knorr-bremse: investments for russian market and...
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Knorr-Bremse Group
Knorr-Bremse: Investments for Russian market and Production in Russia –
Experiances of an succesful and ongoing localisation
│1
Dr. Matthias Krug
General Direktor of LLC Knorr-Bremse „KB 1520“ Russia
March 2016
Knorr-Bremse Group
Agenda
1 2 3 Knorr-Bremse Group Knorr-Bremse Rail Knorr-Bremse Rail in
Russia
2
Knorr-Bremse Group │3
Founded 1905
Experience 110 years of innovation
Independence family owned
Employees 23,9161
Sales € 5.2 bn1
R&D expenses 5.7 % of sales1
Investments € 161 m1
Knorr-Bremse at a glance
1 Annual Report 2014
Locations more than 100 locations in 29 countries
(80 manufacturing sites)
Two divisions both as global market- and technology leader
Systems for Rail Vehicles:
brake and on-board systems for rail vehicles
Systems for Commercial Vehicles:
brake systems for commercial vehicles and
torsional vibration dampers
Knorr-Bremse Group
Knorr-Bremse is the leading supplier for braking and on-board systems as well as
aftermarket services for the truck and railway industry
│4
Metros
Streetcars
Multiple units
High-speed trains
Locomotives
Passenger rail cars
Freight cars
Rail Vehicle Systems
Trucks
Trailers
Buses
Engines
Special vehicles
Commercial Vehicles
Distribution of sales 2014 per division
57%
43%
Development of sales
in € millions
254 520
740
1,494
2,743
4,241 4,300 4,303
5,206
1985 1990 1995 2000 2005 2011 2012 2013 2014
Knorr-Bremse Group CONFIDENTIAL │5
Strategic collaboration with
KAMAZ
2003 2004 1999 1997 2000 2001 2005 2006 2007 2008 2009 2012 2010
Knorr-Bremse open a
new representative
office in Moscow
Supply Air Dryer
system for PAZ on
East Europe area
First contract for the
supply with GAZ
Supply ABS
system on East
Europe market
Strategic
collaboration with
MAZ
ZB44 first
product
developed
special for East-
European
market
Strategic Cooperation
with GAZ Group
Start selling process from
warehouse based in Moscow LLC Knorr-Bremse CVS
(Moscow)
Strategic
Cooperation with
GAZ Bus Division
1st local production in Russia (LLC KB RUS,
Nizhniy Novgorod)
JV with KAMAZ - LLC Knorr-Bremse KAMA (N.Chelny )
2013 2014 2015
Direct deliveries to Mos
(June)
Monoblock for PAZ
(April)
Crankshaft machining
(April)
2011
ISO TU 16949 (November)
100.000 compressors
produced
(November)
SAP
implementation
(October)
KB RUS and KB
CVS merge
(August)
SOP compressors
for YAMZ 530
Compressor for
gas engine ISIZU
Compressor for
CUMMINS
History of Knorr-Bremse Systems for Commercial Vehicles in Russia
ISO TS 16949
Certification
(October)
Knorr-Bremse Group CONFIDENTIAL
53 pers. /чел.
12,3 mio. EUR 626,9 млн.руб. (act rate / курс 50.97)
│6
Site
Moscow, Nizhny Novgorod
Knorr-Bremse SfN – targets
Production
one-cylinder compressors (225cc, 320cc, 360cc belt
drive, gear drive, through drive), twin cylinder (500 cc
gear drive) compressors.
planned SOP for pedal unit, air dryer assembly, 630cc
twin cylinder through drive compressor
Производство
одноцилиндровые компрессоры (225см3, 320см3, 360см3,
с ременной передачей, зубчатой передачей, с проходным
валом), двухцилиндровые компрессоры (500см3 с зубчатой
передачей).
планируется начало производства педального узла,
сборка осушителей воздуха, двухцилиндровый компрессор
(630см3 с проходным валом).
Кнорр-Бремзе СКТ – Основные цели
Company
KB SfN LLC
Employees / Персонал
Sales / Выручка 7,9 mio. EUR 534,9 млн.руб. (act rate / курс 67.52)
Main figures 2014 2015
45 pers. /чел.
Knorr-Bremse Group CONFIDENTIAL
197 pers. /чел.
60,3 mio. EUR 3 015 млн.руб. *Budget rate / курс 50
│7
Site
Naberezhnye Chelny Tatarstan
Knorr-Bremse KAMA – targets Кнорр-Бремзе КАМА – Основные цели
Company
KB-Kama
Employees / Персонал
Sales / Выручка 41,3 mio. EUR 2 063 млн.руб. *Budget rate / курс 50
Production
drum brakes, spider machining, dampers, disc brake
assembly, Kamaz manual SLA, master cylinder, clutch
servo, drum brakes for Kamaz trailer axle (NefAZ), KB
clutch servo (VG).
planned SOP for automatic slack adjusters, actuators,
water pump, compressor, hub and drum
Производство
барабанные тормоза, гасители, механообработка
суппорта, сборка дисковых тормозов, ручной
регулировочный рычаг, главный цилиндр сцепления, ПГУ,
барабанных тормозов для прицепов (НефАЗ), ПГУ КБ (VG)
планируется начало производства автоматических
регулировочных рычагов, тормозных камер, водяных
насосов, компрессоров, барабанов и ступиц.
175 pers. /чел.
Main figures 2014 2015
Knorr-Bremse Group CONFIDENTIAL │8
Total area (incl. offices) / Общая площадь
12 000 m2
Number of CNC machines Кол-во обраб. центров
Number of assembly lines Кол-ко сборочных линий
Location / Местоположение
NBC / Набережные
Челны
9
8
Механообработка Сборка барабанных
тормозов Сборка демпферов
Сборка регул.
рычагов Сборка главного
цилиндра Сборка ПГУ
Production / Производство
Knorr-Bremse Group
Think global - act local. Knorr-Bremse considers localization as the main key to
success
│9
With more than 100 sites in 29 different countries, Knorr-Bremse is represented on all continents
Knorr-Bremse’s global production network consists of 80 state-of-the-art manufacturing sites
Knorr-Bremse has a strong global footprint and a proven track record in localizing its technologies worldwide
Localization guarantees customer proximity and a profound understanding of customer needs as well as high
reactivity and flexibility
Knorr-Bremse enforces globally applied and standardized processes as the basis for equally high quality
standards and efficiency in all locations worldwide
Knorr-Bremse Group
Agenda
1 2 3
10
Knorr-Bremse Group Knorr-Bremse Rail Knorr-Bremse Rail in
Russia
Knorr-Bremse Group
Knorr-Bremse Rail is the leading global system supplier for the railway industry,
providing a broad portfolio of sub-systems and matching service solutions
ON TRAIN OFF TRAIN
Wash and Wipe
Systems
Train Door
Systems
Power Electrics
Control and
Management System Auxiliary Converters
HVAC Systems
Braking Systems
Traffic Management
Systems
Platform Screen Doors
Modernization, Service and Support across the entire life-cycle
Driver Assistance
solution LEADER
CBM System Solution
│11
Knorr-Bremse Group
With Knorr-Bremse RailServices our customers are always on track
Spare parts Service Training
│12
OEM-quality spare parts
Spare part kits
Commonest spare parts
kept in inventory
Obsolescence
management
Maintenance and repair in
local service centers
Maintenance contracts for
entire life cycle
Technical support
Training center and on-site
training
Analysis and evaluation of
existing systems
Installation support
Retrofitting of innovative
products
Modernization/
Engineering
Modernization advice to
optimize technical and
commercial advantage
Modernization concepts
across all systems
Knorr-Bremse Group
Brake System for RUSSIAN High Speed Trains
Moscow – Kazan - ???
Knorr-Bremse Group
KB‘s Concept and Scope offered for Moscow/Kazan HST
Brake control
incl. Service Brake, WSP,
DNRA, Bogie monitoring
Air supply
Bogie equipment
Doors
Air condition
07506N00 - Moscow/Kazan, Brake System for Russian High Speed Trains
Windshield
wipers
Brake control
Knorr-Bremse Group
Knorr-Bremse has a profound experience of requirements for Russian railway
vehicles
System
HST Application 380km/h
Standards
GOST
NBzhT
WSP
Certification
Others
Material qualifications
Severe winter operation
Compatibility with existing
stock and Depot/Service
07506N00 - Moscow/Kazan, Brake System for Russian High Speed Trains
Knorr-Bremse Group
Simulation of the Brake system functions
and components are requested
Test of SW-Brake function
Communication
Brake Blending
Brake test
Test of pneumatic behavior
Response times
Functionality
Dynamometer Tests
Validation thermal
calculation
Friction coefficient
Simulation track profile
07506N00 - Moscow/Kazan, Brake System for Russian High Speed Trains
Knorr-Bremse Group
The Brake Control of KB can manage brake distances, acceleration
and wheel/track adhesions as well as brake power and energy
Brake Force distribution
Thermal load
Adhesion wheel/rail
Decelerations
Failure scenario
LCC
Requirements for
Service brake
Emergency Brake
Brake architecture supporting safety and
Approval
Brake Control and Management
decela
reti
on
a [
m/s
2]
velocitiy v [km/h]
07506N00 - Moscow/Kazan, Brake System for Russian High Speed Trains
Knorr-Bremse Group
Agenda
1 2 3
18
Knorr-Bremse Group Knorr-Bremse Rail Knorr-Bremse Rail in
Russia
Knorr-Bremse Group
Moscow
Knorr-Bremse Rail supplys all modern train platforms in Russia and CIS with its state-
of-the art products (selected examples)
│19
Velaro RUS
Brakes
Doors
HVAC
Power Electrics
Siemens Desiro RUS
Brakes
Power Electrics
Allegro SM6
Brakes
Doors
HVAC
Power Electrics
TVZ Tver
Passenger Cars
Brakes
Stadler
Aeroexpress
Brakes
TCMS
Metro Moscow
Brakes
Doors
HVAC
Power Electrics
Stadler JV Minsk
LRV Kazan
Brakes
Doors
PESA / UVZ
Russia LRV
Moscow
Brakes, Doors
Long Distance Mass Transit R&C
Metro St. Petersburg
Brakes
Brakes
AT / EKZ
KZ8A
Brakes
Locos
AT / EKZ
KZ4A
Brakes
Knorr-Bremse Group Knorr-Bremse Group Knorr-Bremse Group
Knorr-Bremse undertook enormous efforts to extend its GOST compliant product
portfolio and develop state-of-the-art products for the Russian railway industry
│20
■ Engineering Cooperation between RZD and Knorr-Bremse for freight cars: Development of the Distributor
Valve and Brake Load valve for Freight Trains
■ Adaption of components to Russian requirements (e.g. Low temperature adaptation down to -55°C)
■ Accreditation of KB to the Test Centre in Russian System SSFZhT
Distributor brake valve
KAB60 for freight cars
Load brake valve
AKB1
for freight cars
Knorr-Bremse Group Knorr-Bremse Group Knorr-Bremse Group
Knorr-Bremse’s approach to the Russian and CIS market is based on a long-term
strategy and willingness to invest
GOST compliant product portfolio
Adaption of components to Russian requirements
Development of the distributor valve KAB60 and brake
load valve AKB1 for freight cars
Total investment: ~50 Mio. EUR
KAB60 AKB1
│21
Localization in St. Petersburg
2015: opening of new service centre
July 2016: opening of state-of-the-art production plant
(8.000sqm)
Total investment: ~60 Mio. EUR
Production plant Service Center
Knorr-Bremse Group Knorr-Bremse Group Knorr-Bremse Group │22
Certification procedure has to be organized easier
the infrastructure for the production doesn’t come in the right time: the plant is built,
but there are no streets, electricity and gas near the building
the possibilities for Russian suppliers: suppliers have to have interest to be
presented on the global market especially CIS and to work in international business
competition conditions
international market leading products have to be the target for development of
Russian industry
an open question: how to manage working without an import when there is no
technology provided? How Russian Federation can integrate technology partners
from abroad as partners in this case?
total quality management (TQM) need to be integrated in the whole value added
process – leadership needs to be taken by entrepreneurs
What we have learnt by building up our production in Russia? (some experiences I )
Knorr-Bremse Group Knorr-Bremse Group Knorr-Bremse Group
What we have learnt by building up our production in Russia?
(some experiences part II)
│23
Investors are not enough
prepared for doing business in
Russia
Investors have to invest always
more time than excepted
Russian business environment is
not comparable to China or
Europe
long going presence and
partnership are business
success factors
Respect culture, history and
tradition
The decision for the place of
localisation should be a decision
of the investor
Knorr-Bremse Group Knorr-Bremse Group Knorr-Bremse Group │24
Production facility Service Center
The construction of a new state-of-the-art production plant and service centre in St.
Petersburg is a clear commitment to the Russian market
■ The contracts signed on 05th of August 2014
■ Service center in St. Petersburg started operations in February 2015
■ A state-of-the-art production facility (8.000 sqm) was inaugurated in St. Petersburg by end of 2015 after 16 months
Shop floor Knorr-Bremse
production plant in Budapest
Knorr-Bremse intends to bring best in class / top modern production plants to Russia
and build up a tier 2 supplier base
Knorr-Bremse Group
Localisation KAB60 & AKB1 materials from Russian suppliers
March 2016
Knorr-Bremse Group Knorr-Bremse Group Knorr-Bremse Group
Possibilities and tasks for Russian suppliers – localization program since 2008
│26
Knorr-Bremse Group Knorr-Bremse Group Knorr-Bremse Group
Casting & Forging: PREFFERED AND POTENTIAL SUPPLIERS
│27
MetalLitMash,
Kolomna
TS-Engineering,
Voronezh
LMZ,
Rybinsk
MLZ,
Mzensk
UAZ,
Ulyanovsk
URAL AZ,
Miass
MashSteel,
Penza
ChKPZ,
Chelyabinsk
SpezSplav,
Lysva
ZTL,
Ryazan
Knorr-Bremse Group Knorr-Bremse Group Knorr-Bremse Group
Machined Parts: POTENTIAL SUPPLIERS
│28
c
KG,
Kazan
Flaig+Hommel,
Zavolzhye Glaps Engineering,
Tver
Knorr-Bremse Group Knorr-Bremse Group Knorr-Bremse Group
Some ideas for improvement of performance of Russian suppliers for CIS and
global markets
1. Customer satisfaction is not always in mind of management, sales and
production staff
2. Production facilities are not in the best condition
3. Quality awareness has to be on higher level
4. Reaction time needs to be shorter in all steps of production
5. Communication to customer needs to be understood as a key success factor
Prices are not competitive because of philosophy of mass production -
SMED and „one piece flow“ as solutions
Supply chain and inventory management create cash for investments
│29
Knorr-Bremse Group Knorr-Bremse Group Knorr-Bremse Group
Support for russian foundries with german pattern maker and know-how transfer
• 3-D-files for all parts to russian foundries
• Support in Russia by german pattern maker
• Production of pattern and coreboxes in Germany
• Training from german engineers in russian foundries
• Audits by KB-Engineers
│30
Knorr-Bremse Group
VL80 LOCO
Modernization
• Step 1: Tap Changer
• Step 2: Further Proposals
Knorr-Bremse Group Knorr-Bremse Group Knorr-Bremse Group
Actual Solution
+
Knorr-Bremse Group Knorr-Bremse Group Knorr-Bremse Group
New Solution
TAP CHANGER
1. 30 no-load switches with single motor
2. 4 solid state switch
3. LEM for current measurement and feedback
4. TCMS & CAN BUS for configuration
5. New Kinax handle transducer
+
1.
2.
3.
4.
5.
Knorr-Bremse Group Knorr-Bremse Group Knorr-Bremse Group
Future Developments
Traction
• Driver handle
• TCMS
• TAP Changer
• Braking resistor
• DC Motor traction
Control
Auxiliary Converter
DAS
• Leader System
• Intelligent driver desk
Metering
• Ecometer
• DHS
ETHERNET Connection
Local
Train Level
Knorr-Bremse Group Knorr-Bremse Group Knorr-Bremse Group
Maintenance time reduction • Commutation of contactors assisted by static switches
• Easy access to every single component without disassembling the Changer (easy maintenance in situ
without removing the full TAP Changer from the loco)
• Replacement of camshaft and Motor Drive with multiple Permanent magnet motors solution
• Use of Electronic to control the Changer (reduction of wiring and possibility of future integrations)
• Reduction of number of auxiliary contacts with new simplified driver handle
Proposal Advantages
Cost saving solution • Use of standard contactors from the catalogue
• Less number of components
• Reduction of copper connections (main connections in Aluminum bars; aux wiring removal)
Weight reduction • Removal of the big motor and camshaft
• Reduction of dimensions
• From 1015kg to 630kg
Availability • Contactors and Disconnectors designed to work 8 years without maintenance
• Electronic Diagnostics to prevent major loco failures
• Current control for Traction Motor and gear box life improvement
• Corrective maintenance time reduction
Knorr-Bremse Group Knorr-Bremse Group Knorr-Bremse Group
Knorr-Bremse Rail – Safety with Tradition
│36
Dr. Matthias Krug
General Director of LLC Knorr-Bremse „KB 1520“ Russia
March2016
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