Customer Report

MAN Nuremberg, Germany

6-cylinder crankcase manufacturing system.

Customer Report

MAN Nuremberg, Germany

The D20 project. The new heart of the TGA.

Nuremberg, Summer 2000

After four years of development, MAN engineers have completed the prototype of a new generation of 6-cylinder diesel engines. The innovative project is called D20.

6-Cylinder Crankcase Production Line

Phase 1: Specifications
Increasing demands on performance and fuel consumption and stricter emission controls require manufacturers of commercial vehicles to draw on innovative technologies. The R&D division at MAN broke new ground with the development of the latest generation of TGA engines. Expectations of the D20 project are high: more power and longer intervals between maintenance, at the same time reduction of weight, fuel consumption, pollutant and noise emissions. For the first time a vermicular graphite casting (GJV 450) was used as material for the crankcase. In addition to product and process development the project required a state-of-the-art production system.

Customer Report

MAN Nuremberg, Germany

Innovation through co-operation: engineering partnership provides additional time and cost advantages.

Nrtingen, October 2000

HELLER received the assignment to develop a detailed process layout for the D20 crankcase. Close cooperation had a positive influence on the development process.

6-Cylinder Crankcase Production Line

Phase 2: Engineering
It is necessary to ever excel in product and process technology to remain the innovative leader in a field. To keep the innovative edge, MAN and HELLER project teams started to work together early in the prototype phase. HELLER design engineers contributed extensive product and process know-how and the MAN team added in-depth knowledge of the product. Because of the close collaboration and simultaneous engineering the time until start of serial production was reduced by several months and a number of innovative ideas could be incorporated in the development process. A system partnership was forged that opened up innovation potential and assured MAN a competitive lead.

Customer Report

MAN Nuremberg, Germany

Process technology made to measure: system partnership with HELLER unlocks innovation potential.

HELLER system solutions ensure a maximum level of dependability and planning reliability. Experienced project engineers will answer any of your questions throughout all phases of a new project, from the preparation of the performance specification to the development of an optimum process chain, including system layout, successful commissioning of the system and achieving production targets.

computer-based modeling of the complete process from raw to finished part. This has the advantage that modifications can be quickly and easily integrated into the ongoing development process. As a result, the development period to the actual start of production can be significantly shortened an important factor when time is money.

HELLER makes sure customers are kept up-to-date However, HELLERs co-operation is not restricted to the layout of the production technology. HELLER also supports the customer in questions of productionfriendly workpiece design, material flow, design of clamping fixtures or material handling between the operations. Today, simultaneous engineering involves with the latest trends in production technology so they can concentrate on their production. Partnership with HELLER guarantees customers innovation ability for a lasting competitive edge on the world market.

Customer Report

MAN Nuremberg, Germany

Nrtingen, January 2001

On the computer 20 different layout versions are modeled, based on available space and planned production.

A short way from model to reality: computer-aided layout design speeds up decision-making process.
17 16 15 14 13 12 11 10 9

6-Cylinder Crankcase Production Line

Phase 3: Layout planning

Integrating a system into an existing structure is subject to different requirements than building a new facility. The MAN plant in Nuremberg had several areas within the facility available for the production of the D20 crankcase. In a short time, HELLER's layout experts were able to submit alternative layouts to MAN by using efficient CAD systems. Special software tools determined the required machine capacity based on planned production volume. In this process, various combinations and automation options of special and serial machines are considered as well as alternative manufacturing concepts using various machine types. The ideal solution for MAN was a combination of 18 machining centers of the model range MCH 400 and 4 FST (Flexible System Transfer Lines) and single machines from other suppliers.

Customer Report

MAN Nuremberg, Germany

Nuremberg, September 2002

Modular building blocks for the D20 project are beginning to take shape in HELLERs final assembly shop. All system components of the manufacturing line successfully pass the required acceptance tests a prerequisite to meet the high expectations.

6-Cylinder Crankcase Production Line

Phase 4: Machine configuration

Detailed planning of each process step during the development phase resulted in time savings that benefited machine configurations and process trial runs. In case of the D20 crankcase, installation of three machining centers with three clamping positions was sufficient to test run the NC programs and to verify the required process capability. The remaining fifteen MCH 400 machining centers were shipped to MAN after geometrical acceptance. Because of this positive experience, MAN released the transfer systems for shipment after they had passed the function tests and trial machining. The extensive machining competence of the project engineers contributed to saving time on the project. At the Nuertingen plant, HELLER is able to machine prototypes required by MAN for trial tests before commissioning of the manufacturing system. For this purpose, the machining content of the special-purpose machines (FST) was transferred to a machining center. Fine adjustment for maximum process capability, a very time consuming process, was completed at the MAN facility.

Customer Report

MAN Nuremberg, Germany

Nuremberg, January 2003

HELLER installs the first machines in the former turbine building. Five months later pilot production started. One hundred and fifty units will be manufactured by the end of the year.

6-Cylinder Crankcase Production Line

Phase 5: Commissioning
The hybrid production system applied to the MAN project assures efficient installation of each machine and fast commissioning of the complete system. It is based on HELLER's highly modular system components, characterized by standard basic machines and flexible assemblies. This is the reason that HELLER manufacturing systems can easily be extended without major investments. If an increase in production volume creates a bottleneck in a production area, HELLER can easily solve the problem with alternatives from its modular range. In addition to twin-spindle machines and turret head solutions, dynamic packages are available for enhancing the performance of existing machines.

Customer Report

MAN Nuremberg, Germany

Two steps to full performance: integrated process measuring guarantees highest quality.

Nuremberg, April 2004

The new MAN manufacturing system goes into production. It is planned to increase production from 14,000 cases in 2004 to 55,000 units in 2007.

6-Cylinder Crankcase Production Line

Phase 6: Start of production

It was planned to ramp up production at MAN in two steps. In the first step, the system had been laid out for a production of 30,000 units. In the second step, production was gradually raised to the required 55,000 units. To achieve this goal, only the capacity of the machining centers for the intermediate operations had to be increased. Due to their high flexibility, the transfer systems are scalable according to requirement. To ensure maximum reliability of the system in highvolume production, finish-machining is performed using in-process gauging. Integration of the measuring technology into the final step of the process chain allows to compensate for any wear effects that may occur during pre-machining and to ensure consistent part quality in batch manufacturing.

Customer Report

MAN Nuremberg, Germany

Nuremberg, June 2005

The D20 project moves full speed ahead, all sales forecasts have been exceeded. MAN decides to implement step 2 earlier than planned.

The product
The outcome of the partnership between HELLER and MAN was remarkable. The new D20 engine generation surpassed all expectations and the projected sales volume was already exceeded in the first year. This comes as no surprise considering the improvements made on the engine: a 25 % reduction in engine components and a weight reduction of 100 kg are a quantum leap in heavy engine design. Significantly reduced pollutant emissions ensure that all existing and future exhaust emission standards are met. To ensure this, the engine is equipped with common-rail technology, exhaust gas recirculation and a special maintenance-free filter. As a result, maintenance intervals were extended to 120,000 km and fuel consumption was cut by more than 5 percent.

6-Cylinder Crankcase Production Line

HELLER a reliable partner for best results.

The manufacturing system

4 Flexible System-Transferlines (FST) with 4 6 single and double machining stations each 18 machining centers MCH 400 with direct loading 1 stand-alone FST Washers, Alfing cracking system Lift-and-carry-system for automation of FST GSA overhead gantry loaders for automation of the MCH 400 machining centers

The process chain

Step 1 (1st and 2nd FST): pre-machining of cylinder head and oil pan face, pre-machining of cylinder bore, deep hole drilling and pre-machining of crankshaft bore Step 2 (MCH): milling (using angular milling head), deep hole drilling, multispindle machining Step 3: intermediate washer Step 4: cracking of crankshaft bearings, machining of oil holes in 3rd FST with integrated head changer and TBT gun drilling unit. Step 5 (4th FST): finish machining of crankshaft bore and thrust bearing, machining of front faces, machining of cylinder bore (2 spindles), milling of cylinder head joint faces Step 6: deburring/assembly Step 7: washing Step 8: final inspection

Customer Report

MAN Nuremberg, Germany

6-Cylinder Crankcase Production Line

HELLER system solutions: a long line of success.

Development and implementation of the manufacturing line for the machining of the D20 crankcase was only one aspect of the successful system partnership between Gebr. HELLER Maschinenfabrik GmbH and MAN Nutzfahrzeuge AG in Nuremberg. HELLER also took on overall responsibility for the planning and commissioning of manufacturing lines for further key components of the 6-cylinder engine generation. MAN was more than satisfied with the outcome of the partnership with HELLER. On 12 May 2005, CEO Berndt Heller and HELLERs director of sales and engineering, Manfred Maier, received the prestigious Trucknology Supplier 2004 award in Munich. The Meanwhile, the complete machining of the cylinder head is performed on HELLER machines. The manufacturing line comprises ten machining centers model MCP-H 400, four HCS 400 head changers and a flexible transfer system. The latest generation of HELLERs internal milling machines is employed for prize is subject to a strict selection procedure and is awarded to the ten best of the 1000 MAN suppliers. The success of the D20 project once more underlines HELLERs outstanding position as supplier for the truck powertrain production. crankshaft machining. The machines of the RFK 400 (300) range provide excellent quality in the machining of mains and pins.

The Power of Progress

www.heller-machinetools.com

We are here for you.

Investments in manufacturing need results that are guaranteed. HELLER as your partner offers these guarantees with a range of innovative, product oriented machines and machining centers, with project and process competence, and with fast responding, qualified service teams. More detailed information on products and services is available at the following locations or on the internet.

Deutschland Gebr. HELLER Maschinenfabrik GmbH Neuffener Strasse 54 72622 Nrtingen Postfach 14 28 72604 Nrtingen Tel. +49 7022 77-0 Fax +49 7022 77-610 E-Mail: sales@hnt.heller-machines.com HELLER Werkzeugmaschinen Hattingen GmbH Httenstrasse 45 45527 Hattingen Tel. +49 2324 9245-0 Fax +49 2324 9245-99 E-Mail: sales@hdn.heller-machines.com HELLER Werkzeugmaschinen GmbH Chemnitz Sandstrasse 116 09114 Chemnitz Tel. +49 371 3300-790 Fax +49 371 3300-791 E-Mail: sales@hdo.heller-machines.com HELLER Werkzeugmaschinen GmbH Neufrach Am Riedweg 16 88682 Salem-Neufrach Tel. +49 7553 82728-0 Fax +49 7553 82728-61 E-Mail: service@hds.heller-machines.com

France HELLER Machines Outils 5, rue Saarinen Silic 128 94523 Rungis Cedex Tl. +33 1.46.87.34.52 Fax +33 1.45.60.54.84 E-Mail: ventes@hfr.heller-machines.com Italia HELLER Italia Macchine Utensili S.r.l. Via Leonardo Da Vinci, 5 37029 San Pietro in Cariano (Verona) Tel. +39 45 6838-231 Fax +39 45 6838-234 E-Mail: vendite@hit.heller-machines.com UK HELLER Machine Tools Ltd. Acanthus Road Ravensbank Business Park Redditch, Worcs. B98 9EX Tel. +44 121 275-3300 Fax +44 121 275-3380 E-Mail: sales@huk.heller-machines.com USA HELLER Machine Tools L.P. 1225 Equity Drive Troy, Michigan 48084 Tel. +1 248 288-5000 Fax +1 248 288-9560 E-Mail: sales@hus.heller-machines.com

Mexico HELLER Machine Tools de Mexico S. de R.L. de C.V. Cortazar No. 102 Col. Hidalgo C.P 37329 Leon, Gto. . Tel. +1 248 288-5000 Fax +1 248 288-9560 E-Mail: sales@hus.heller-machines.com Brasil HELLER Mquinas Operatrizes Indstria e Comrcio Ltda. Rua Joaquim Machado, 250 Bairro Aparecidinha Caixa Postal 126 18087-280 Sorocaba So Paulo Tel. +55 15 3235-1360 Fax +55 15 3235-1304 E-Mail: vendas@heller-maquinas.com.br China HELLER Machinery & Trading (Shanghai) Co., Ltd. Rm. 4402-4403, Shanghai Maxdo Centre No. 8 Xing Yi Road, HongQiao Development Zone Shanghai 200336 Tel. +86 21 52080485 Fax +86 21 52080495 E-Mail: sales@heller-machinetools.com.cn

Subject to alteration. MAN Nuremberg/GB-08/05