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OUR VISION
Dear Reader,
We are the ZKW Group – your specialist for innovative premium lighting
systems and electronics. As a system supplier, we are one of the world’s
leading strategic partners in the automotive industry. We are a reliable,
independent, and owner-operated Austrian company with over 9,000
employees in Europe, America, and Asia, and we are continuing to ex-
pand even further. We are improving our efficiency with flat hierarchies
and short decision-making pathways.
We develop and produce premium lighting systems and electronic
modules for the automotive industry. Our product portfolio ranges from
interior and license plate lamps to highly complex, AFS-capable full LED
headlamps with integrated laser high beams; we also develop and manu-
facture circuit boards and electronic modules for LED headlamps, thus
electronic systems by ZKW for more individuality, safety, and environmental compatibility. They
receive attractive products with more personality and expression.
for all mobility concepts As a successful player in all of our locations, we offer our employ-
ees the opportunity to be part of a dynamic success story with good
01 03
FACTS AND FIGURES HEADLAMP PRODUCTION
PAGES PAGES
05–10 23–32
07 EMPLOYEES
26 STEP BY STEP
Our ZKW family continues to grow
Research, develop, and manufacture:
From idea to finished product
08 PRODUCT RANGE
From electronic components
to highly complex headlamps
04
10 OUR CUSTOMERS
42 MILESTONES
16 IN DETAIL
Overview of ZKW history
8 locations working in concert
THE WORLD OF ZKW 2018 THE WORLD OF ZKW 2018
06 07
IN MILLION EUR
1400
AT
IN
WR. NEUSTADT
NEW DELHI
1300
224 250
CZ
AT
1200 VRATIMOV
WIESELBURG
1,625 2,862
1100
EMPLOYEES
MX
SILAO
2017*
1000
409 TOTAL
8,914
900 CN HEADQUARTERS
AT
DALIAN
WIESELBURG
864 245
800 US
TROY
700
SK 13
KRUŠOVCE
2,421 * Status Q4 2017
600
AT
IN
WR. NEUSTADT
500 NEW DELHI
224 330
CZ
400 AT
VRATIMOV
WIESELBURG
1,513 2,895
300
MX EMPLOYEES
2,517
* Forecast Q4 2018
THE WORLD OF ZKW 2018 THE WORLD OF ZKW 2018
08 09
PRODUCT RANGE
Headlamps, fog lamps, daytime running lights. All available in laser, LED,
xenon, and halogen – we put customer requirements in the right light.
AUXILIARY LAMPS
CAR HEADLAMPS
ELECTRONIC COMPONENTS
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10 11
OUR CUSTOMERS
Whether they are premium or volume manufacturers, or whether they make cars,
trucks or motorcycles: Our customers demand innovative lighting systems.
LOCATIONS
PORSCHE ŠKODA MERCEDES-BENZ OPEL
ZKW WORLDWIDE
From Austria, through Europe, to the world.
ZKW – We export traffic safety worldwide.
Troy, US Vratimov, CZ
ZKW Lighting Systems USA, Inc. KES – kabelové a elektrické
systémy, spol. s.r.o.
Dalian, CN
ZKW Lighting Systems
(Dalian) Co., Ltd.
Wieselburg, AT
ZKW Holding GmbH
New Delhi, IN
Neolite ZKW Lightings Pvt. Ltd.
Krušovce, SK
ZKW Slovakia s.r.o.
Silao, MX
ZKW México, S.A. de C.V.
Wiener Neustadt, AT
ZKW Elektronik GmbH
THE WORLD OF ZKW 2018 THE WORLD OF ZKW 2018
14 15
• Administration • G roup
• 200 m² management
Chief Executive Officer • 7 employees* ZKW HOLDING ZKW GROUP • Administration
CEO GMBH GMBH • Research &
Oliver Schubert development
Rottenhauser Straße 8 Rottenhauser Straße 8
3250 Wieselburg 3250 Wieselburg • 800 m²
Austria Austria • 303 employees*
* Forecast Q4 2018
THE WORLD OF ZKW 2018 THE WORLD OF ZKW 2018
16 17
ZKW LOCATIONS
ZKW is represented in key growth markets,
and is continuously working to expand its international influence.
• Headlamps • Headlamps
• Research & • Auxiliary lamps
development • Development
• 151,700 m² • 101,300 m²
• 2,895 employees* • 2,517 employees*
* Forecast Q4 2018
THE WORLD OF ZKW 2018 THE WORLD OF ZKW 2018
18 19
• Headlamps • Headlamps
• Auxiliary lamps • Auxiliary lamps
• Development • Development
• 52,500 m² • 116,800 m²
• 1,528 employees* • 654 employees*
* Forecast Q4 2018
THE WORLD OF ZKW 2018 THE WORLD OF ZKW 2018
20 21
ZKW LIGHTING
SYSTEMS USA, INC.
• Headlamps
• Auxiliary lamps
• Development
• 20,300 m²
• 224 employees*
FROM IDEA TO
NEOLITE ZKW
LIGHTINGS PVT. LTD.
FINISHED PRODUCT –
New Delhi (IN)
26 %
THE HARMONY OF DESIGN
36, Sector-4B, HSIDC, Industrial
Area, Bahadurgarh – 124 057
District Jhajjar (Haryana)
AND TECHNOLOGY
India
* Forecast Q4 2018
THE WORLD OF ZKW 2018 THE WORLD OF ZKW 2018
24 25
2 DESIGN 3 DEVELOPMENT 4 TESTING 5 TOOL SHOP
6 RAW MATERIALS
PUTTING
12 ASSEMBLY
PEOPLE FIRST
3 DEVELOPMENT
2 DESIGN
6 RAW MATERIAL S
8 INJECTION MOLDING: LENS
Headlamps and lights are manufactured using a
large number of materials, which mainly include For components critical to light technology such
synthetic materials. ZKW uses technical thermo- as bezels, light rings, reflectors, or lenses, ZKW
plastics, which must fulfill high requirements for uses injection-molding technology in specially
mechanical and thermal stability and in some enclosed areas. They are primarily manufactured
cases must provide outstanding surface quality. from recyclable synthetics.
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9 SURFACE 11 HARDCOATING
For functional reasons, and because decorative All lenses are covered in a protective varnish
elements are becoming more and more impor- before assembly. This seals the surface and be-
tant on premium products, finishing the surfaces comes a hard wear-protective layer that guards
of our components plays a key role in manufac- against environmental influences and scratches.
turing.
Special effect paints for bezels are available, as In general, over 200 individual components must
are partial sputtering and transparent compo- be assembled to produce one single headlamp.
nents. Synthetic parts are metallized, reflector That’s why we need the most up-to-date assembly
plates are powder coated, bezels and reflectors concepts available to produce our high-quality
are mirrored under high vacuum pressure with products. Final manufacturing on our fully auto-
aluminum and with the greatest possible clean- mated equipment and manual work stations is
liness, and coated with a protection film of completed with a variety of different methods
silicone to fight corrosion. and highly sensitive technology.
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32 33
FURTHER DEVELOPMENT
INNOVATION FOR
THE MARKET,
WITH A CONSISTENT
EYE TOWARDS
OUR ENVIRONMENT
TO INTELLIGENT SYSTEM
For many years, comparatively little attention was paid to vehicle lighting.
Today, however, lighting’s contribution to safety is indespensable.
In the early years of automotive history, lanterns jor step towards providing the best possible night
mounted on the sides or directly on the hood of the car vision is the adaptive high beam assistant, developed
gave drivers a minimum sight distance at night. In other by ZKW, which always attempts to drive using the
words: The first headlamps were nothing more than high beams and uses a camera to recognize other road
candles in wind-proof boxes. Later, electrically operated users and turns off the high beams when it does – pro-
lamps took their place. Over time, companies like ours viding glare-free high beams. To further improve night
have revolutionized this technology; modern vehicles vision and allow drivers to recognize obstacles even
today are equipped with better lighting than has ever earlier, we are integrating more and more infrared
been available before. Light-emitting diodes (LED or systems into our headlamps.
laser) today provide very high levels of light quantity We are currently working on project like “smart”
and facilitate light levels above 1000 lumens and inten- headlamps – a front light that reacts autonomously to
sities at the limit of what the law allows – hundreds traffic and driving conditions, automatically adapts
of times the power of a candle. to changing light and traffic situations, and actively
However, today how strongly a light shines is supports drivers in recognizing situations, such as
less important. A variety of applications today are marker lights. Sensor technology in vehicles is also
used to ensure the best possible traffic safety: such becoming more and more complex as it becomes an
as adaptive light from ZKW, for instance. Headlam- integral part of headlamps – without the right amount
ps adjust their lighting focal point, lumininous range, of light, even a sensor can’t see anything. In the not-
and width to your driving direction and speed so as too-distant future, headlamps in self-driving cars will
to provide an optimal range of sight. We have also also be used to communicate with the outside world,
created further developments on this basis. Onema- such as with other road users or pedestrians.
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36 37
Because innovation is kept in motion through research • Testing and measurement laboratory to verify the most exacting demands. The laser is a new form ZKW customers, this means all solutions come from a
and development processes, we don’t just work to ful- development results, including light channel for of semiconductor-based light source and is already in single source.
fill customer orders. Based on a corporate strategy with legally conforming measurements and assess- use in some cases where high light intensities are re- At ZKW, innovation means combining and build-
the goal of making complex products and processes safer ment of the light distribution of individual quired, such as in high-power projectors. It will be used ing the knowledge we need to consistently apply new
and more efficient, we promote innovation management headlamps up through testing of complete ve- more and more frequently in cars in the future. Com- technolog ies throughout our entire product range.
and work to create our proprietary developments. hicles and trucks. pared with traditional light sources like halogen, LED What are the advantages for road users? Improved light
Continued development of oursimulation methods In the ZKW Group, we use one of the largest light chan- and above all lasers have entirely different properties. quality makes it easier to see and be seen, and light dis-
and virtual night trips to simulate customer-specific light nels available and the world’s most modern measure- That’s why they need a new approach when it comes tribution adapted to a specific driving situation provides
distribution patterns allow us to continuously improve ment technology to assess prototypes and series produc- to optics, electronics, mechanics and thermal manage- additional safety. In addition,new types of optical mod-
our quality assurance. We promote quality assurance tion headlamps for their homogeneity, light color, and ment. The process and production technology, produc- ules facilitate exclusive design, their long service lives
through the following points: light intensity. tion safety, and general safeguards are also new. save costs, and reduced energy consumption protects
• Measures to ensure project quality through a LED technology is the technology of the future, The development of analog switches, software for the environment.
FEM simulation program for temperature, struc- and it's already here today: This light technology facil- control units, LED driver topologies, and the visual use Our patent division works with the innovation
tural stability, condensation and de-icing, injec- itates innovative applications, while also placing new of LEDs with fully automated systems – the ZKW Group department to develop a global patent strategy. It is
tion molding, and vibration testing, taking pedes- and higher demands on electronics. To remain a leader is already working on all of these issues. In the future, integrated into the entire innovation process, and allows
trian protection into account in this field, ZKW is developing our company from a we will also be promoting innovations in miniature us to protect a large number of inventions from our re-
• Static and dynamic front LED light applications, system integrator into a system manufacturer. lasers, digital light processing (DLP), micro electrical search and development area each year.
including cooling and electronic implementation The share of LED vehicle lighting continues to mechanical systems (MEMS), organic light diodes (OLED),
grow. LED tail lamps and front headlamps came first, but and specialized LED configurations. In the future, other
were only available in premium vehicles – today it is technologies like sensors will also be used in headlamp
clear that LED lighting will completely replace the technology, turning the headlamp system into a key
halogen and xenon systems on the market in and fully networked sub-component of the vehicle. For
the future. However, laser lighting can
be seen as the next step in light-
ing technology to fulfill
THE WORLD OF ZKW 2018 THE WORLD OF ZKW 2018
38 39
PRODUCTION
Of painting booths and clean rooms: Perfect light demands
perfect surfaces, created with materials from our own workshop.
SUSTAINABILITY
Leading by example:
through sustainable action.
Sustainability begins in the mind and consumption and the associated nega-
all our actions are based on holistic tive environmental effects, we are pur-
thinking. As a global corporate group suing our goal of reducing the ecolog-
with an international production and ical footprint of our products across
purchasing network, we believe fulfill- their entire life cycles.
ing our responsibilities in the areas of Effective environmental protec-
business ethics, resource management, tion must be systematic, which is why
environmental protection, and social we are minimizing risks through our
considerations is an essential part of environmental management in accor-
our responsibilities. We also believe dance with DIN EN ISO 14001:2015. We
we need to establish requirements continuously adapt these guidelines
to meet these demands in our supply according to current law and to the
chain. A constant flow of information request s and requ i rement s of ou r
and a motivated company culture an- customers. Our waste management
chor these considerations in the minds concept regulates material cycles and
of our employees. We have their com- recycling, ensuring the best possible
mitment and collaboration to thank for use of all remaining waste.
ensuring ZKW has been able to estab- As a global player, however, the
lish processes with results that go far issue of social responsibility is becom-
beyond statutory requirements. ing more and more a focus in our com-
pany – including in our supply chain.
In view of limited resources and At ZKW, it is fundamentally important
increasing environmental stresses, to us that all of our partners in our pro-
conducting business without consid- curement network accept their social
ering sustainability and ecological as- responsibility towards their employees
pects is unacceptable. With this aware- and society.
ness, we have expanded our concept
ZKW is improving its company
of quality: We only call a product high Competition demands the best
environmental protection
measures voluntarily, quality if it is produced as responsibly quality at marketable prices, with high
going beyond statutory requirements. as possible using innovative processes. efficiency and the best possible envi-
Through proactive and consistent man- ronmental compatibility – and we will
agement of our environmental impacts travel this trusted path alongside our
and continuously reducing our resource suppliers.
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42 43
MILESTONES
Moving ahead step by step:
Overview of the history of ZKW.
1938
Company is founded by Zizala Karl in Vienna (ZKW) (AT)
1954
Company is expanded by adding the Wieselburg plant (AT);
the factory produced metal components for Lohner/Puch
1982
Takeover by the Mommert family
1989
First car headlamp rolls off the line
1995
Production of the fi rst truck headlamp
1998
The fi rst truck headlamp with xenon technology enters series production
2002
Premier for the AFS development vehicles
2005
Production of the fi rst Bend-lite ® headlamp
2007
Establishment of the company location in Krušovce (SK)
and the MICs (Management & Innovation Center)
at the main headquarters in Wieselburg (AT)
2010
Establishment of our factory in Bahadurgarh (IN)
alongside our joint venture partner
Establishment of company location in Dalian (CN)
2011
First full LED headlamp
2012
Construction of the electronics factory in Wr. Neustadt (AT)
2014
Establishment of a factory in Silao (MX)
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