had left on reaching retirement age, and a field supervisor had suddenly fallen ill. It therefore became necessary to re-allocate the maintenance and repair activities concerned – resulting in additional work loads for the personnel. It had taken some five months beforehand to prepare the work and procure spare parts. What had to be repaired and serviced had already been identified in advance – by evaluating the repair work undertaken in 2011 as well as the findings submitted by the plant manufacturers’ service technicians. Added to this there

were malfunctions and plant and equipment faults that had come to light in the meantime. The total maintenance and repair programme was budgeted at around 500,000 euros, which also includes still outstanding spare parts that were not delivered on time and cannot therefore be installed until later. This concerns primarily the new pistons for the Lasco pre-forming press. It proved possible to keep within schedule. A time extension became necessary only in the ring rolling mill, this being due to, among other things, the unforeseeable state of wear of the rolling table guides. Inspection findings regarding individual groups of installations are already available, enabling BTBED to start planning, budgeting and scheduling the maintenance and repair work for 2013. Bernd Vogel

RAFIL · Original Ilsenburg Lightweight Wheels developed for the PRASA

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adsatzfabrik Ilsenburg (RAFIL ) is to supply the Passenger Rail Agency of South Africa (PRASA ) with Original Ilsenburg Lightweight Wheels. According to Andreas Bader, the key manager responsible for the region, “We established initial contacts as long ago as the 16th International Wheelset Congress in Cape Town in 2010.” Which goes to show that being present at trade fairs does pay off. Background: With the exception of thoroughly state-of-theart business trains fitted with air conditioning and other features, the vehicle fleet operated by the Republic of South Africa is outdated – and not really equipped to meet the requirements of the modern age. Nevertheless, much of the rolling stock can still be used in the future – provided it is suitably retrofitted and upgraded (e. g. with air-conditioning, communication and safety systems). But modernise which parts, and how? Design engineers from Ilsenburg under the direction of Matthias Schwartze made several visits to take a closer look at the rolling stock. They promptly

photo: Andreas Bader

Old and new: modern and traditional side by side.

submitted a proposal on how to retrofit the running gear for a large part of the short-distance trains. This also took account of PRASA ’s wish to save weight as a means of achieving higher energy efficiency. The short-distance trains still operate with tyred wheels as part of their driven and non-driven wheelsets, in accordance with the AAR (American Association of Railroad) Standard. They are, as a result, of heavyweight

Completely within budget BTBED · Easter repairs encompassed “axle and ring” production chain including rotary hearth furnace

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ithin the space of three weeks, Bahntechnik BrandErbisdorf (BTBED ) carried out a major overhaul of three facilities in parallel: its rotary hearth furnace, the Linsinger-built sawing line, and the SXP 25 axle forging machine. Three weeks had also been estimated for the entire “ring” production line, including heat treatment stage. Peripheral and downstream facilities that were inaccessible during ongoing production (due to continuous operation) were additionally

serviced and repaired. These included the charging machine for batch furnaces 11 to 25, and the quench tank. The main focus of this year’s repair and maintenance work was, without doubt, the rotary hearth furnace, which was in a very rundown state. Emergency repairs had only just made it possible to keep it operating until the start of the scheduled overhaul. “Supervisory responsibility” lay in the capable hands of BT-

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Idea costs time, but saves money BVV · Special “energy saving” drive generates a host of proposals - and a lucky winner.

photos: Daniel Weihmann

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Sven Hedwig (painter in the Machining Department) at work

hat prompted this A prize draw has meanwas a large-scale while been held at the first poster campaign by GMH employee meeting to reHolding on the topic ward these six suggestions. of “energy saving”. It Good luck fairy Kathleen gave Bochumer Verein Vowe (works councillor) Verkehrstechnik (BVV ) drew the lucky winner of the idea of launching a the main prize: Sven Hedspecial drive within the wig, a painter in the Mascope of its Employee Main prize winner Sven Hedwig chining Department. DanSuggestion Scheme. The iel Weihmann, Chairman of the Employee company used its special drive with a twoSuggestion Scheme, presented him with the fold aim in mind: firstly, to save energy and, main prize, an i Pad II. secondly, to stimulate its Employee SuggesThe suggestion entered by Sven Hedwig tion Scheme. was an energy-saving and more cost-effective And successfully, too. Between April and way of cleaning dummy components. Such November last year, 22 improvement suggesdummies are needed to be able to apply coats tions on the topic of “energy saving” were of paint to wheels that, because of their size entered. Of these 22 suggestions, six were and design, are unsuitable for painting inrated positively. They will, as a result, be adopted because it will be worthwhile for the dividually in the wheelset paint shop. To do this, they are mounted on so-called “dummy company to do so – which in turn also benaxles”. efits the entrants financially.

After painting, these dummies are totally smeared with paint, and would be cleaned in a work-intensive process in a dry ice blasting unit. This unit would be operated for several hours using a 65 kW compressor, resulting in an enormous power consumption in relation to the comparatively small components. The idea submitted by Sven Hedwig has led to a remedy. He has suggested 24-hour immersion of the dummy components in a medium that removes the paint not only in an environmentally friendly way but also cost-effectively. The outcome: the dummies can be cleaned without any power being needed at all. The dry ice blasting unit is now only used to strip paint quickly and efficiently from wheels, axles and complete wheelsets that are due for repair.

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Daniel Weihmann

 

When a job is difficult, Harz Guss Zorge is the one to contact HGZ · Thermal analysis as a means of process control and monitoring I n t e r view

Put in plain terms, then, the graphite is present in the component material either in leaf (lamellae), worm (vermicular) or spheroid (globule) form. How do these differences come about? Dhonau: The final shape of the graphite is determined by the imparted magnesium content and inoculation treatment. To produce GJV or GJS , the molten metal has to be both treated with magnesium and inoculated. Grey cast iron is not treated with magnesium, but just inoculated. And that’s how the differences come about. High-strength GJV materials are not at all easy to produce Why is that? Dhonau: It’s because their production poses very specific chal-

Which has drastically increased the scope of the project. Dhonau: Of course. Because the aim was to realise the existing GJS production process by means of the new system – without significantly altering the operating procedures or reducing productivity. Has that been difficult? Dhonau: Yes. Because the “tempo” in series production at HGZ has surprised even the experienced OCC specialists. We have as many as 28 treatments per hour, in other words an average time interval between treatments of somewhat over two minutes. This rate at which the processes take place at HGZ presented the technicians with a several major challenges.

OCC – most associate this abbreviation with a firm called Orange County Choppers from the TV series “American Chopper”. However, in the foundry industry these three letters stand for Mönchengladbachbased company Octagon Computer Concepts which, since mid-2010, has been working as a partner with Harz Guss Zorge (HGZ ) on a project to implement thermal analysis as a means of controlling and monitoring the processes for the production of vermicular and nodular cast iron. HGZ employee Björn Dhonau gives a few details in this regard.

glückauf: Mr. Dhonau, please throw a little light on such terms as vermicular, grey and nodular cast iron, and so on, for our readers. What do they mean exactly? Björn Dhonau: Standards classify grey solidified cast iron according to the shape of its graphite precipitations, namely lamellar (EN-GJL , grey iron), vermicular (EN-GJV ) and spheroidal (ENGJS , nodular cast iron).

is why the foundry management has decided to use the now installed analysis and control technology for nodular cast iron production as well.

photo : mh

Molten iron undergoing OCC-controlled magnesium treatment

lenges in regard to the process parameters. Which is why by no means everyone operating on the global markets has mastered this process. And Harz Guss Zorge has, hasn’t it? Dhonau: It has now. We saw it as an outstanding opportunity to raise our profile as an innovative, specialised supplier – a strategy we have already been pursuing for years. And successfully so. In fact, HGZ is a partner soughtafter by customers when it comes to resolving difficult materialrelated problems. Difficult in what way? Dhonau: Let’s take the requirements that have become more exacting in the past few years concerning diesel engines. They have forced our customers to replace traditional materials such as GJL with new ones. It is with this in mind that various customers approached HGZ in 2009,

requesting the supply of components made of high-strength GJV. To meet this demand, we conducted trials in the first half of 2010 involving different means of treatment for the production of GJV . Successfully? Dhonau: Yes – but they left a few things to be desired regarding process robustness and automation possibilities. We therefore got OCC onboard as a cooperation partner. The company has made a name for itself installing GJV production systems in the industry. Several successful market competitors as well as customers have been putting their faith in OCC production systems for years. Have your expectations been fulfilled? Dhonau: More than that, because we are able to use the process not only to produce GJV , but also to optimise GJS production. Which

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What is the situation at the moment? Dhonau: The system has been in use in series production since Easter of this year and will reach its full potential in the course of the year – once the usual teething difficulties and specific issues that crop up only in actual operation have been put right. Thank you for talking to us.

For the expert

The OCC system

is based on thermal analysis as a means of controlling and monitoring the treatment process. Thermal analysis is a technique whereby the temperature of solidifying molten metal is measured in a sample crucible and plotted over time. The cooling curves thus generated enable metallurgists to reach various conclusions regarding the state of the melt. Thermal analysis has been used for years in aluminium and iron foundries. The OCC system automatically determines significant values from the cooling curves and, using them as a basis, calculates the wire lengths for the magnesium and inoculation treatments, such that the treatment parameters are reliably adapted to the current metallurgical state of the base iron, and documented.

Dialogue on equal terms raises awareness WH · It is always a good idea to investigate new methods – also as far as communication is concerned: two colleagues communicate aspects of industrial safety in a new way – and receive very positive feedback from their colleagues.

Photo by courtesy of the GMH Group

Shortly before the start (from left to right): Martin Heistermann (Quality Management), Murat Gür (Finishing Department) and Hans-Peter Limberg (Safety Officer) doing a final check before giving a talk to colleagues on the subject of industrial safety.

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ndustrial safety is one of the most important guiding principles in the manufacturing of products and the prime objective of superiors and employees alike. This applies particularly in the foundry industry. Because in this industry employees have to deal with dangerous machinery and substances – molten material, metals, and dust, just to mention a few examples – on a daily basis. In such a context “safety first!” takes on a special significance. Two safety officers from Walter Hundhausen have taken

this issue particularly seriously. It all started with their two-stage training to qualify as Safety Officers I and II, conducted by the “Berufsgenossenschaft Holz und Metall” (employers’ liability insurance associations for the wood and metal industries). After their training sessions they did not want simply to return to their workplaces and continue as before. Murat Gür (Finishing Department) and Martin Heistermann (QM Department) had the idea of sharing their knowledge with

their colleagues. This is why they spent many hours of their free time preparing an “industrial safety presentation” together. This presentation contained elements from the safety training sessions which they attended as well as industrial safety topics which are particularly important at Walter Hundhausen. The result was an impressive and very comprehensible presentation. It has already been seen and very well received by a substantial number of colleagues. They particularly liked the fact

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that it was so easy to understand and was also of direct practical application. Acceptance of the content conveyed has also increased significantly – according to comments made by colleagues who have already attended the events. The presentation focused less on the consequences that ensue for the employer in connection with accidents at work. Instead it concentrated on the consequences for the employees concerned. Murat Gür and Martin Heistermann made the situation quite clear: any serious accident at work – for example, loss of an eye, an occupational disease, impairment to hearing – means a significant reduction in quality of life. Such arguments made it possible for them to increase employees’ awareness of how necessary it is to take steps to avoid such dangers. Other important issues were cleanliness and orderliness at the workplace (according to the “5S” method), how to deal with forklift trucks and electric lifting trucks (so-called industrial trucks) as well as the wearing of personal protective equipment, and what it should include. Many interesting discussions evolved in connection with the subject of “industrial safety” and the risks which are to be found lurking at work. Further training was also provided about how to behave in case accidents do occur. The presentation, however, also made it clear to the employees that safety does not stop when you leave the works premises. It is to be taken equally seriously in leisure time and in a private context. The two “trainers” answered participants’ questions extremely knowledgably and with great empathy. Maik Lücke, Head of the Finishing Department also found the training sessions to be very positive. This is why he supported the initiative taken by the two employees. Finally the experts and employees were all in agreement: it was a great idea this time to deal with the subject of safety on a “colleague to colleague” basis – and not always “from the top downwards”. nh

Successful start: Now DHG also casts steel DHG · New field of business was prepared well in advance.

A

fter two years of preparation, Dieckerhoff Guss has entered into the steel casting business. Development contracts for renowned turbocharger manufacturers have also been secured in parallel over the past few months. Prototype fabrication is currently in progress. The first components have already undergone acceptance inspection and are being tested by the end user. Once they have passed the trial phase, their volume production could begin. But why cast steel? One thing is for certain: the cost of fuel will continue to rise. Automobile makers are responding to this with the development of more efficient engines meaning that exhaust temperatures will also, inevitably, rise. In case of petrol engines,

A core made with a special binder system specifically for the steel castings

they get as high as 1,050 °C. The only class of materials able to withstand such thermal loads are heat-resistant austenitic steels, namely 1.48xx. And how does the casting take place? The cast steel components are produced on Dieckerhoff’s HWS moulding line. A new binder system optimally suited to cast steel has been adopted for the coremaking process. The molten steel comes from a separate crucible furnace that has a special refractory lining.

League of quality all of its own SGG · Producing for a global player: Offshore castings to NORSOK standard.

Photo by courtesy of the GMH Group

Assembly of the chain guide

S

BM Offshore (Netherlands) operates internationally in the offshore oil and gas industry. Stahlguss Gröditz (SGG ) recently had the opportunity to produce castings for SBM’s representative office based in Monaco (the enquiry having been received from a Spanish component supplier). It was a challenging task, as the castings were to be produced in a material listed in offshore standard NORSOK M-122 , namely NORSOK M-122 grade 420 /ASTM A148 grade 90-60 (modified). Technologically, its production regime calls for high accuracy in its melting, heat treatment and testing. The castings are needed to anchor a dynamically positioned oil drilling ship. And because the required delivery period was so

short, the Spanish customer split the contract between three foundries: ebroacero (Zaragoza), GUIVISA (Basauri), and Stahlguss Gröditz. By doing so, the Spanish company wanted to make sure that the requisite castings are available on time for assembly. The joint technical kick-off meeting took place at SBM’s office in Monaco as early as mid-October. Also present were the contracted foundries, the representatives of manufacturer asturfeito (Carreno), and engineers from SBM . The discussed topics included the type of material, the mechanical-technological properties expected during the material testing, and the machined condition of the individual components within the required deadlines. The foundries were able to clarify outstanding questions regarding design and type of material, so as to prepare optimally for production. After the necessary pattern equipment had been fabricated, Stahlguss Gröditz began in October 2011 with the production of the castings. The aim was to deliver twelve batches of three different castings by February 2012. In the course of the castings’ production, a series of material quality tests were conducted, which were

Photos by courtesy of the GMH Group

Company employees Shakir Öksuzoglu (left) and Sevret Karamugara pouring molten steel, which comes from a separate crucible furnace.

Interim assessment: Dieckerhoff has made a successful entry into the steel casting business. Market demand is set to increase, and the response among customers is extremely good. Despite all the euphoria, though, there must be caution not to expand all too rapidly in this segment. Dirk Oebel  

monitored and certified by inspection agency ABS (American Bureau of Shipping). The outcome: the set requirements were reliably met. The castings also had to demonstrate in further tests that they satisfied current international standards. Required were an accompanying welding procedure qualification test, CTOD tests, and notch impact and tensile testing for wall thickness ratios ranging from 50 to 600 mm. This resulted in valuable information concerning the general material behaviour in these fields for future applications and approaches. This accumulation of knowledge was not the only positive experience to come out of this project, however. The parts were also supplied successfully, on schedule, to the customer, who expressed his appreciation to the entire SGG team with photos showing the units after their final completion in Spain.

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ul

source: SGG

Outstanding questions regarding the design and type of material. One example of this is the casting proposal for a selected part depicted as a 3D representation, using the magmasoft casting simulation programme.

Crane manufacturer custombuilds system for automatic coil annealing facility

Witke: We have, for example, installed a fence to screen off the envelope for automatic operation from unauthorised personnel access. The crane control system is, additionally, linked via a data interface to the customer’s data system and to the annealing shop.

KBK · The first construction phase saw the delivery of the crane system for the new batch annealing shop. The second phase will see the installation of an automatic coil store and cold mill.

How did the transportation and installation turn out? Witke: It wasn’t a very easy job. The annealing pit in the new building lies four metres below floor level, making it necessary

I n t e r view In May 2011, Bilstein Service GmbH awarded a contract to Kranbau Köthen to supply a crane system for its new batch annealing shop in HagenHohenlimburg. In the new shop the crane will handle (i. e. charge and dispose of) coils in automatic mode. Heiner Witke (project manager) gave details in this regard in an interview with glückauf: glückauf: How should we picture the crane, Mr. Witke? Heiner Witke: The crane features two hoist units mounted on a crab frame. They have a lifting capacity of 50 tonnes and 28 tonnes respectively, operating over a span of around 32.8 metres. The classification of the drive system is group 5m and thus of maximum possible design. And to optimise availability, the hoist units are fitted with planetary gears. What advantages does that offer? Witke: Even if one drive unit fails, production can continue, because the remaining drive unit is capable of lifting the entire load, albeit at only half the lifting speed. Were there any special safety requirements in this regard?

And up it goes …

photos: Heiner Witke Photo by courtesy of the GMH Group

Top: Ready for transportation. Left: Distance measurement.

Heiner Witke

Witke: Certainly. Within the operating envelope of the crane there are pressurised hydrogen lines used for the annealing facility. We therefore have the same safety systems in place as for transporting molten materials. And because of the shop’s environmental conditions, the ambient temperature while the crane is operating is around 60 °Celsius. The entire crane control system is therefore installed within the insulated and air-conditioned crane bridge. There is also a dust extraction system in proxim-

ity to the crane rails and, of course, fire extinguishing appliances for the switchgear. Why is a dust extraction system necessary? Witke: So that any material abraded from the crane wheels and rails can be removed immediately and not affect the annealing process. The crane, as mentioned, will operate in automatic mode. What will this mean in terms of on-the-job safety?

… and fits – and the first bridge element …

to manoeuvre the crane components around within the shop. This was the only way we could realise the lifting and assembly work from the outside via the roof opening using a mobile crane. Its installation concludes the first construction phase. What is the next step? Witke: In the second construction phase, an automatic coil store and cold mill are to be installed. The automatic control system of the present annealing shop crane has already been prepared for the second construction phase. And we are also looking to supply the crane equipment for the second phase. Thank you for talking to us.

… is in place on the rails.

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Rainer Becher and his radio messages

beyondtheplant

GMHütte · Many more of these are likely to be heard in future, especially by amateur radio enthusiasts tuned in to the relevant frequency: “CQ CQ, here is DL0GMH, the club station of Georgsmarienhütte GmbH.” I n t e r view Many former as well as current employees of GMH ütte share a hobby: amateur radio. And they are in good company with this passion. Worldwide the number of amateur radio enthusiasts is estimated to be around two million. In an interview with glückauf, Rainer Becher (DO1BR ), chargehand in the roll and fittings shop in the rolling mill, explains what is so fascinating about radio transmission: glückauf: Mr. Becher, what exactly do you mean when you talk about amateur radio? Rainer Becher: Amateur radio is a hobby for technical enthusiasts who like to communicate with other people via radio transmission.

How do you find your conversation partner “somewhere out there in the world”? Becher: In Germany alone there are about 82,000 licensed radio amateurs who are active on all bands, including well-known personalities such as the politician Friedrich Merz or the astronaut Thomas Reiter. And internationally there are a number of active VIPs such as the widow of Elvis Presley and even the King of Spain. Can anyone transmit via radio? Becher: You have to take an examination at the German Federal Network Agency (Bundesnetzagentur) which covers three areas:

operating technology, legal issues and electrical engineering. In order to pass, you have to do a bit of swotting, but for technology enthusiasts it should be no problem. Once you have passed the examination you can register your own call sign, and then you can enter the world of amateur radio. What about hardware? Becher: You have the right to build your own radio transmitter. We are allowed to do that, unlike CB radio enthusiasts. Or you just buy your radio equipment and set up your own antenna. Setting up an antenna cannot be so easy. How does that work?

Becher: There are local groups of the “Deutscher Amateur Radio Club e. V.” all over Germany. They are always happy to help setting up an antenna or purchasing the equipment. One of these groups is also located in Georgsmarienhütte. Is there any special news from there? Becher: We, the radio amateurs of local group I 37 of “Deutscher Amateur Radio Club e. V.” have applied for club sign DLOGMH for our GMH ütte. We would like to keep in contact with our colleagues in other companies of the GMH Group. How can interested persons participate in these activities? Becher: Anyone who would like to take part is welcome to contact me. I am active in the D-Star field (Ref 010) or you can contact me via emai:l Rainer.Becher@ gmh.de. Thank you for talking to us

What kind of technology and techniques do radio amateurs use? Becher: We radio amateurs have a wide choice of possibilities available. First of all there is simple voice transmission and telegraphy, in other words Morse code. Furthermore there are the teleprinter, today usually done by PC, the PSK31 procedure and also package radio, the predecessor of the internet. And what kind of things do you exchange information about? Becher: Most of us talk about our hobby, amateur radio. There are, however, lots of interest groups as well as individual radio amateurs who always meet at certain times and on the same frequencies. In addition to amateur radio, they also talk about other subjects. For example there are the naval radio operators, the railway group and many other forums.

photo: Thomas Becher

A hi-tech hobby: Rainer Becher with his radio equipment and the club signal of the GMHütte.

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The glü ck  

Rather rice than pasta – basta!

r chef recomm en aste ds fm : u a

Creative cooking the simple way: Just vary the recipes of a master chef. Ingredients

Recently I tried out an adapted version of a recipe created by British star chef Jamie Oliver: his wife Jools’ favourite pasta dish. My wife loves this pasta dish as well. Not only because it tastes fantastic but also because it is so easy to make. But she liked my Risotto variation even more because rice absorbs the flavours better. So when using rice you should reduce the spice quantities as otherwise the subtle and elegant flavour would be overpowered. The quality of the cinnamon is crucial. Take a cinnamon powder which smells strongly of cinnamon. As a matter of fact you can also enhance the taste if you ensure all other ingredients you select are of very high quality too. Particularly as far as the tuna fish is concerned. And, incidentally, buying tuna from sustainable fisheries will also be good for your conscience.

 

photo: Thomas Hesselmann

Preparation: • Dice the onion. • Pick the basil leaves off the stalk and chop the stalks into small pieces. • Heat the stock in a pot. • Grate the parmesan. • Drain the olive oil from the tuna into a second pot. Add olive oil if required to ensure the bottom of the pot is well covered. • Lightly fry the onions together with the basil stalks and the chili flakes in this oil. Add a little salt.

: • Add a piece of • 250 g risotto rice tuna with each • 1 small onion or shallot ladle of stock. • 5 stalks of basil IMPORTANT : A • 1 heaped teaspoon cinnamon powder good risotto needs • chili flakes to be stirred. Oth• olive oil erwise the starch • 0.1 l white wine will sink to the • 200 g tuna in olive oil • 400 g pealed tomatoes (tin) bottom and the • approx. 0.75 l stock risotto will burn. • 50 g parmesan The heat should be • butter as constant as pos• salt sible, which is why the tuna should be added piece by piece. • When all the tuna has been added to the risotto, add the drained chopped tomatoes. • At the end of the cooking time (after approx. 20 to 25 minutes) check whether the rice is properly cooked. It should be firm on the outside but soft on the inside. • Now remove the pot from the oven and gradually stir in a sizeable piece of butter (directly out of the fridge) and about 2 handfuls of grated parmesan (to taste). Arrange basil leaves and sprinkle parmesan over the dish before serving.

• Add the rice and the cinnamon powder and roast it briefly in the oil. There should be enough oil in the pot for the rice to absorb some of it. • When the rice starts to stick on the bottom and there is no more oil left, add the white wine. Reduce the heat and stir constantly until it has boiled down. • As soon as the liquid has been completely absorbed by the rice, add the stock gradually with a ladle and allow to boil again.

from all correct entries submitted. The winner will receive a polo shirt from the GMH Fan Shop. (No legal recourse permitted.) And where is your photo? Would you also like to submit a picture puzzle? Just take a photo featuring glückauf in the foreground. In the background there should be enough specific details to be able to recognise in which place or in which town the photo was taken. Mail your photo to [email protected].

Did you know? photo: privat

Take a look here! In which city and in front of which building is Vera Loose (GMH ütte) reading glückauf 1/2012? Tip: In order to enter the city of her birth a popular singer does not always require a bright red rubber dinghy. And in the building, noble prizes are award in the interest of peace. Send your reply to [email protected] or (by postcard) to Matthias Krych, RRO GmbH, Rheinstraße 90, 49090 Osnabrück. Closing date for entries is 30th August 2012. If more than one correct entry is received, the winner will be drawn

In our last picture puzzle, Petra Meier (ESB ) was standing in front of the station in Lüttich (Liège-Guillemins). The winner, Philippe Scheepers (Engineering Steel Belgium) was drawn from all correct entries submitted (thank you for taking part!) Congratulations! The winner will be informed by the glückauf editorial team.

photo: Frank Swierzinski

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Bon appetit! and best wishes from your glückauf Master Chef

Masthead Publisher: Ge­orgs­ma­ri­en­hüt­te Hol­ding GmbH Neue Hüt­ten­stra­ße 1 49124 Ge­orgs­ma­ri­en­hüt­te www.gmh-hol­ding.de/uk/ Responsible in accordance with press law: Iris-Kath­rin Wil­ckens Translations: Carol Hogg, Michael Snowley Design: elemente designagentur, Münster