1 FORUM The magazine for customers, staff and friends of the Wirtgen Group NUMBER 49 ISSUE 1/15 At your service worldwide! ROAD AND MINERAL TECHNOLOGIES
3 EDITORIAL FORUM 49 3 Dear customers, employees and friends, T he sustained growth of the Wirtgen Group allows us to further strengthen our group of companies again this year through selective investment in our German brand headquarters, in our foreign production plants and in our worldwide sales and service network. Our aim here is to further increase performance and efficiency for our customers locally and to fulfill our pledge around the globe of staying close to our customers. In this issue, which focuses on worldwide growth, we are proud to reveal the results of our commitment on all continents and show you where we stand today on those markets. We are pleased to take you with us on a journey to our Wirtgen Group locations in China, India, the USA and Australia and to give you an in-depth look at the tremendous developments that have taken place on these markets. GROWTH MEANS PROGRESS Momentum and change have accompanied us since the first days of the Wirtgen Group. Growth has become an engine that drives us to continuously review all types of business processes and to bring them in line with increased product volumes. In this way, true progress is possible. Professionalism is in demand more than ever here. Growth means both the opportunity and the need to increase efficiency in all areas of the Wirtgen Group, and to consistently direct this efficiency towards one focal point: customer satisfaction. This strategy has made our Road Technologies business sector strong and successful and has enabled us to earn the trust of our customers on a daily basis, right up to the present day. Our task now is to harness these experiences so that our Mineral Technologies business sector which has assumed an entirely new signifi cance following the incorporation of Benninghoven into our Group can reap the benefits in equal measure. FOCUS ON MINERAL TECHNOLOGIES The ongoing development of the production processes in our German brand headquarters is another key element contributing to our success. It is this which enables our dedicated team to achieve their full potential and creates the necessary space for innovations. Alongside targeted investment, enhanced efficiency and the leveraging of hidden potential are vital in enabling production to adapt in a flexible way to increasing demand. We provide some powerful examples of this in the section Plants + Know-How. We are devoting all of our attention to the sustainable integration of Benninghoven into our worldwide sales and service organization. We have already achieved initial successes, above all in Europe. In many places, what belongs together is already growing together as we can see if we look towards France, for example. Not only was the first joint participation of all five product brands at Intermat in Paris very successful, the Wirtgen Group subsidiary in Paris has also grown and completely realigned itself in the Mineral Technologies business sector. PROGRESS MEANS OPPORTUNITIES The examples in this FORUM indicate that growth will provide excellent opportunities for all employees in our plants and companies to carry out challenging projects and to help shape the future of our Group at a high level. In our core business, Road Technologies, we will continue to work passionately to develop our service portfolio and to consistently adapt it to meet the needs of our customers. Each and every day, we see how our long-term employees and the new staff we are attracting to our company tackle these tasks, working hand in hand with a high level of commitment, but also with the necessary sense of proportion. In this way, they are making a valuable contribution to the strategic development of our Group, and this ultimately serves to inspire our customers with long-lasting enthusiasm for our technologies and services. Forward-looking personnel development is an important cornerstone for us in achieving this: product innovations are created by people, processes are optimized by employees. Therefore, we work specifically on increasing the level of expertise in our Group of companies by recruiting additional specialist employees and systematically developing them, just as we do our own long-term specialist staff. This ensures that our team is more than capable of handling future challenges. Our warmest wishes Jürgen Wirtgen Stefan Wirtgen
4 ROAD AND MINERAL TECHNOLOGIES NUMBER 49 ISSUE 1/15 6 The Wirtgen Group is still growing. Tradition met technology at the festive plant opening in China. The Wirtgen Group is helping to conserve the environment and resources with the latest technology and optimized processes The Wirtgen Group offers training in twelve different trades. FOCUS FORUM 49 focuses above all on the worldwide growth of the Wirtgen Group. WORLDWIDE GROWTH 6 Fabulous opening Investment in the Chinese growth market. 16 India is booming Wirtgen India opens a new plant. 22 Wild about technology Know-how secures market leadership in North America. 26 Excellent service Wirtgen Australia expands its sales and service network. Plants + know-how FORUM The magazine for customers, staff and friends of the Wirtgen Group At your service worldwide! 30 Redirecting the flow The environmentally friendly cold milling machines from Wirtgen. 34 Go green How Vögele s paver production saves resources. 38 Complexity made simple The new operating concept for Hamm rollers is a hit. 42 Fit for series production Kleemann optimizes production structures. Spurred by customer satisfaction: The Wirtgen Group is expanding its presence worldwide.
5 CONTENT FORUM Children in Need has been helping people to help themselves for 30 years, supporting needy children and families in the Philippines. + BENNINGHOVEN 46 Great achievement A big challenge: Asphalt mixing plants from Benninghoven plus 1 The Wirtgen Group fields a full strength team at Intermat. 58 A strong equipe Wirtgen France and Benninghoven France merge. 60 Total commitment Benninghoven delivers asphalt mixing plants to Norway. PEOPLE + MACHINES 64 Young talent from within Training in the Wirtgen Group. 68 Children in Need e.v. Helping people to help themselves The charity group comes to the aid of needy families. DIGITAL FORUM Download this issue of Forum as a pdf-file with the QR-code or use it to send Forum 49 to a friend. PUBLICATION DATA FORUM The magazine for customers, staff and friends of the Wirtgen Group PUBLISHER WIRTGEN GROUP Holding GmbH, Reinhard-Wirtgen-Straße 2, Windhagen, Germany, Montabaur Regional Court HRB 10492, VAT IdNo. DE MANAGING DIRECTORS Jürgen Wirtgen, Stefan Wirtgen, Rainer Otto EDITOR RESPONSIBLE FOR CONTENT Michaela Adams, Tel.: , Fax: , EDITORS Michaela Adams, Mario Linnemann, Angelika Schüler. All rights reserved. Reprints and duplication only with the written consent of the editors. PRODUCTION muehlhausmoers corporate communications gmbh, Cologne; project management: Joscha Duhme; editor: Joscha Duhme, Rebecca Lorenz, layout: Anna Gruchel TRANSLATION interteam Übersetzungsbüro, Grünwald PRINTED BY Gebr. Kopp GmbH & Co.KG, Cologne, Germany
6 6 CHINA: NEW PLANT Fabulous opening China is one of the world s key growth markets. The Wirtgen Group has now invested some EUR 50 million in the construction of a new plant for its subsidiary in China and hence in the Group s continuing growth in the People s Republic.
7 WORLDWIDE GROWTH FORUM 49 7
8 8 There s plenty of space in the assembly halls at the new Wirtgen China production facility. Perfect conditions for the series production of local machines: This is the Vögele SUPER L paver. C ompetition is tough in the Chinese market. Nevertheless, the Wirtgen Group is one of the few western manufacturers of construction machinery and plants to increase its market shares. One of the reasons for this is its premium products. Another is the Group s comprehensive range of services, which provides for reliable across-the-board customer service. With eight of its own sites, two new service centers and a network of dealers comprising 35 partners, Wirtgen China has a highly efficient tight-knit sales and service network that now covers virtually all of China s 22 provinces. As a result, Wirtgen China is close to its customers at all times. The Wirtgen Group has responded in full to local customer needs. Since 2004, the Group has been producing equipment in China for China based on German quality standards. For example, in addition to the construction machines manufactured at the Group s German plants, 14 different milling machines, pavers and rollers are currently manufactured at Langfang, tailored specifically to the requirements of the local market. And the demand for construction machines is huge. We use milling machines from Wirtgen, pavers from Vögele and rollers from Hamm. As a loyal customer, we value the superior product quality. Chen Qiuhua, Taizhou Huitong Highway Maintenance STATE-OF-THE-ART PRODUCTION FACILITY The urbanization of the country is steadily increasing, which is why China has embarked on a massive drive to develop its infrastructure. This is spawning a vast number of road construction
9 WORLDWIDE GROWTH FORUM 49 9 Hamm rollers such as the HD 128 and HD 138 produced in Langfang are also manufactured under state-of-the-art conditions. and recycling projects, for which we can provide the appropriate equipment, says Ulrich Reichert, CEO of Wirtgen China. The construction of our new plant just 2 km from our existing site is a true milestone and ensures that we are optimally equipped in good time to meet the challenges of the future. IMPRESSIVE TOUR OF THE PLANT The state-of-the-art production facility alone occupies 33,000 m2 of the 200,000-m2 grounds. The new and spacious bays provide plenty of space for the production of local machines, including e. g. the Wirtgen cold milling machine W 100 H, the Vögele SUPER L paver and the Hamm 320 compactor. Early on in its development, Wirtgen China assembled a team of production, logistics and IT specialists from the German plants and the Chinese subsidiary with the aim of harnessing the know-how. The project benefited from the cumulative experience gained from plant expansions and newbuilds in Germany as well as the expertise of Chinese colleagues. Processes on individual production lines and the flow of material within the plant were optimally coordinated in a team effort. This is also evident in the state-of-the-art equipment fitted outside Production, such as the vertical lifts already in use at the Group s German plants. These help to dispatch construction and production parts to their destination in next to no time. Together with the automatic order picking system for Production and The construction of our new plant is a true milestone and ensures that we are optimally equipped in good time to meet the challenges of the future. Ulrich Reichert, CEO of Wirtgen China
10 10 WORKSHOP The 1,200-m² workshop comprises seven repair stations which can be individually adapted to the machine. It also has its own integrated electrical workshop. TESTING GROUNDS All Wirtgen Group machines must undergo rigorous testing before the customers put them into operation. SPARE PARTS WAREHOUSE Over 10,000 different spare parts are stored in the warehouse, which has 3,500 pallet spaces. CTT The Center for Training and Technology (CTT) offers rooms for groups of up to 50 persons and machine training in two large halls, each 280 m² in size.
11 WORLDWIDE GROWTH FORUM PRODUCTION HALLS Multifunctional workstations and cutting-edge production facilities in the halls offer optimum manufacturing conditions. Heavy modules can be lifted safely thanks to 18 gantry cranes with a maximum load of 20 t and 21 slewing pillar cranes with a jib length of 7 m. PAINT SHOP Components large and small are coated in the paint shop. An automatic conveyor system optimizes the handling of the parts and protects the surfaces. ADMINISTRATIVE BUILDING The main building of Wirtgen China with its administrative offices is located directly in front of the production halls.
12 12 The visitors pay close attention to the live demos showcasing the combined expertise of the Wirtgen Group from road rehabilitation using cold recycling technology, for example,...
13 WORLDWIDE GROWTH FORUM to asphalt paving and compaction. It is a fantastic event. Such a huge and well-organized high tech event mounted by just one company is unique in China. Mr. Chen Jialong, Beijing University of Civil Engineering and Architecture ample storage space for the 120,000 or so parts that come in every day, processes at the plant are undergoing lasting improvement. The vertical lifts are a star feature of the production facility at Langfang and a clear sign that the plant meets all the Wirtgen Group s high quality standards. KNOW-HOW TRANSFER High standards have also been met in the new administrative building, which is an impressive example of modern architecture and whose extensive glass facade provides pleasant working conditions for the staff who work there. Its central position on the subsidiary grounds strengthens communications between the individual departments. The shorter walking distances within the building and to Production, the Workshop or the adjacent Centre for Training and Technology (CTT) allow for quick consultations. As a result, the place where know-how is transferred to customers, users and employees is right next door. The Training Center covers an area of 2,000 m2 and accommodates two generously sized halls for machine training and its own Customer Service Workshop, as well as rooms for general training purposes. Wirtgen China is hence optimally equipped to offer Chinese customers the best possible support in terms of applications expertise and customer service.
14 14 WIRTGEN CHINA Plant data Investment: > EUR 50 million Total size of development: 200,000 m 2 Centre for Training and Technology (CTT): > 2,000 m 2 Customer Service Workshop: > 1,200 m 2 Spare Parts Store: 10,000 different parts Incoming goods: 120,000 different parts Warehouse: 3,500 pallet spaces Live demo alongside the machine exhibition. GRAND OPENING AND TECHNOLOGY DAYS More than 2,000 visitors took the opportunity to peruse the professional facilities during the two-day opening event at the end of March. And they got to see far more than just the new premises. Inspired by the Technology Days, a well-established event in Germany which is hosted by each of the brand headquarters in turn, Wirtgen China staged a similar industry event for the local market for the first time. The event presented the Group s wide range of products and services, leading application technologies and latest machine highlights for the Chinese market to Chinese trade visitors. Right at the start, visitors were able to get a close look behind the scenes on a guided tour of ongoing production operations. They were clearly impressed by the vertical integration and the dovetailed processes employed to manufacture the locally made premium products. But the real highlight of the day was still to come, namely the official opening ceremony. Picking up on a Chinese tradition that is more than 1,000 years old, the Wirtgen Group staged a dragon dance. The dragon symbolizes royalty, wisdom and power in Chinese society, and in Asia it is venerated as a talisman with supernatural powers. A special honor was also granted to Wirtgen Group Managing Partner Stefan Wirtgen when at the end of the dance he was invited to paint the color on the eyes of the dragon. On the second day, Wirtgen China put on an entertaining program with exciting live demos and informative ex-
15 WORLDWIDE GROWTH FORUM Special honor for Stefan Wirtgen: painting the eyes of the dragon. pert presentations. The 70 or so exhibits in the machinery exhibition also provided an impressive overview of the Wirtgen Group s extensive product portfolio, while being the perfect platform for experts to confer and swap notes particularly as they were able to observe 23 of the exhibits in operation. Apart from the local produced machines, the Vögele SUPER SprayJet paver, the Hamm HD 14 VO tandem roller, the Kleemann MCO 9 EVO cone crusher and for the first time on the Chinese market the Wirtgen recycler and soil stabilizer WR 200 were also shown in action. The Grand Opening at Langfang demonstrated once again that, with the expertise and solutions of the Wirtgen Group, customers always have the right solution to hand and a reliable partner on their side in the growth market of China.
16 16 TECHNOLOGY DAY AT WIRTGEN INDIA India is booming India s economy is a dazzling gem among emerging markets. Keeping step with this growth, the Wirtgen Group is also steadily expanding its business on the subcontinent. The extension of the production site in Pune was duly celebrated with a Technology Day event.
17 WORLDWIDE GROWTH FORUM We have been able to achieve a gradual increase in our market share in India s roller market in recent years, says Ramesh Palagiri, CEO of Wirtgen India, delighted that the local production concept initiated in 2011 has borne fruit. The Hamm 311 and HD 99 rollers that are produced in Pune for the Indian market are catching on among customers. Today, we sell more than 500 rollers per year, giving us a market share of around 20%, Ramesh Palagiri adds. Optimally tailored to the needs of the customers in the Indian market, the rollers have a distinct advantage over the competition due to their high quality, ease of operation and and their price, which is in line with the market. Added to that is the Wirtgen Group s exemplary after sales service. INVESTING IN THE FUTURE We d like to harness the positive experience we ve had with the local production of Hamm rollers to establish ourselves more firmly in India, systematically and across all Wirtgen Group brands. Compared to China, India is still at a fairly early stage of economic development, says Stefan Wirtgen, Managing Partner of the Wirtgen Group. That s why following the construction of completely new facilities in 2011 we ve invested once again in our local production site in India. Another 8,000 m2 of covered space have been added to the existing plant and the premises have been extended by 28,000 m2. Space which will be used in future for the series production of other Wirtgen Group products for the Indian market. In addition to the Hamm 311 and HD 99 rollers, the Vögele Ritual ceremonies, fascinating expert presentations and breathtaking machine demonstrations the Technology Day event held on the occasion of the expansion of the Wirtgen India plant was very much in keeping with the spirit of the country: colorful, loud and swarming with optimistic people who delight in innovative technologies and progress.
18 18 The Kleemann MS 952 EVO and MS 953 EVO classifiers made in Pune will go on sale at the end of the year. Mukunda Venkatesh, Wirtgen India Customers are looking forward to locally produced Kleemann products. Master series and Kleemann screens will soon be produced in Pune as well. An overall sum of around EUR 11 million has been invested. The expansion of the Wirtgen Group s production facility in Pune will mark the start of local mobile screen production by Kleemann. In total, four different models are to be produced: two classifiers which sort individual granulations after crushing and two scalpers which are used for cleaning the material before crushing. The screens are intended for sale in emerging markets. The first two models will go on sale at the end of For 20 years, the Wirtgen Group has had a strong presence in India. The expansion of the plant and the products has been flanked by measures to systematically develop the Indian sales and service network throughout the country. As well as today s bases in Pune, Chennai, Hyderabad, Talcher, Ranchi, Kolkata, Mumbai, Ahmedabad, Delhi and Guwahati, other bases are planned in Chandigarh, Jaipur, Indore and Bangalore. In India today, some 330 employees live up to the Wirtgen Group pledge of being close to our customers on a daily basis. The expansion at the production site close to the industrial center of Pune is another step towards sucess for the Wirtgen Group in the growing Indian market. It is also the country itself that profits from the success of the Wirtgen Group in the Indian market, since the technologies of the Wirtgen Group create the infrastructure and hence shape the future the future of India. In his opening speech, Ramesh Palagiri, CEO of Wirtgen India, also touched on the challenges of the Indian market. The visitors avidly watched the live demonstrations of Wirtgen Group machines.
19 WORLDWIDE GROWTH FORUM WIRTGEN INDIA As well as the Hamm 311 and HD 99 rollers, the Vögele 8503 and 8500 Master series as well as four Kleemann screens will be produced in Pune in future. Site expansion in Pune Investment: EUR 11 million Increase in size of premises: 100,000 m ,000 m 2 Increase in size of plant: 7,500 m 2 + 8,000 m 2 Locations Plant, central store and head offi ce: Pune Subsidiaries: Ahmedabad, Chennai, Delhi, Guwahati, Hyderabad, Kolkata and Mumbai Spare parts stores: Ahmedabad, Delhi, Hyderabad, Ranchi and Talcher Planned subsidiaries: Bangalore, Chandigarh, Jaipur, Indore Planned spare parts store: Chennai Growth in employee numbers The Wirtgen W 130 F cold milling machine gives the trade audience an impressive live demonstration of its superb milling performance.
20 20 HALL 2 In future, Kleemann screeds for the local market will be produced in the spacious new Production Hall 2. HALL 1 The Vögele Master series and Hamm rollers will be produced in Production Hall 1. Among other things, quality control, the spare parts warehouse, workshop and paint shop are also located in this part of the facility.
21 WORLDWIDE GROWTH FORUM GUESTHOUSE Customers can lodge at Wirtgen India s own guesthouse. MAIN BUILDING The Training Center offering courses for both employees and customers is also integrated in the main building.
22 22 NORTH AMERICA: TECHNOLOGY DAYS AT WIRTGEN AMERICA Wild about technology Bigger, faster, farther three words that describe the North American market to the rest of the world, and effectively sum up the development of the Wirtgen Group in the USA and Canada.
23 WORLDWIDE GROWTH FORUM Forging know-how Wirtgen America. The in-house training center was the focus of the event. US industry gathering at Wirtgen America. A lively exchange among road construction professionals. Established in 1985, Wirtgen America has been taking care of Wirtgen Group customers on the North American continent for no less than 30 years now. From headquarters in Nashville, 35 dealers with over 250 locations sales offices, workshops, spare parts warehouses and optimally trained personnel provide a complete service for customers in the road construction and mining industries. In their work, they see themselves as reliable partners. At the Technology Days event in April 2015, 1,000 guests from Alaska to Key West experienced a unique program focusing on the current technologies from Wirtgen, Vögele, Hamm and Kleemann. Host of the event was Wirtgen America in Nashville, Tennessee, headquarters of the Wirtgen Group in the USA and Canada. But the 30th anniversary of this Wirtgen Group branch was not the only occasion to celebrate. The growth we ve seen in North America is tremendous. Three decades ago, we started out here with one machine; today, as a German manufacturer, we are the undisputed market leader for our core technologies in the USA and Canada, too, says Jürgen Wirtgen, Managing Partner of the Wirtgen Group, describing his company s career on the North American continent. Rising market success was accompanied by successive expansion of the sales and service network. Know-how is an important keystone on the way to such success. Expertise is critical in our business and that s why we attach great importance to the WIRTGEN AMERICA The Wirtgen Group in North America Established: 1985 Headquarters: Nashville, Tennessee, USA Number of dealers: 35 Total number of locations: Over 250 Business hours: 24/7 Special feature: In-house training center, where the employees, dealers and customers can attend training classes year-round continuous technical training of both our own team and our dealers. Our in-house training center is busy all year long. Naturally we also offer training programs for our customers machine operators, and they frequently take advantage of the offer, explains Jim Mc Evoy, CEO Wirtgen America. At the event, visitors could see and experience what makes Wirtgen so special: Its serviceorientation, its continuous push for new technical solutions and its passion for road und mineral technologies. The enthusiasm at the live demonstration was unmistakable. With competence and a friendly approach, the experts from Wirtgen America presented their machines and technologies for subgrade construction,
24 24 Close to our customers: a dialog with Jürgen Wirtgen. LIVE DEMOS As many as 32 Wirtgen Group machines were shown in the live demonstrations. The applications: Reclaiming, paving, soil stabilization, cold recycling in-plant, crushing, screening and compaction, as well as various cold milling applications. Some 1,000 visitors came to learn more about Wirtgen America s portfolio of products and services. concrete paving, asphalt paving with subsequent compaction, road rehabilitation and material recycling. The demonstration also gave an impressive indication of how well the individual technologies from the Wirtgen Group product brands complement one another, and of how the individual processes have been optimally intercoordinated. Presenting these technologies in action, the Wirtgen Group showed just where its strengths lie: Each individual product brand presented technological innovations that together make up leading, complete solutions for economical road construction. Following the example of the German brand headquarters at international events, the American representatives of the individual product brands also worked hand-in-hand during the superb presentation. Jürgen Wirtgen summarized what makes them such a strong team: The will to create comprehensive, cross-brand solutions, with which our customers can work successfully in North America and around the world. Wirtgen America s own training campus was the ideal platform for such a major event.
25 WORLDWIDE GROWTH FORUM HISTORY No future without a past: The rapid growth of the Wirtgen Group was documented in a past-to-present exhibition. TECHNOLOGIES Wirtgen Group machines serve the entire process chain in road construction: Processing, mixing, paving, compaction and rehabilitation. The topical exhibition had a learning effect. WIRTGEN GROUP AVENUE At the machine exhibition, the market leader presented sections of its broad product range. Every customer was able to find the right machines and technologies for his applications in the US market.
26 26 AUSTRALIA: NEW SUBSIDIARY IN PERTH Excellent service A high level of specialist expertise, in-depth advice and rapid availability: These are the hallmarks of the Wirtgen Group s worldwide service. The same applies Down Under, where Wirtgen Australia is expanding its sales and service network.
27 WORLDWIDE GROWTH FORUM The flagship of Wirtgen surface miners, the 4200 SM. The Kleemann MOBIREX MR 130 Z impact crusher in action. Customers talk shop with Wirtgen Australia specialists in the workshop and on the machines. Australia is not only rich in natural resources. With a surface area of some 7.7 million m2, the country is also the sixth biggest in the world in geographical terms and distances from A to B can be vast. When you look at the Wirtgen Group s portfolio, one thing quickly becomes clear: The market in Australia and New Zealand offers huge potential. Thanks to our top quality products, expertise in technical applications and reliable service, we re now one of the biggest players in the road and mineral technologies business over here, says Wirtgen Australia CEO Paul Hockridge, reflecting on the Wirtgen Group s successful positioning on the Australian and New Zealand markets. Yet his sights are set on the future: With our new head office in Perth and the expansion of the regional sites across both countries from Brisbane to Melbourne in Australia and on to Auckland in New Zealand we re continuing to step up our presence in the continent. For our customers, this means even greater availability of staff and faster availability of materials, whether it s a mining project in the outback or a road construction or rehabilitation project. The opening ceremony of the new headquarters in Perth gave 600 or so customers a chance to see just how the Wirtgen Group practices what it preaches. While live demonstrations showcased the performance range of Wirtgen Group machines, visitors also gained in-depth insights into the high level of service expertise on offer from Wirtgen Australia on a guided tour of the premises. From the workshops where jobs can range from component modifications to a complete overhaul of Wirtgen s biggest surface miner, the 4200 SM and the spare parts store with 3,700 m2 of storage space, right up to the training center, the entire site is designed to cater to the needs of customers in Australia and New Zealand. The expertise of Wirtgen Group specialists from Wirtgen Australia plus the expanded sales and service structure make for an ideal combination, laying the ground for sustainable growth and excellent customer service Down Under. WIRTGEN AUSTRALIA Organization Established: 1986 Workforce: 160 Locations: Five in Australia and one in New Zealand New Perth headquarters Area: 12,000 m² of which the Spare Parts Store covers: 3,700 m 2 Wirtgen Australia is an extremely professional set-up. Mark Filsell, General Manager of Highway Stabilisers