No. 27/2015

InPractice

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ContentsEditorial

34 Automatic positioning system 46 Intelligent LED technology lights the way forward

04 Referenceprojects

12 Productpresentations New ideas from the SFS Group

18 Trimminginstyle Challenging components make for comfortable grooming

20 Stayingontrack Steering angle sensor components from SFS intec

22 Strongfixingsforastrongroof A spectacular roof for the Elephant House at Zoo Zurich

26 Managingrisk in industrial collaboration projects

30 Afresheyeonsupply A new lean logistics concept for Bosch

34 Anautomaticpositioningsystem for mass production

38 Clevercladding Rear ventilated suspended cladding

42 UNI-ALLOY™ Thread forming screws for non-ferrous metals

44 Innovativeseatingstructures Components for seat adjustments from SFS intec

46 Improvedcorrosionprotection for truck frame rivets

48 IntelligentLEDtechnologylightsthewayforward Plastic frames for efficient lightning

Dearreader,

SFS is the international specialist in cold forming, fastener solutions and assemblies. We offer our customers not just products, but complete system solutions. We support our clients with fundamental development work from the very first innovative concept – as in the Frame project.

We address individual needs and desires, like producing specially coated hollow rivets which combine function-ality and aesthetics for Daimler AG;. The precision of our production enables us to manufacture parts with extreme tolerances; while in products like the Valeo steering angle sensor we marry different technologies as required.

When it comes to quality, our products really do set new standards. In the Elephant House at Zoo Zurich, for instance, they ensure long-lasting security! Our package is rounded off with logistics support: we can even supply the exact quantity of parts required on a "ship-to-line" Jens Breu, COO SFS Group AG

22 Strong fixings for a strong roof

programme for you to install without further checks and tests – as we do for Bosch. With SFS, you have a one-stop-shop partner offering comprehensive solutions.

I am sure you will enjoy reading about these and many other stimulating examples of SFS in Practice.

Yours truly,

20 Staying on track

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Location: Wembley,CanadaProject: MuseumPlan: NewbuildProducts:WBthreadedrods

The dinosaur park in Alberta, Canada is a UNESCO World Heritage Site. An archaeological museum is being created directly next to one of the many locations where fossils were discovered. Within the spectacular building are housed research facili-ties and training rooms, alongside the exhibition halls themselves. The whole complex takes the form of a giant dinosaur and is named after the renowned palaeontologist Philip J. Currie.

Energy efficiency and sustainability were forefront when the building was designed. Given the massive temperature differentials in Alberta, these issues represent a major challenge. The build features a complicated roof design and leaning, free-standing timber columns. The connections where the columns were adjoined were made up of multiple bonded layers of plywood cut to the required shape.

The jointed ply needed reinforcements to inhibit cracking or, worse still, split-ting. WB threaded rods from SFS intec were the answer. They offer a very high tensile strength and have been specially developed for applications involving complex or contorted timber sections. As they are completely recessed, they provide reinforce-ment without detracting from the aesthetic appeal.

PhilipJ.CurrieDinosaurMuseum

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Location: Basel,SwitzerlandProject: AdministrationbuildingPlan: RenovationProduct: CardaFlex®

KunstamBau

The Swiss artist Pipilotti Rist is internationally renowned for her video installations. For her latest project instead of video she chose sunlight and synthetic lighting, both illumi-nating a colourful wall hanging created from transparent globes. The projec-tion of the light results in a cathedral-like effect.

The work is located in the five-storey stairwell of the Nationale Suisse insur-ance company in Basel. The 24'500

individual polymer balls are attached to 18 m long carrier cords,

whereby each ball has to maintain a precise separation from its neighbours.

This was achieved using CardaFlex®-Technology. This system enables contin-

uous over-moulding of any repetitive geometric shape along a carrier line:

in this case, spheres along a steel cord. SFS intec

produced the cords with incredible precision to enable the installation to reveal its full effect.

n This imposing piece of art is supported by steel cords produced by CardaFlex® technology.

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Location: Istanbul,TurkeyProject: Shoppingcentreand residentialcomplexPlan: NewbuildProduct: W-Tec3D+hinges

Koru-Florya

A modern building complex has recently been completed in the vibrant Florya neighbourhood of Istanbul. It contains 298 luxuri-ously appointed apartments and an up-market shopping centre. In addition to the numerous shops themselves, there are various restaurants and leisure facilities.

A high quality, adjustable hinge system was called for to be in keeping with the luxurious style of the complex. It was required to be concealed when fitted, in keeping with the aesthetic demands. A lot of value was also placed on a reliable, experienced supplier.

The project management decided to collaborate with SFS intec. In addition to the highly compe-tent technical support, the load-bearing strength of the W-Tec 3D+ hinge was of particular importance. It meant that it was possible to reduce the number of hinges from three to two units for each door.

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Location: Manchester,EnglandProject: HotelPlan: NewbuildProducts:fasteningsystems isoweld®andTIA

InnsideHotelManchesterFirstStreet

The new First Street development in Manchester has rapidly developed into a most attractive area of the city. Home to numerous cultural attrac-tions, shopping opportunities and leisure facilities, at its centre is the new four-star Innside Hotel with its spectacular architecture. The eleven floor building contains 208 rooms, restaurants, bars, conference spaces and a large fitness suite.

The six roof levels of the building complex are constructed from concrete panels at heights reaching up to 39 m above street level and hence subject to considerable wind forces. The roof with its sloping insulation requires different fastener lengths for each insulation thickness; an archi-tecture which places considerable demands on fastening system and installer alike.

The nominated installer, Lakesmere, chose the isoweld ® induction system in conjunction with the TIA fastener solution. Using isoweld ® minimised the number of fixing points, making for significantly faster installation. What's more, thanks to the TIA's height adjustment flexibility, just three fastener-sleeve combinations were sufficient over the entire project. Using isoweld ® and TIA in combination enabled really rapid, uncomplicated installation.

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60mm

Rapid,reliablewindowinstallation

"SMART-BITE"–thescrewswitharealbiteThe tried-and-trusted WT-T fastening system enables economical and lasting connections in timber engi-neering: generally fixing main supports to secondary ones. The latest advance has been the crea-

tion of an innovative drive-tip for these fasteners.

The revolutionary design of the drive-tip means the screws literally bite into the timber. Insertion under 90° is thus rapid and effortless. Fast insertion is particularly improved at angles below 45°, while splitting of the timber is almost eliminated.

The low insertion torque of the new tip makes it a joy to use. Assembly work with the new generation WT-T fastener is quite simply faster, more exact and much more ergonomic.

insteadof

n The JB-D®/L system consists of a powerful double-act: the base plate (upper image) and the bracket (lower image).

Windows are often installed at the outer edges of the reveal. This means they are exposed to stresses from daily use, wind and temperature variations. Direct fixing at the front of the reveal, often with under 60 mm of space between the window and the edge of the masonry, leads to the danger of damage to the walling. This in turn impairs the seal, leading to heat loss and water ingress.

The JB-D®/L is an innovative solution developed by SFS intec for secure installation close to masonry edges. The actual fixing takes place outside of the 60 mm danger zone, with the fully-tested system allowing safe force transfer into the wall structure.

JB-D®/L is suitable for various window and walling materials. With its use of high performance plastics, it is also resistant to heat bridging. The new system even allows rapid, reliable installation of windows extending beyond the masonry edge.

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Anabsolutemulti-talent:thenewgenerationPolyGrip®

AsfastaslightningBlind rivet guns driven by compressed air have always set the standard for operating speeds; whereby the neces-sary engineering infrastructure is, of course, rather expensive. The pipeline connection also limits the freedom of movement of the operator. Cordless, battery-operated machines have never represented a suitable alternative because of their considerably slower operating speeds.

Now the new cordless GESIPA® AccuBird® Pro can achieve setting

speeds equivalent to compressed air units. It offers a real alternative to compressed air rivet setting equipment; particularly in indus-trial applications. With an inser-tion frequency of up to four times higher, the GESIPA® AccuBird® Pro is much faster than normal cord-less systems on the market. In short, it combines the advantages of speed, reliability and maximum flexibility of the two technologies – cordless and compressed air in a single machine.

Blind rivet nuts and blind rivet threaded bolts are mechanical fasteners. They essentially serve the same function as conventional nuts and bolts, with one impor-tant difference – fixing is from just one side. Another plus point is their usability in different material strengths, thicknesses and even in non-weldable materials.

Their pronounced collar width gives blind rivet nuts a particularly high tear-out resistance. They demonstrate their real potential in thin wall connections, where uses can range from vehicle bodywork to threading in profile sections; though the trade uses them in numerous other spheres, because blind rivet nuts offer so many ideal solutions to awkward problems.

The secret is a brushless, effectively wear-free motor offering a massive 10 kN setting force, coupled with the auto-stop, auto-reverse func-tion. The intelligent control system is able to detect the pin being severed and automatically stop the setting procedure, returning the drive to the starting position.

The GESIPA® PolyGrip® is one of the most purchased multi-application blind rivet nuts on the market. It has been well established for a number of years, having proven itself in many demanding situations. Now GESIPA® blind rivet specialists have launched their latest development: the new generation PolyGrip®. Currently available in steel at M6 and M8, the PolyGrip® combines the ability to cover wide clamping ranges and broad bore tolerances.

The new blind rivet nut has a longitu-dinal knurl to increase turning resist-ance. This ensures uniform setting behaviour across the entire clamping range. Meanwhile a pronounced head width always covers the bore. In an ideal case, this multi-faceted new rivet

n The GESIPA® FireFox used with the multi-purpose PolyGrip® blind rivet nut enables a simplified and thus more capable production process.

can replace five existing DIN standard sizes, saving massively on storage costs and eliminating the risk of using the wrong component.

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UnderlockandkeyComponents for the aircraft industry must withstand extreme conditions. A long working life, terrible weather conditions and temperature differ-entials of up to 140 degrees Celsius make very exacting demands on design and functionality. They have to be able to withstand all the forces and vibrations exerted on them over the considerable working life of an aircraft.

There are particular requirements placed on the locking mechanisms of service hatches and engine bay panels. Built into the tail end of the plane, they have a direct influence on the plane’s aerodynamics. This means they have to sit flush with the outer skin. The industry jargon refers to such closures as "pin latches".

SFS intec has developed such a closure, meeting all the specifica-tions required. It is used, among others, on the airbus A330, built into the service bay cover of the auxiliary drive. This so-called auxiliary power unit or APU provides a plane with energy and compressed air when it is on the ground, without the main engines having to be switched on. The closures are ideally suited to mainte-nance work as they can be released by hand without a tool.

IncreasedsafetyforflatroofingFlat roofs are frequently subject to nature's moods. As well as heat and cold, wetness and dry spells, wind is the enemy of flat roofing. SFS intec supplies installers with top quality products for fixing flat roofing systems. The package is rounded off with comprehensive advice from installation experts.

SFS intec has been using its own in-house wind tunnel for exhaus-tive testing for over thirty years. It was replaced in 2014 by a new test rig designed by SFS intec. With many unique features, it is one of the most modern of its kind in the world. The wind test rig is set up to measure exactly which wind force the roofing can sustain.

The information gleaned from the numerous tests is fed into the wind stress calculation software. This determines the number and location of fixing points on the flat roof. The calculations are individually elaborated for each country according to the specific local building regulations. Customers receive a list of critical data and a roof layout plan.

The precision wind load test rig, combined with state-of-the-art soft-ware, is the perfect support package for carrying out flat roofing work.

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TrimminginstyleThehealthcareandlifestylemarketplacesgreatdemandsonmanufacturers.Inadditiontoqualityandeconomicconsiderations,hygienemustbeguar-anteed.That'swhysomanymanufacturersplacetheirtrustintheknow-howofSFSintec.Throughclosecollaboration,productsemergewhichcan,forexample,enhancetheflexibilityofthedailyshave.

The healthcare and lifestyle market covers products used in daily grooming, like razors, depilators and hair trimmers. Considerable demands are made on these products in terms of design, durability and function. These requirements represent a major challenge to the manufacturers. They must, moreover, find components which are economical.

Taxingrequirements

Products in the healthcare and life-style segments are mostly used in bathrooms, where there is inevitably an increased level of atmospheric moisture. This means that compo-nents for these products have to have high-level corrosion protection. With

the added danger of water splashes, additional surface sealing such as spedseal ® is essential.

Razors are in direct contact with the human skin, leading to further demands in terms of hygiene. Components used must therefore exhibit extreme clean-liness. Manufacturing components which fulfil all the requirements calls for a high degree of know-how.

Yearsspentdevelopingourknow-how

For over twenty years, SFS intec has been supplying numerous renowned manufacturers of healthcare and lifestyle sector products. Dedicated specialists develop each component

Sascha Willi, Division Industrial, sascha.willi@sfs.biz

according to the application-specific requirements. On this basis, particular materials (plastics metals etc.), surface treatments and secondary operations are specified.

For the customers, the benefits derive from broadly-based experience in these areas. They receive optimum quality components at the best possible price. SFS intec also makes a decisive contribution to the develop-ment, enabling manufacturers to turn their ideas into reality.

Additionalfunctions

A manufacturer of electric razors wanted to enhance their product with a hair trimming attachment. The core element was an eccentric bolt. It would convey the turning motion of the motor to the hair trimming attachment. SFS intec produced this demanding component economically, meeting the high quality requirements.

A solution was arrived at jointly, whereby the eccentric bolt could be

produced ready-to-fit without the need for secondary operations. The proposal from SFS intec was to use cold forming. The process offers enor-mous economies of scale and material savings, notwithstanding the complex geometry of the miniature part.

Worldwideprojectco-ordination

Another challenge in the healthcare and lifestyle sector is global project co-ordination. While development

generally takes place in Europe, manufacture these days is normally in Asia. Total engineering support from SFS intec, coupled with a global presence, is the basis for successful product development and manufacture.

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StayingontrackTheValeoGroupisoneofthelargestautomotivesuppliersintheworld.ThecompanyworkscloselywithSFSinteconarangeofapplications.Currentlytwoco-developmentprojectsareinprogressonsteeringanglesensors.Technologycombinationsofdeepdrawnpartsandplasticinjectionmouldingsarebeingdeveloped.

Requirements for safety and comfort in vehicles are continuously increasing. ABS, ASR and ESP are examples of vehicle preventative safety systems. Meanwhile, the driver is supported by applications like the adaptive headlights and adaptive chassis control which help improve comfort.

Hugeamountsofdata

These systems rely on a series of elementary data feeds. These have to be evaluated to subsequently influence driving behaviour. Elec-tromechanical steering contains a turning angle sensor which continu-ously furnishes data on the driver’s steering activity.

The engine management system receives further data from a tachom-eter and pressure sensor, from which it generates vital results. These are used by various driver assist func-tions to avoid critical driving situations and impede accidents. The sensor-supplied data also supports active parking assist.

Deepdrawnandpolymerpartsincombination

The components supplied for the steering angle sensor include a deep drawn bushing, over-moulded in plastic. It serves as a fastening element on the steering column. The bushing diameter is designed to provide a snug press fit, so that it

Matthias Germann, Division Automotive, matthias.germann@sfs.biz

cannot tilt, while an additional coining operation fixes the sensor in position.

The thin-walled cup and complex gear form on the polymer part demand high levels of production precision. A deci-sive role is played by the close collabo-ration between the plastic moulding and deep drawing specialists at SFS intec. Overarching technological know-how is what enables incredibly tight tolerances to be held and burr-formation to be avoided during the injection moulding step.

Aone-stopshop

The components are delivered directly to the customer’s produc-tion line in multi-use blister packs.

There they are turned into complete sensors. Valeo then supplies them to nearly every major steering system supplier; whereby the different systems are matched exactly to customer requirements.

For such technologically demanding products, Valeo needs a multi-disciplined partner. SFS intec offers a genuine one-stop shop: tooling, process and manufacturing develop-ment, the production of the deep drawn bushings and their over-moulding. The customer has one point of contact for all issues and any problems associated with multiple interfaces are eliminated.

n Bottom: the deep drawn metal bushing; Top: the plastic over-moulded finished component

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Strongfixingsforastrongroof

Nils Horn, Division Construction, nils.horn@sfs.biz

Anewelephantpark,"KaengKrachan",wasopenedinJune2014attheZooZurich.Theelephanthouseitselfhasaroofshapedlikeanorganicallyformedshallowwoodenshellwithapiercedstructurethatisalmostlikeamesh.Theskylightscreatedfilterthesunlightlikeaforestcanopy.TheambitiousdesignwasmadepossiblethankstofastenertechnologyfromSFSintec.

Extendinganalreadyspectac-ularexhibit

2008 saw the start of planning for a new elephant enclosure. Architects were invited to tender a design in keeping with the extraordinary buildings already in existence in the park.

The contract was awarded to Markus Schietsch und Lorenz Eugster, who had the idea of re-creating the natural environment of the elephants in Thailand. The centrepiece of the concept was the elephant house, featuring a spectacular dome. This represented a leafy canopy, perfectly blended into the surrounding landscape and vegetation.

ThepowerofSFSfastenersprovenintests

Due to its linear, elastic design, the support structure required fasteners not generally available at that time of 850 mm in length, as well as corro-sion proofing. The planners decided to use the WR-T system from SFS intec.

A total of 15'000 fully threaded rods of the type WR-T-13×850 were used. To meet corrosion-proofing require-ments, these were treated with a specially developed coating from SFS called Durocoat®. The effectiveness of this treatment was confirmed by independent salt spray tests carried out by the EMPA Institute in Düben-dorf, Switzerland.

Alivinglight-showfortheelephants

The 6'800 square metre free-form timber roof spanned the 5'400 square metre enclosure like a massive net. 271 sky lights were created featuring UV-translucent air-cushion membranes. This creates a lot of natural light in the house, which rises in places to 18 metres. The resulting space is a living light-show of shadows and sunlight.

The differently-shaped windows of up to 40 square metres in size were not placed at random, but rather in line with static calculations. The perforated shallow shell did, however, need a reliable light-weight support structure, to which end a nailed and screwed assembly was developed.

Zoo Zurich is well known for its spectacular animal houses. It was back in 2004 when the Masoala Pavilion, based on the Madagascan rain forest of the same name, was opened. Within its walls across an area measuring 11'000 square metres over 17'000 plants and trees and 430 animals can be viewed. This makes the exhibit not only the largest in Switzerland, but unique inter-nationally. The planned elephant enclosure was to achieve the same impressive standard.

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The WR-T fasteners used in this project were fully approved to ensure their suitability. Numerous tests were carried out to prove out the rigidity of the overall system, using a 1:1 mock-up of a partial roof structure. This allowed the interplay among all the components to be examined. The results gained helped the planners to optimise the installation procedure.

ThecompletepackagefromSFShelpstoachievetheobjectives

As well as the core WR-T fasteners, SFS supplied other fastening systems for this project. There was also consid-erable project consultancy support. SFS specialists were frequently on site to help the installation team: a real

example of customer care that helped enormously in bringing this spectac-ular project to life.

n Wooden blocks for the cavity were also used to help insert the WR-T bolts. These were used to fix the entire cross-section.

What were the particular issues surrounding this project?

The precept was to develop an architectural concept creating a symbiotic merger of the natural and the built environment. The iconic timber roof dome was the atmos-pheric casing for the topography within the new elephant house, its aspect blending perfectly with the park-like outside area.

Alongside specific demands in terms of building a home for the elephants, the issue was enabling the public to view the animals in an environment resembling their natural habitat, with the enclo-sure forming a part of the visitors’ encounter with nature.

What was the inspiration for the project?

During the design phase we looked at numerous structures for inspira-tion in creating a back-to-nature construction. It was not just a case of transposing natural elements into a man-made structure, but rather deriving an architectural language evoking nature in the mind of the visitor.

The atmospheric effect of the inte-rior was the key concept for us: the sunlight filtering through the complex mesh-like roof structure which almost emulates a forest canopy, creating an ever-changing interplay of dynamic contrasts between sunbeams and shadows.

Which product or material contrib-uted to the success of the final construction?

We conceived the "wooden shell" roof construction at the bidding stage. The free-form 80 metre high dome was created from three layers of three-ply timber sheets, which were formed on site using an arched mould framework and nailed together. The numerous irregular openings were cut out later.

AninterviewwithMarkusSchietschGraduateArchitectETH(ZurichUniversityofTechnology)SIA(SwissArchitects’Association)

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Managingriskinindustrialcollaborationprojects

Themarketcallsfortheefficientmanufactureofchallengingproducts.Thisisincreasinglyleadingto"divisionoflabour"inindustrialmassproduction,withtheplayersadoptingtightlyinterwovenroles.Processimprovementsandcomprehensivequalitymanagementsystemshaveledtomarkedreductionsinfailureratesoverthepastyears.Eventoday,however,faultsandfaultyproductscannotbecompletelyeliminated.WespoketoFrançoisLongpré,ClientandDistributionLeaderattheXLGroupinSwitzerland,abouttheriskssurroundingproductandmaterialdefectliabilityforindustrialmanufacturingcompanies.

Mr Longpré, as Client and Distribu-tion Leader of the XL Group you are in close touch with industry. In your opinion, is there sufficient understanding of risk and active risk management?

I can definitely say that companies have been developing an increased risk awareness in recent times. Particularly those companies oper-ating on the international stage have begun to recognise the value of active risk management.

What do you think that's down to?

On the one side we can clearly see how the topic has begun to be integrated into further education programmes, with particularly broad coverage in formal academic courses. And on the other side competition is continuously increasing thanks to globalisation. Industrialists can do themselves a big favour in minimising expensive breakdowns in plant. You

can also observe how a corporate structure involving proactive risk management itself brings behavioural changes among personnel.

How do the parties involved find common ground when it comes to incidences of loss and damage and what does the XL group offer?

When it comes to insurance, claims really separate the wheat from the chaff. At XL we are well known for settling genuine damage claims rapidly and fairly. Our 400 loss adjusters around the world take all the immediate decisions at the scene, often managing discussions on behalf of our insured client and generally settling out of court thanks to our extensive experience.

How does the law operate in interna-tional situations and what relevance do terms and conditions of business have as against national jurisdiction?

A clear trend is apparent: the legal framework operating internationally is becoming increasingly complex. Our customers are much more internation-ally diverse than even ten years ago. At the same time, compliance require-ments are increasingly stringent and more complex. National laws always override company terms and conditions and here the insurer plays a key role. The XL Group operates seamlessly across 140 countries, either with their own branch offices, subsidiaries or with network partners. A single point of contact keeps things as straightfor-ward as possible for the customer. This adviser is the one contact for every issue and is responsible for service quality. That’s how we try to progress our customers’ business smoothly.

We keep hearing in the media about recall and exchange actions. Who bears the cost?

It differs from case to case. The manufacturer generally bears their own

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XL GroupInsuranceReinsurance

costs, such as personnel required for the administration of the recall or the manufacturing costs associ-ated with replacements. If an insur-ance policy is in place, the insurer covers the recall costs or the costs of notifying known and unknown purchasers of the product or the costs levied by a third party on the manufacturer - say for physically replacing a particular component or system.

What can be insured and what are the recommendations?

In branches operating in industrial mass production - take for instance car makers - the key insurance is for claims against faulty prod-ucts. Here you can differentiate between claims for personal injury and material damage, as against so-called financial loss i.e. meas-urable, monetary damages not following from an insured party or property damage.

Personal injuries and damage to property are the main cover associated with product liability insurance. Pure wealth damage insurable via secondary policies can be divided up roughly as follows:

n the physical replacement costs of faulty or unsatisfactory products

n recall costs required by the authori-ties to avoid personal injuries or damage to property.

n denial of use due to products which suddenly and unexpectedly fail, perhaps because of breakage or explosion.

n purely financial losses from guar-antees where the damage associ-ated with the delivery of products is caused by some sudden event, which was neither intended nor predictable.

n Errors & Omissions insurance for products and services, e.g. broader consequential loss insurance.

The cover offered by such policies differs widely, and can be adopted for individual or multiple issues. Generally speaking the full amounts guaranteed in the policy are not available but rather a sub-limit. A higher excess may also be agreed or a higher risk premium. The decision to insure such potential financial losses has to be based on individual risk assessments. The decision is based not least on whether to pay a higher premium or bear the risk yourself.

What do you recommend for manufac-turers and buyers in industrial manu-facturing set-ups to protect them-selves against risk?

My experience tells me that the most important thing is a comprehensive quality management system. That means from goods inwards to the finished product. When products are further developed or modified, a parallel risk analysis is essential. Also a lot of manufacturers do not appre-

ciate that every new supplier brought on board brings new risks. It is vital to choose vendors carefully and monitor them – ideally via formal audits. I also recommend careful contract review. This is particularly the case with pure financial losses, which are generally contractually protected. And last but not least, purchasing made-to-measure insurance from a global player is highly recommended. That really is a sensible investment.

The XLGroup, headquartered in Dublin, is a company operating worldwide via daughter compa-nies and is a specialist for primary and re-insurance. It was founded in 1986 by 68 large American concerns from different branches who were dissatisfied with the insurance available at that time.

XL Group insurance companies are active in 140 countries. Their speciality is covering complex material and liability risks for global operators. The XL Group is listed on the New York Stock Exchange (NYSE: XL). Michael S. McGavick has been their CEO since 2008.

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AfresheyeonsupplyThetwoBoschplantsinBlai-chachandImmenstadthavedevelopedarevolutionarylogis-ticsconceptwithSFSintec.Referredtoas"ship-to-line",theprincipleinvolvesdirectsupplyofcomponentstotheassemblylineswithnobufferstocks.Bothprocessingstepsandstoragecostsareeliminated.

Sharingsuccess

Bosch and SFS intec – two big brands that stand for quality and innovation. The first cold formed components were jointly conceived and created back in the Seventies. There is a strong, long-standing bond between the two companies. Right from the start the development personnel were invariably involved in purchasing decisions.

As one of the largest suppliers to the automotive industry, for Bosch, cost (alongside quality and innovation), is a key concern. These are critical factors when it comes to achieving success in the highly-competitive automotive sector. The same focus is expected of their own suppliers.

Logicallogistics

An analysis of the existing logistics arrangements by experts from the two companies revealed a tremen-dous potential for optimisation. To date, all component deliveries were to a centralised consignment stocking facility. Some parts would then be transferred into Bosch transport cases for daily deliveries to the respective assembly plants.

This procedure was identified as no longer up-to-date: long routings and associated logistics support all took time and money. They also occasioned unnecessary transport and storage costs. It was clearly time to jointly develop a more efficient process to achieve a low-waste delivery concept.

Tobias Loher, Division Automotive, tobias.loher@sfs.biz "Ship-to-line"onthehorizon

The first objective was to rationalise the material flow. SFS intec would start delivering directly without a buffer stock. To enable rapid processing of parts on the production lines, the packaging arrangements also had to be standardised. In place of cardboard boxes with timber frame supports, in future standard KLT euro container boxes on transport trolleys would be deployed.

Once the ground rules were in place, the new logistics system had to be tested. To this end the six highest volume ABS components from SFS intec were chosen. These were being used in both plants.

Successfromstarttofinish

Within the first three months, experts from Bosch and SFS intec elaborated on the procedures. Then in March 2014 the system was good

to go. The first high runners were supplied using the new method, accompanied by daily telephone conferences to smooth out the fine details of the process.

The new system established itself as a complete success and in the meantime has already been extended to further components. The parts produced by SFS intec for Bosch are packed in KLT boxes on transport trol-leys before being stored in the Heer-brugg "supermarket". Daily deliveries to the two locations follow directly to the corresponding "supermarkets" at the plants, ready for use on the production lines.

Future-focusedsolution

The new "ship-to-line" concept increases productivity all along the supply chain. Non-value-added processes like goods inwards, buffer stocking and storage are eliminated. Rather, the components ordered are

collated by SFS intec and are then delivered directly to the user plant.

Rationalising the delivery concept has dramatically simplified internal procedures at both companies. This accelerates re-ordering of the required components, maximises transparency and significantly reduces costs.

n Components produced by SFS intec are packed into customer-specific KLT boxes. Subsequently these are stacked onto floor roller trolleys in the truck, which delivers the goods ordered directly to Bosch in Blaichach and Immenstadt.

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The Bosch Group is a leading technology and support services provider internationally. During 2014, some 290'000 employees generated a turnover of 48.9 billion euros. The company’s activities are split among four core businesses:

nMobility Solutions n Industrial Technology nConsumer Goods n Energy and Building Technology

The Bosch Group consists of Robert Bosch GmbH and its approximately 360 subsidiaries and regional offices across 50 countries. Including marketing partnerships, Bosch is active in around 150 different countries.

n At Bosch, the ready-to-fit parts are sent directly to the assembly lines. The entire process dramatically shortens the time lag between

Today’s close collaboration between Bosch and SFS intec began over forty years ago. The co-operation on ABS systems during the Nineties was an important milestone.

SFS intec specialists were able to convince Bosch to convert formerly turned parts into cold formed versions. This produced numerous advantages: alongside increased strength, cost savings were gener-ated by the redesign of the compo-nents for cold forming.

Today SFS intec supplies over one billion parts to Bosch annually. This includes cold formed compo-nents, plastic injection mould-ings, fastener systems and deep drawn parts.

AninterviewwithRupertHoellbacher,TechnicalPlantManager

Where did the "ship-to-line"-project originate?

At the end of 2012 we conducted a complete analysis of our plant supply logistics. During that review it became apparent that we had a very low quota of bought-in compo-nents delivered to our production lines by the shortest routes; which for us is "ship-to-line", as all unnec-essary and costly non-productive steps along the supply chain are eliminated

What advantages does the new delivery system offer?

We have shorter throughput times, since the parts are delivered directly from the supplier to our plants. Moreover, we save on using storage facilities and thus reduce stock-holding and costs across the supply chain; and this applies to both parties. We have also dramatically altered the packaging. The heavy timber frame pallets requiring material handling equipment have been replaced by manually manoeuvrable floor trolleys with standard stacking KLT's.

What extensions are planned for the future?

We couple the "ship-to-line" method to consumption monitoring. This proce-dure sees the request for restocking of a "ship-to-line" component issued automatically by our production.

Kanban cards transmit the required information electronically to SFS intec. The next stage will incorporate Radio Frequency Identification (RFID) into the system. This couples the informa-tion sources even more closely into the loop – company-wide, real-time data and fault-free, fully-automated information flows. That's the future!

Why did Bosch choose SFS intec as the most appropriate partner to launch this pilot project?

SFS intec has always been one of our largest suppliers in terms of the value of bought-in components over the years. Consistently-maintained quality is another factor in launching such a project and with SFS intec that is very much the case. Otherwise it would be impossible to launch "ship-to-line". The distance between Heerbrugg and Blaichach / lmmenstadt is also small enough to suggest that short interval,

direct supply would be technically feasible. So really, SFS intec was the natural choice as our partner in launching this pilot project.

How has the collaboration with SFS intec worked out?

Just excellently. The working party made up of employees from the two companies managed to achieve all the targets set. The procedure is running smoothly and is continuously matched to the way the business is developing. I would like to thank SFS intec most sincerely for their commitment to this project.

despatch and processing of components.

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AnautomaticpositioningsystemformassproductionFasteninglooselytoleranced,flatsheetcomponentsgenerallycallsformanualoperations.TheFraunhoferInstitutehasbeenresearchingwaysofautomatingsuchprocesses.Theirdevelopmentengineershavebeencarryingouttrialsusingthehighlyreliableauto-matedblindrivetgunsfromGESIPA®.

Automaticblindrivetingdespitewidetolerances

Automated blind riveting offers numerous advantages and is thus used in wide-ranging applications. It enables different materials to be joined quickly and securely without the application of heat. As access is only required from one side, the use of robots is simpli-fied. So all-in-all, the process offers an economical, high-quality alternative to other joining methods.

The tolerances on large pressings used in the manufacturing industry can be massive. That makes repeti-tive robot processing rather difficult. It means that riveting generally has to be carried out manually; whereby automation would be a big step in increasing efficiency.

Acameratokeepaneyeonthings

Researchers from the Fraunhofer Institute for Production Technology and

the holes. This is particularly advan-tageous for fitting large panels with wide tolerances.

Aninnovationprovesitsmettle–increasedmassproductionefficiencies

The researchers were looking for a rapid and reliable riveting tool for their experiments. They found this in the fully automated GESIPA® GAV 8000 riveting system. This enabled Fraun-hofer IPA to take advantage of a well-established, easy-to-use piece of kit. It can be readily integrated into fully automated production lines, achieving shorter stroke frequencies and increased productivity.

Rivet technologists supported the project with both equipment and know-how. The close collaboration played a big part in bringing the research project to fruition. The outcome has been a very promising solution for industrial mass production riveting.

Automation, recognising this deficiency and looking for a solution, set up a research project called "Lean Intel-ligent Assembly Automation" or LIAA. The primary objective is to develop a system where a camera can recognise holes automatically. Here they were able to bring extensive experience in image recognition to bear.

The first tests worked out very posi-tively, with hopes of a solution in real series production close at hand. The core element is a stereo camera with an integral light source able to reliably locate holes and transmit the location to a robot. This, in turn, precisely posi-tions the rivet such that it can be set with a high level of process capability.

The hole recognition system has no problems dealing with low light situ-ations, different materials or surface finish issues. A rapid image processing time of less than one second per position guarantees efficient riveting frequencies. The camera covers a wide area of many centimetres in detecting

Kay Brenning, Division Riveting, kay.brenning@gesipa.com

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The FraunhoferGesellschaft with its 23'000 employees is the largest applied research organisa-tion in Europe. It currently encom-passes 67 different institutes and research centres.

With its central mission of "research in practice", Fraunhofer focuses on innovation processes and the development of key technologies. It collaborates closely on these matters with commissioning agents from industry and the public sector. At the centre of research stands the needs of all mankind for health, security, communication, mobility, energy and the environment.

The FraunhoferInstituteforProductionTechnologyandAuto-mationIPA was established in 1959 and is one of the largest institutes within the Fraunhofer concern, employing 435 people.

The annual budget amounts to 58.4 million euros, of which 22.9 million derive from industrial projects. The department involved in this project – "Robotics and Assistance Systems" - designs innovative robotic and automation solutions for industrial applications and for the service sector.

n A stereo camera detects the hole contour (left). This information enables the exact positioning of the rivet to be ascertained (middle). The riveting is done by the fully automated GESIPA® GAV 8000 riveting system (bottom).

AstatementbyBerndWinkler,B.Eng.,FraunhoferInstituteforProductionTechnologyandAutomationIPA

"GESIPA® supported us in using an automatic riveter on the SME robotics project. The combina-tion of GESIPA® riveting expertise and Fraunhofer IPA's knowledge of image recognition proved very fruitful."

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Clevercladding

Apeekbehindthecurtain

A building's outward appearance is determined by the facade. It can offer innumerable design options for architects. And alongside aesthetics, it influences the climate and energy effi-ciency of the rooms within. The way it is fitted contributes massively to the useful life of the building beneath.

VHF systems are among the most durable facade systems. The decisive feature is the rear ventilation space between the outer structure and the insulation layer which enables air circu-lation, such that any moisture – be that from the interior of the building in the form of condensation, or from external sources such as rainwater – is fed away. So the system effectively

Oliver Bachmann, Division Construction, oliver.bachmann@sfs.biz

regenerates itself automatically. That's the reason that a useful life of fifty years and more can be achieved.

Asystemoperatingatthreelevels

Over recent times architects have been adopting VHF rear-ventilated facades ever more frequently. The construction can be broken down into three essential levels:

n The building itself is the basic support structure of the VHF facade to which the insulation layer and sub-structure is anchored. n The sub-structure forms the bridge between the building’s walling and the outer cladding, but it can be designed to eliminate thermal bridging. In this way it contributes decisively to the energy efficiency of the system. n The cladding protects the construc-tion from the weather and imparts character and individuality to the building.

Visuallyandeconomicallysuperior

VHF systems offer maximum design freedom, whether it’s a new build or a renovation project. There is a wide choice of materials available for building’s walling, sub-structures and the final cladding alike. Timber, aluminium and steel can all be used for the sub-structure, with plastic wall fixings used where thermal bridging is to be avoided. Outer clad-ding can be made from fibre-rein-forced cement and concrete panels, High Pressure Laminate (HPL), aluminium composite, timber clad-ding and ceramics.

Insulation thicknesses of up to 300 mm are currently available, contributing greatly to the energy rating of the building concerned. While winter heating costs fall, in summer the insulation serves to provide a cooler climate inside. The sound insulation offered by the clad-ding is a positive side-effect.

Qualityfittingsforqualityfacades

SFS intec offers a comprehensive range of economical, secure and lasting fixing solutions for each level of the suspended rear-ventilated facade. These range from power drill and thread forming fasteners in stainless steel to blind rivets made of aluminium and stainless steel, as well as the associated plugs and other accessories.

The broad spectrum of support is rounded off by expert advisers, comprehensive site services and the "Speed Paint Process", which enables the extremely rapid delivery of pre-painted fasteners. All of which means that SFS intec customers benefit from maximum efficiency and security during the entire project timeframe.

Suspended,rear-ventilatedfacades(VHF)arecharac-terisedbyintelligentdesignfeatures,withtheiruseachievingsignificantcostsavings.Aswellastremen-dousaestheticappeal,thesystemoffersanextendedservicelife;andthecomprehensivepackageavailablefromSFSintecplaysabigpart.

n A sample of the comprehensive range of products for VHF systems available from SFS intec

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Location: Essen,GermanyProject: StudenthostelPlan: RenovationProducts:SLApowertool fasteners

The Summer of 2015 will see the opening of a new student accom-modation centre on Tiegel Strasse, Essen, Germany. It is located just opposite the large "Audimax" lecture hall on the Essen campus in a green oasis. The building, constructed in 1958, used to contain the "Luther-haus", the community centre of the evangelical church, before being acquired by student services in 2009 to be initially used as a crèche.

The decision was made in 2013 to convert the building into accommoda-tion for students with children. A new home for thirty-six students will soon emerge, paying maximum regard to energy-saving construction tech-niques and conservation concerns.

By increasing the number of floors, the total area will be increased from 969 square metres to 2'170 square metres. This will enable the creation of 24 comfortable one-bedroom apart-ments, each of 25 square metres and a further six family-orientated flats of 51 square metres.

Due to the requirement for maximum energy efficiency, the architects decided on a suspended, rear-ventilated facade. The sub-structure consists of carrier profiles featuring fixed and moveable attachment points. The sub-structure was attached to the wall with SFS intec power tool fixings type SLA5. These consist of 1.4578 (A4) stainless steel, meeting the requirements of DIN 18516 building regulations.

Location: Niedernberg,GermanyProject: LogisticscentrePlan: NewbuildProducts:BULB-TITE®blindrivets

There is a new distribution centre owned by the Gries Deco Company in Niedernberg, Germany. It consists of a logistics centre, an administration building for 400 employees and an indoor car park. From afar, the building looks as if it has been assembled from crates stacked high: quite intentional, as an allusion to the purpose of the building.

This effect has been achieved by a complex design featuring a rear-ventilated facade. Reflective white and grey-tone surfaces alternate across its surface. Based on the differing sizes of the individual cover panels, the architects chose the variable FC facade system from Kalzip, attached directly to Fischer sandwich panels.

Static load calculations suggested the use of high tensile fasteners, with the choice falling to GESIPA® BULB-TITE® blind rivets, type RV6604. These are characterised by their extraordinary grip and extreme weather resistance, guaranteeing secure connection of the sandwich panels and FC facade.

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Unisteel®haslaunchedaspecialthreadformingscrewontothemarketwiththebrandname"UNI-ALLOY™".Ithasbeenspeciallydevelopedforuseinaluminiumandzincalloys.

Anewthreadprofileenhancesthefastener’ssecurity

The new fastener family features a symmetrical thread profile, enabling an ideal female thread to be produced. There is no danger of deformation to the fastener.

Thanks to the wide gap between the insertion threading torque and the over-torque moment, there is a wide safety margin when it comes to assembly. This increases

the process security in numerous assembly situations; in turn leading to productivity increases.

Morepartsforlessmoney

Direct thread forming using UNI-ALLOY™ offers the customer numerous advantages. In conventional assembly, the preceding process is cutting the thread. This often leads to concerns surrounding tolerances and other quality issues when the

fasteners do not fit the threads, resulting in thread re-working.

These processes are eliminated by using UNI-ALLOY™. This fastener forms its own thread and thus invariably sits snugly and securely. That provides weight and cost reductions. By inserting UNI-ALLOY™ directly into cast or machined holes, savings of up to 40% can be generated; at the same time creating a more robust fixing.

Threadformingscrewsfornon-ferrousmetals

George Poh, Division Electronics, george_poh@unisteeltech.com

Idealforrobustapplicationslikecameras

A good example is the battery compartment cover of a camera. The cover has two drilled holes and is made of series 6'000 aluminium alloy. Conventional assembly with thread tapping was not an ideal solu-tion due to the small size and overall cost constraints.

Unisteel® specialists thus recom-mended the use of the new UNI-

ALLOY™ family of fasteners. With their thread forming feature, they were ideal for direct inser-tion into the aluminium cover. This meant considerable assembly cost savings, while the integrity and security of the connection was guaranteed.

UNI-ALLOY™ thread forming screws are pushing back the barriers. They enable exotic alloys to be used, offering attractive, robust and light-weight products.

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Innovativeseatingstructures

Roland Deisböck, Division Automotive, roland.deisboeck@sfs.biz

Oneplatform=numerousmodels:thishasbeenthemuch-sought-afterequationforreducingdevelopmentandmanufacturingcostsamongseatandOEMvehiclemanufacturersforyears.Thetrendwillcontinueintothefuture;seatadjustmentsareaclearexample.

Auniformplatformstrategy

One of the leading producers of mechatronic systems for vehicle doors, trunk / boot lids and seating structures is Brose of Coburg, Germany. They supply around eighty different vehicle builders and a further thirty first-tier system suppliers. Adapting to the individual require-ments of so many manufacturers has resulted in a multiplicity of different seating systems; for instance, each model requires another base console

with different motors, gears and auxil-iary components.

In order to achieve a leaner product range, Brose embarked on devel-oping a platform strategy. The key aim was to achieve a uniform seat structure, universally suitable for wide-ranging makes and models. Engineering design and production costs would also be reduced by using the maximum possible number of common parts.

Aninnovationseminartotargetsolutions

An innovation seminar was arranged in the Coburg HQ in the Spring of 2013. At this event Brose presented the concept backdrop and the require-ments of the individual components to a select range of vendors. Simul-taneously, a considerable cost-reduction was targeted. The invited companies were to submit quota-tions and proposals towards reaching these aims.

When the first strength tests at Brose produced disappointing results, SFS intec specialists in collaboration with the customer took a long hard look at the overall application. This revealed optimisation potential in the overall design. The cold formed component originally quoted was to have been coupled to sintered and fine blanked parts. SFS intec engineers suggested merging these components from different manu-facturing technologies into a single new design.

Sharingfuturesuccess

The cold formed component finally achieved offers an impressive geom-etry. It both guarantees the required strength characteristics and offers economic advantages. SFS intec invested in a special purpose machine for the limited secondary operations required on the part.

This project enabled Brose and SFS intec to demonstrate their readi-ness to think outside the box and push

back the limits. The jointly developed components form part of a platform planned to run for twelve years. It will be used at numerous vehicle manu-facturers. Meanwhile, Brose has been able to implement further projects.

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ImprovedcorrosionprotectionfortruckframerivetsDaimlerandtherivetspecialistW+O–acompanybelongingtotheGESIPA®Group-havejointlydevel-opedanewcoatingtechniquecalledSheraBlack®.Itischaracterisedbyitsexcellentcorrosionprotec-tion,negligibleenvironmentalimpactandveryattractivefinish.

Christoph Dumpe, Division Riveting, christoph.dumpe@wo-niettechnik.com

process. This technology exhibits tremendous corrosion resistance, is economical and environmen-tally friendly. It also eliminates hydrogen embrittlement.

Successfulseriesstart-up

The aim now was to add an aesthetic sealing coat to further improve the finish. To prove out the quality, the rivets were checked in both the raw and assembled conditions. In both

Extensivequalitytests

Requirements for corrosion protection are continuously on the increase. Against this backdrop, Daimler and W+O initiated a development project back in 2008. The aim was a marked improvement in the corrosion resistance of truck body frame assembly rivets. The new system would also have to meet requirements for paint-ability and be environmentally friendly.

Previously, W+O had been sherardising the rivets, which is a thermal diffusion

cases they had to stand up to salt spray and Kesternich tests. There were also numerous field trials on vehicles in actual use.

Since 2013, the SheraBlack® corrosion protection treatment has been used on all series production commercial vehicle box frame rivets. Its deep black colour is easy on the eye and can be used without further paint coating. SheraBlack® is an economical solution for demanding corrosion proofing requirements.

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Functionsandfeatures

LED technology offers numerous advantages over conventional lighting techniques. In addition to much improved brightness, these modern lighting solutions actu-ally use much less energy. The world’s largest manufacturers are thus continuously working on new products. An innovative plastic framework for use in LED lights has been developed in close collabora-tion with SFS intec.

Despite its tiny weight of just 0.004 g, the plastic frame encircles multiple LED lights. It thus has to exhibit a very sharp edge. There are additional stringent requirements on flatness, cleanliness and tolerances.

Closecollaborationpromotesinnovation

For this latest generation, the developers were looking for an optimum cost alternative. Working together with SFS intec they opted for plastic injection moulding tech-nology. This was also intended for use on future projects, generating savings again and again.

A stand-alone process needed to be developed for the manu-facture of this new part. Multiple prototype steps were required. SFS intec was able to impart their expertise in the injection moulding of finely structured components and automatic handling techniques.

IntelligentLEDtechnologylightsthewayforwardWhenitcomestocomponentsforLEDlighting,numerousmanufacturerstrustintheknow-howofSFSintec.Anew,highlypreciseminiatureframehasbeendevelopedforthelatestrangeoflightemittingdiodes,usingplasticinjectionmouldingtechnology.Theparthastomeetverydemandingrequirementsintermsofdimensionaltolerances,flatnessandclean-liness.Thislatestdevelopmentisalsogeneratingconsiderablecostsavings.

Sascha Willi, Division Industrial, sascha.willi@sfs.biz

3 mm

n The tiny plastic frame weighs just 0.004 g and meets very demanding requirements in terms of dimensional tolerances, flatness and cleanliness.

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Imprint

PublisherSFS Group

EditorialteamStaff of the SFS Group

ChiefeditorArthur Lenart, arthur.lenart@sfs.bizTel. +41 71 727 50 38

FrequencyofpublicationAnnual

PrintingVVA GmbH, St. Gallen CH

CoverVisionstudios, Balgach CH

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Fullyautomatedequipment

To meet the exacting standards which had been set, a fully auto-mated system was developed and set up. After ejection from the precision moulding tool, a robotic arm transfers the parts to another cell, where the runner system is removed using a laser.

Multiple camera systems monitor a range of defined attributes such as freedom from burrs around both the internal and external geometry. The parts are then finally packed in specially-designed carrier magazines. The entire manufacturing process is conducted under clean room equivalent conditions.

n SFS intec has developed a special transport tray for the delivery of the tiny plastic frames.

Thefollowingimagesarecourtesyof:

Page 6 Pipilotti Rist und Hauser & WirthPage 17 Airbus S.A.S.Page 18 Philips Consumer Lifestyle GmbHPage 22+23 Zoo ZürichPage 38 Rieder Faserbeton-Elemente GmbHPage 44+45 Bayerische Motoren Werke AGPage 46+47 Daimler AGPage 48–50 Osram GmbH

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