InPractice - SFS

29
No. 28/2016 InPractice

Transcript of InPractice - SFS

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No. 28/2016

InPractice

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Dear reader,

SFS is an international vendor of precision custom com-ponents, fastening solutions and complete assemblies, operating our own production plants in the most important centres of the world’s economy. By way of example, you can read about how we supply critical valve control com-ponents for the American market, produced at our Medina site, in the article "High Lift Follower."

Another strength of SFS lies in our involvement with our customers from the design phase, establishing the most economically viable manufacturing route for their products at the outset. In the article on actuator contacts you can get a feel for how we produce ready-to-fit, ultra-clean hybrid components for automatic gear boxes for our customer Bosch.

Logistics systems represent another vital element in our armoury, radically reducing the cost of supply and Josef Zünd, Head of Distribution & Logistics

strengthening the competitive edge of our customers. In the article "Industry 4.0" we describe the various applica-tions we offer under the designation "M2M by SFS". We also present a real-life solution provided to our customer Stadler Rail in Minsk. The customer benefit results from the fact that both components and information flows operate in complete unison, reducing the cost of supply and guaranteeing availability.

So here’s wishing you an invigorating and thought-provok-ing read about our many practice-based applications from real life!

Contents

38 Clear cut 50 The heart of the matter

04 Reference projects Achieved through close co-operation with SFS

12 Product presentations New ideas from the SFS Group

18 A modular approach Rivets for Schneider Electric

20 Good contacts count High precision hybrid parts for Bosch

22 Football fever across Europe Football grounds with fastening technology by SFS

26 Interview Dr. Helmut Binder

30 Logistics solutions for Industry 4.0

34 Valve clearance Saving fuel thanks to complex assemblies by SFS

38 Clear cut Efficient supply of Sandvik

42 "Turn ideas into reality." Customers’ visions come true

46 A clean drive Technical cleanliness components for hard disk drives

48 Carefree parking Optimising design and production

50 The heart of the matter Multifunctional fastener by SFS intec

52 Value analysis opening up new markets Complex geometry realising captive fastening solution

Editorial

22 Football fever across Europe20 Good contacts count

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Location: Berlin, GermanyProject: Apartment houses Plan: New buildProducts: JB-D®/ L window installation system

Eleven exclusive townhouses known as "Flottwell Living" have been built close to the Potsdamer Platz in Berlin. The residential quarter, completed during the Summer of 2015, now represents one of the capital’s go-to locations. The apartments are equipped to a high spec, in tune with the upmarket nature of the overall development.

The buildings are also extremely energy efficient, racking up just 70 % of the energy use allowed in a conventional new build. One contributory factor is the classical facade with flush-fitted windows. In order to offer maximum heat insula-tion they are mostly triple glazed and correspondingly heavy.

Fitting over 5’000 heavy-weight, flush windows was a major chal-lenge. To achieve the minimum fastener depth requirements, the developers chose the innovative JB-D®/ L system enabling simple,

efficient installation of the windows into the reveals in line with all prevailing building regulations.

Flottwell Living

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Location: Bergen, NorwegenObject: Multi-storey buildingPlan: New buildProduct: Wood drilling screws WT-T and WR-T

Treet in Bergen

Back in 2005, the architect Geir Bakke had the idea of building a high-rise in timber. Certainly the material offers a much more advantageous carbon footprint than conventional materials like concrete and steel. In 2015 this vision became a reality, with the 45 metre-high structure in Bergen representing the tallest timber structure in the world.

The height of the structure does, however, impose huge demands on the timber structure. The geographi-cal location was another concern – Bergen is within an earthquake zone and in one of the wettest parts of Europe. In coming to terms with the prevailing conditions, the construc-tion engineers took their inspiration for the static structure from bridge building concepts.

Two well-known companies within the Scandinavian timber industry, Sweco and Moelven, rose to the challenge. They chose SFS intec products for the demanding fasten-ing requirements, using type WT-T and fully-threaded WR-T fasteners to couple the plywood panels. This resulted in a really efficient and secure assembly process.

n WT-T (upper) and WR-T (lower)

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Location: Mallorca, SpainObject: Hotel complexPlan: New buildProducts: W-Tec 3D+ door hinges

Park Hyatt Mallorca

The American hotel chain Hyatt opened its first hotel on the island of Mallorca in the Spring of 2016. It features more than 142 guest rooms and numerous public areas. In point of fact, the luxurious complex is also the very first Park Hyatt Resort in Europe. It owes its style to a traditional Mallorquin hilltop village and draws for inspiration on local art and culture.

Because of the design specification, particular requirements were placed on the doors. They had to be of a certain special colour shade, blending seam-lessly into the overall design concept of the hotel. The large doors placed huge demands on the support strength of the hinge system. There was also the need to offer a high degree of fire protection.

In the light of these requirements, ACM, the company entrusted with the joinery work, chose the SFS intec W-Tec 3D+ hinge. With its attractive

finish and thought-through construction, it fulfilled both the structural and the aes-thetic stipulations of the architects. What’s more SFS intec was able to meet the very short lead times demanded for delivery of such a considerable quantity of this product. This was a decisive factor in keeping to the tight schedule for project completion.

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Location: Weizen, GermanyObject: R and D centrePlan: New buildProducts: TU-S blind rivets

The Sto Research Centre

Sto SE & Co. KGaA is a global leader in coating and insulation systems. Some 160 people are employed in their in-house research and devel-opment centre, working on future innovations. To create the ideal workspace, a new research centre has been created at the HQ in Weizen, Germany.

When it comes to people-centred, sustainable designs for living, Sto is one of the technology leaders in the built environment. So the new research centre features a particu-larly stylish, innovative rear-venti-lated facade created using the latest StoVentec SmartFlex panels. These offer maximum design freedom with fully through-coloured, almost limitlessly transformable, facade systems.

An almost ideal fastening solution for this ground-breaking product is offered by the innovative TU-S fastening system from SFS intec. Like the Sto Ventec panels, this product is so new that it has never been used in this way before. Indi-vidual approval had to be obtained for each application; whereby extensive experiments carried out in Heerbrugg and close collaboration between Sto, the panel producer Evonik and SFS intec proved a decisive factor.

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Anti-fall security and window installation all-in-one with JB-D®/ FA

Big windows quite simply let in more light, improving everyone’s quality of life and sense of well-being. They also offer an attractive external impression; but the downside is their exposure to damage from general use and environmental impact.

Glazing installed at knee and floor level also has to prevent people quite literally from falling out, resulting in enhanced requirements for their anchorage in the brickwork. If they are to eliminate danger to life and limb, they have to be engineered to resist static and even occasional shock loads.

These exacting requirements are fulfilled by the JB-D®/ FA-System from SFS intec for every routine window setting. The existing range was specifically developed for such applications, following on from many years of experience in window installation. Among other things, specially strengthened com-ponents and approved fasteners and fixings serve to ensure that any loads are permanently and securely transferred to the brickwork. All of which means that the system meets and exceeds the current building control requirements.

Using JB-D®/ FA does not just ensure secure installation; it offers fast, efficient installation, too. All customers also enjoy total engineering support.

n The JB-D®/ FA installation system (shown in orange) enables simple, secure, efficient window installation.

Aesthetic fastening of cement fibre facade panels

Quality buildings are often clad in fibre concrete panels. For aesthetic reasons, the fasteners and fixings should be as far as possible invis-ible. The new TUC-S blind fastener enables a bracket to be attached to the rear of the panel, which can hook the panel onto horizontal support sections attached to the sub-structure. This new product is a great improvement on anything previously used in terms of ease of installation and flexibility.

Attaching the brackets with the TUC-S fasteners is similar to conventional visible facade rivet-ing, with the main advantage that a single blind bore is all that is needed to attach the TUC-S. It is a really simple, efficient proce-dure, offering time-savings of up to 50 % over alternative invisible fastening solutions.

The well-established rivet setting tool, PowerBird® from GESIPA®, is ideal for the installation work. TUC-S fasteners can also be removed once without the need for special tools. What’s more, the blind bore can be drilled on site if required.

Despite the simple, time-saving installation, TUC-S offers a truly secure solution. Used in combina-tion with the EPDM sealing washer, the fastener offers maximum tear-out resistance. Self-loosening through dilatation or vibration is also impossible.

The austenitic, A4-grade stainless steel sleeve also guarantees com-plete corrosion resistance. All-in-all, the SFS intec TUC-S simply offers the optimum solution for invis-ible installation of cement fibre facade panels.

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n IF240-B

n IT260-B

MEGA GRIP® – economical, high-strength riveting

Light-weight construction has placed increased emphasis on the use of high-tensile, thin plate. This trend calls for appropriate mechani-cal fasteners. This was the back-ground to GESIPA®’s development of their high-power structural rivets, the MEGA GRIP®.

The new product exhibits excel-lent bearing strength, enabling optimum protection against water ingress. Because a particularly large clamping area is sealed with

a single rivet, the handling costs are greatly reduced.

The mandrel tip stays in place in the rivet after setting. This guarantees high shear strengths, due to the double strength connection. The tear takes place right on the head of the rivet, leaving no sharp edges.

This makes the GESIPA® MEGA GRIP® ideal for automotive applications. It is used in the latest Jaguar Land Rover models, amongst others.

The GESIPA® MEGA GRIP® is avail-able in flat round head and hexagon versions and in the standard alloy combinations alu / alu and steel / steel.

The latest rivet setting equipment featuring extended battery life

When it comes to attaching thermal insulation and flat roofing mem-branes, speed and efficiency are the order of the day. The associated fas-teners must, of course, be perfectly installed in the right position if the long-term functionality of the roof is to be guaranteed over the entire life of the building.

Installation can be manual or achieved via a special insertion tool; whereby the setting tools IF240 and IT260 from SFS intec have become the benchmark for mechanical roof membrane fastening. The IF240 is the ideal specialised tool for install-ing full-metal fasteners in steel and timber supports, while the IT260 is the best choice for fasteners with sleeves.

Both tools have been proven time after time on building projects all over the world in terms of power, quality and reliability. Both are now available in cordless versions.

Powerful battery sets enable out-standing riveting speed and ease of use, without having to take care of a cable. What’s more the battery powered system now coming onto the market is extremely quiet: great for the installer and great for the environment. Mains-powered units can also be readily converted to battery power; while reverting to mains power later also represents no problem whatsoever.

The new, cordless insertion tools IF240-B and IT260-B are the latest

highlight in the SFS intec product range. They offer simple, fast and efficient installation on every flat roof site. This has been confirmed by the massive customer interest and the numerous building projects already completed.

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Bosch Rexroth uses Speed Rivet technology from GESIPA®

Joachim Jansen, Division Riveting, [email protected]

Efficient assembly at Bosch Rexroth

Bosch Rexroth is a specialist in state-of-the-art, secure and environmen-tally-friendly drives and controls. The globally-active company employs 33’700 people in 38 different coun-tries. In Erbach, in the Odenwald area of Germany, complete resistance welding solutions are developed and manufactured. Alongside the drives, transformers and operating devices, their main products are controllers.

One of the main requirements in pro-duction is riveting the metal housings containing the electronics. The maga-zine-fed, paper-strip rivets previously used did not achieve the required clamping force needed to pull the two sheet metal housing parts sufficiently together. In particularly hard-to-access positions, the rivets were often inserted out of true and were difficult to remove. The connectors also had a tendency to bend and buckle after just a short time, making them difficult for the operator to insert.

Optimising the riveting process

The existing process was demon-strably subject to faults and rather slow. Consequently, the engineers at Bosch Rexroth were looking for a suitable alternative to the rivets and setting tools used up to now. The first alternative solution to be con-sidered was the use of breakstem rivets utilising an automatic feed. This solution proved, however, to be uneconomical because of the rela-tively small number of rivets used.

Following in-depth analysis, the developers favoured the latest Speed Rivet design. The rivets concerned feature a lost mandrel which minimises the chance of injury through a possible mandrel tear-off. There is also no residual mandrel in the connector capable of being loosened by vibration. This is particularly critical in electronic applications, as the potential for short circuits from foreign bodies is eliminated.

Matching setting tool

After a solution had been found for the connectors, the next task was to optimise the setting tool. The operators at Bosch Rexroth were less than happy with the products on offer at that time. Meanwhile, GESIPA® had been developing a new insertion tool for their Speed Rivet technology. This was to be decid-edly faster, lighter, more ergonomic and indeed more economical than the competition.

The TAURUS® series units seemed to offer the ideal solution. Built on a modular basis, the many advantages such as the ergonomic design, low weight and the economy offered by this range could be readily adapted to the new product. When the results of the first trials appeared very positive, GESIPA® was looking for a partner to test the new product under series production conditions. Bosch Rexroth seemed to fit the bill as the ideal partner.

New TAURUS® 1 Speed Rivet

The Research and Development Department at GESIPA® was able to rapidly develop functioning proto-types for Bosch Rexroth to work with. Thanks to excellent collaboration among sales, design engineering and product management, the equipment was soon optimised for series applica-tions. After having inserted 1.2 million Speed Rivets at Bosch Rexroth, the test units have come through with flying colours. In fact the new TAURUS® 1 Speed Rivet functions so reliably and efficiently that it is the only system now in use.

The tool is 600 g lighter than compa-rable products from alternative manu-facturers. That makes it significantly more ergonomic, which is very impor-tant for easy, fatigue-free handling; while the slim build makes access to tight spots much easier. As the product range was extended, further work stations were equipped with the GESIPA® TAURUS® 1 Speed Rivet.

Reaching our goal together

An intensive collaboration and rela-tionship of trust has developed with Bosch Rexroth. The tests on the Erbach shop floor really supported the engineers at GESIPA® in the development of the new TAURUS® 1 Speed Rivet. Going forwards, the plan is to supply application-customised rivets as well as the perfect setting tool, providing Bosch Rexroth with the optimum solution for their needs.

Bosch Rexroth in Erbach, Germany, produces various control units for machines and manufactur-ing systems. With the help of the latest generation in Speed Rivet technology, they have been able to optimise housing riveting opera-tions. The biggest part is played by the newly-developed TAURUS® 1 Speed Rivet from GESIPA®. With its trim build it ensures secure, efficient assembly operations.

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A modular approach

The latest Molded Case Circuit Breaker MCCB from Schneider Electric is made thanks to a fasten-ing system from SFS intec. Rivets were specially developed to be produced on made-to-measure manufacturing set-ups.

Innovative modular build

Schneider Electric Industries SAS offer products for the mid-to-low voltage sector. This French concern is also a leading developer and supplier of automation and control systems. Among their best-known products are power circuit breakers & switches – known particularly for their reliability and robustness.

The new Compact NSXm Molded Case Circuit Breaker MCCB com-bines reliable protection and new innovative features. One of their chief characteristics is the small size, offering up to four poles MCCB and switches. These are fastened together with specially designed fasteners in different lengths.

Demanding rivet connections

Rivets were chosen from a range of feasible alternative fastening solu-tions. The technology had been used before; albeit for individual switches rather than block-build systems. The challenge is fitting the long thin rivets into the switch units. They are then fastened into place via orbital riveting.

The straightness required in such long, thin parts places extreme demands on their manufacture. SFS intec developed an efficient process based on conventional cold forming. The choice of material was of paramount importance, with the starting material chosen by SFS intec requiring less handling and fewer processing steps.

Gérault Frejaville, Division Industrial, [email protected]

An economical manufacturing route

Over the course of the project, SFS intec prepared various prototypes using their conventional manufactur-ing equipment. These were used by Schneider Electric to carry out all the necessary build and functional tests in their pilot plant. This enabled both the design to be tested and optimised and the customer’s production line to be rationalised. SFS intec used the results to produce their manufacturing plan.

The close project co-operation between Schneider Electric and SFS intec enabled both to develop the necessary know-how. Investing in a special purpose production cell offered an economically attractive

solution. Schneider Electric thus received ready-to-fit parts from a totally secure manufacturing process; permanently improving the customer’s productivity levels.

Schneider Electric is a globally-active specialist in energy manage-ment and automation. The company, founded back in 1836, had a turnover of 25 billion euros by 2014. Some 170’000 employees help customers in over one hundred countries to use their energy and processes reliably, efficiently and sustainably. From the simple switch to the most complex operating system, Schneider Electric helps customers run and automate their plants. All of which calls for comprehensive know-how; whether

in technology, software or services, their network of technologies renew and advance industries and cities – enriching our lives everywhere.

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Good contacts count

The latest nine-gear automatic gearbox from Mercedes-Benz is a technological wonder. It is con-trolled by an electronic module developed by Bosch, with actuator contacts ensuring the seamless transfer of the electronic signals to the box. These components are produced by SFS intec against stringent cleanliness requirements.

Automatic gear boxes are enjoying a steady increase in popularity. They used to be criticised for being thirsty on fuel and breakdown-prone. But these days one in four new vehicles is fitted with an automatic selector. Indeed the sports car manufacturer Porsche produces no fewer than 84 % of all its vehicles with either a Tiptronic transmission or a DSG double clutch.

State-of-the-art automatic transmissions

The trend has resulted not least from dramatic technical developments over recent years. Automatic transmissions offer a more efficient gear-change than their manual counterparts. The latest, electronically-supported transmissions

find exactly the right change point much faster than the hands of any driver. That translates into a more sporty but also smoother driving experience.

Another advantage of modern trans-missions is the increased number of gears – in the latest Mercedes-Benz models there are no fewer than nine. Thanks to the closely-stepped gear ratios, vehicles are more often at their optimum r.p.m. level. This results in a combination of reduced fuel consump-tion, lower environmental impact and better acceleration.

Strong and dependable contacts

The nine-gear automatic transmission from Mercedes-Benz mentioned above

Günter Leitner, Division Automotive, [email protected] is controlled by an electronic module from Bosch. It is built directly into the box, floating in oil at up to 140°C. The control unit also has to stand up to the vibrations resulting from ever–increasing vehicle life. The housing has therefore to be particularly robust in order to protect the sensitive electronics inside.

Special contact positions on the housing are needed to transfer signals to the control mechanism. This requires both high precision, to ensure seamless contacts, and complete cleanliness, to eliminate any particu-late matter settling on the contacts; potentially resulting in a short circuit.

A clean bill of health

The electronic modules for the nine-speed Mercedes automatic gearbox are produced at the Bosch plant in Eisenach, Germany. Nine actuator contacts are attached to each module; each one fitted with two press-fit

contacts. Bosch worked closely with specialists at SFS intec on the devel-opment of these high-precision com-ponents. Together, high-tech solutions were co-engineered.

The total elimination of both metal-lic and non-metallic contaminants in every production area was an impor-tant aim. The machines scheduled for use, together with neighbouring areas, had to be carefully analysed. Particle traps were used to assess the issues concerned; with even weather-dependent influences checked and addressed.

Trouble-free production

The results furnished the information necessary to enable the implementa-tion of appropriate combat measures. The injection moulding process is carried out in line with these cleanli-ness parameters in Korneuburg, Austria. Subsequently two metal contacts are pressed into place. The

finished components are then packed into returnable blister packs.

SFS intec operates ship-to-line deliv-ery of these ultra-clean, ready-to-fit parts. Against a back-drop of increas-ing demand, Bosch meanwhile has set up additional production lines to mirror the Eisenach facility. Both companies left their conventional manufacturing comfort zones behind for this project, choosing to fundamentally rethink their systems. This willingness to embrace change certainly paid divi-dends for both partners.

n The electronic module (left) is fitted with the actuator contacts shown (centre and right).

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Stade Matmut Atlantique, Bordeaux

Stade Matmut Atlantique, BordeauxStade Pierre-Mauroy, Lille

Football fever across Europe

Christophe Borel, Division Construction, [email protected]

Football stadia have changed dramatically over the years. In addition to the degree of comfort on offer and the overall aesthet-ics, safety considerations have increased massively. Numerous stadia have either been refurbished or constructed from new for the 2016 European Championships in France. SFS intec products were used extensively.

Football and emotion

More than almost any other sport, football draws on tradition and the atmosphere in the stadium. The emotions on the pitch seem to be conveyed seamlessly to the crowd and vice versa. That’s why the audi-ence can sometimes be referred to as the twelfth man. Big crowds of regular followers are also an impor-tant income stream.

A modern ground can thus play a decisive role in a team’s success. That’s why so much has changed over recent years. Until well into the nineties, most teams played at grounds which they themselves did not own, but rather were owned by their home towns and cities. With

the focus on other competitive sports, there was often a running track around the field of play, pushing the position of the low-profile, largely uncovered stands away from the action.

Features of the modern stadium

These days stadia generally belong to the clubs and have been modernised or completely rebuilt to meet the real needs of football. Stands now reach the edge of the pitch, and are invari-ably fully covered. Meanwhile their steeply tiered construction provides every fan with a good, unrestricted view of the field of play. That way the players’ emotions spill over to the fans and vice versa.

Another feature of the present-day football amphitheatre is the integration of luxurious VIP boxes, and confer-ence rooms. These pull in top-paying visitors and corporate clients to the games. Events can also be arranged for customers and employees alike. Clubs benefit from better utilisation of their stadia and from additional income streams outside of football.

Influences on architecture

The architecture of new stadia has changed in line with modern thinking. Whereas old stadia were purely utili-tarian concrete creations, completely open to the elements, these days high-end facades convey the right image, while inside there are invariably numerous roofed areas. High-quality materials create a pleasant atmos-phere, inviting visitors to stay a while and come back soon.

The internal architecture has also changed tremendously. Whereas before most of the crowd had to stand, now most stadia are exclusively all-seater. That means increased comfort and also enhanced safety for the public. Also wide access gang-ways and aisles enable rapid evacua-tion in the event of emergency.

Building the Euro 2016

A fully-functional safety concept is a critical aspect in choosing a venue. The European Football Association, UEFA, as the organising body, sets very stringent requirements on that front. In addition to the core safety considerations, the infrastructure of the stadium and its surroundings were addressed. There have to be adequate parking spaces and access roads. These latter requirements in

particular often mean that a new build on another site proves imperative.

The 2016 European Championship games in France will be played at ten different stadia, all of which have either been massively mod-ernised, or completely rebuilt. Build-ing costs for the 487’000 seats installed across all the grounds amount to over 1.5 billion euros, with a good deal of the money spent on SFS intec products!

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Parc Olympique Lyonnais, Lyon Stade Geoffroy-Guichard, Saint-Étienne

Stade Geoffroy-Guichard, Saint-ÉtienneStade Allianz Riviera, Nice

Parc Olympique Lyonnais, Lyon

Stade Pierre-Mauroy

The OSC (Olympic Sporting Club) Lille stadium was named after the long-serving mayor of the city. The new stadium, designed by the archi-tectural practice Valode & Pistre and the architect Pierre Ferret, offers a capacity of 50’083. A particular high-light is the retractable roof, which can be closed in just thirty minutes. The pitch can also be raised to provide a roof for a smaller event arena.

As Lille is close to the English Channel, the westerly winds off the Atlantic are extremely salt-laden – making considerable demands on the various materials used. That’s why the construction company charged

with the build, Martifer, used stain-less steel power tool fastenings type SX from SFS intec to fit the steel box panels. These meet all the techni-cal and safety-related requirements in full.

Stade Matmut Atlantique

Steeped in tradition, the Giron-dins Bordeaux club is leaving its old stadium, the Chaban-Delmas, after almost ninety years. The new arena, deigned by the Swiss archi-tects Jacques Herzog and Pierre de Meuron (Herzog & de Meuron architectural practice) offers seating for 42’052. As well as football, rugby games will be played here; requiring

a lengthening of the playing surface. To that end, four mobile seating rows were installed in the lower levels of the stands behind the goal. 1’000 temporary seats can be removed and replaced in just seven hours.

The project construction company Castel & Fromaget used various power tool fixings from SFS intec, some of which are colour-matched to the exter-nal cladding. They feature an irius ® head integrating seamlessly into the sine wave profile cladding. The combi-nation offers an aesthetically pleasing system solution.

Stade Allianz Riviera

The multi-functional OGC (Olympic Gymnast Club) Nice stadium was conceived by the architectural prac-tice Wilmotte & Associés. It offers a capacity of 45’000 for concerts and a limit of 35’000 for football matches. As with the Stade Matmut Atlantique in Bordeaux, the stands behind the goals can be rolled away to enable the playing area to be lengthened for rugby games.

The building exterior is made up of multiple layers. The stands are framed by a complex timber structure covered

in a steel grille. To this is attached a transparent outer casing. This rather complex construction forms an interesting, transluscent facade. To strengthen the timber profiles, the builders, Fargeot Lamelle Colle from Arbonis, used the WR-System from SFS intec.

Parc Olympique Lyonnais

This stadium, also known as the Stade des Lumières, belongs to the Olympic Lyon club. The new-build cost around 381 million euros and offers a spectator capacity of 59’186. It replaces the original 1926 Stade Gerland and is actually on the out-skirts of the city. The Parc Olympique Lyonnais also includes space for a leisure complex, numerous offices and two hotels!

The form of the stadium roof is par-ticularly unusual. Attaching the syn-thetic roof membrane and insulation layer was achieved using economical IRFP system fittings from SFS intec; while power tool fasteners type SDZ5 were used to fix the transparent roof sections. These featured coloured heads with a zamac (zinc-aluminium alloy) cap to meet the required corrosion proofing.

Stade Geoffroy-Guichard

Stade Geoffroy-Guichard has been the home ground of the distin-guished AS Saint-Étienne since 1931 and was one of the venues origi-nally featured in the 1984 European Championships and the 1998 World Cup. It offers 35’352 seats and is named after the club’s founder. During renovation works the exist-ing open stands were fully covered; while a superb facade sheathes the entire stadium, lending it an air of impenetrability.

The wall coverings were made of perforated panelling attached to the support structure using SD6 screws with an irius ® head from SFS intec.

The facade was finished off with decorative elements fitted by the construction company Couvrisol using stainless steel rivets from SFS.

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Interview with Helmut Binder

Over thirty-four years ago Helmut Binder joined the then press shop known as SFS Presswerk AG. He had a number of managerial roles there in various depart-ments. Since 1996, he has been directing the destiny of the SFS intec Group as its CEO, during which time the company has developed from a screw factory with a mainly European focus to a globally-active industrial conglomerate. Helmut Binder went into well-earned retirement at the end of March 2016. We spoke to him about his time at SFS.

Mr Binder, what was it like working for SFS Presswerk Heerbrugg AG when you first started?

At the beginning of the Eighties, SFS was an easily-manageable concern with around 300 employees and a turnover of 60 million Swiss francs. Alongside the main Heerbrugg site, there were subsidiaries in France, Germany and Sweden.

The company was still characterised by the spirit and pragmatism of the found-ing fathers. There was an overarching optimism and relatively strong invest-ments; and the company grew a lot at that time.

How has the industrial picture changed in the interim?

The lifting of the Iron Curtain proved a turning point: previously, we had been focusing our activities on Western Europe. We were effectively preoccu-pied with the local markets.

While our customers increasingly inter-nationalised their activities, there was a noticeable parallel consolidation within our own customer circles. As a conse-quence, business relationships became more concentrated and critical. Mutual dependency increased, while, at the same time, competition intensified.

To what extent did SFS change?

SFS has been growing strongly since 1980. In 2013 for the first time a turnover of a billion Swiss francs was generated. The number of employees rose over the same period to over 6’000. Our company is not just larger, it has become far more international and diversified.

These days the activities of SFS are spread across fifty sites in over twenty different countries. The tech-nologies deployed, range of products on offer and customer segments served have also changed dramati-cally. Clearly the organisational struc-ture of the eighties would no longer be appropriate today.

The development from a purely functional organisation back then to today’s divisional structure has involved several intermediate stages spanning a twenty-year period.

You had to manage crises too during your time in charge – how did you do that?

Of couse there were difficult phases at SFS. We came through reces- sions in the early nineties as well as in 2001 and 2002; while the 2008 crash still looms painfully large in our memory. Of course, the strengthen-ing of the franc – particularly over the last five years – has been another issue we as a company have had to cope with.

We can, however, show that we were in the black even during the difficult years. We also came through every recession stronger, thanks to taking the right steps in good time. The understanding and unswerving loyalty of our staff was a tremendous support.

You have been involved in several acquisitions during your time at SFS. Where were the greatest challenges?

Acquisitions played an important role from the outset. They were an inte-gral factor in our expansion strategy.

During my time I must have been involved in around thirty such projects. In the main, buying other compa-nies was about expanding into new regions. Later on we realised we could use it to reach different technologies and new customer segments.

My core concepts were always the industrial logic behind the merger, together with the poten-tial and the mindset offered by the new management. Looking back, I think we can be proud of a very positive balance sheet in our acquisi-tive strategy; though early on we took over some rather-too-small, under-capitalised companies.

What differentiates SFS from its competitors?

I think we would first have to agree who the competitors are, because our business model always made us very broadly based.

Cold forming capabilities were initially at the centre of our activities, but from early on we began to develop quasi-independent business units, primarily focused on specific user segments in the market and their particular needs.

This concept helped us to more fully understand the peculiarities of these user groups. It meant that we were often able to respond to their very specific needs. This meant we were competing within a rather hetero-geneous competitive environment. Depending on the business, the tech-nology or the region, there were differ-ent competitors involved.

How did you develop as a person during your time at SFS?

You have to embrace lifelong learning during a long-term period of employ-ment. That was certainly the case for me. At the start I was strongly marked by my scientific and technical

n Internationalisation saw the Asian market massively developed under the management of Dr. Helmut Binder.

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education. In many analytical situa-tions the costs were in the vanguard. But looking back, that is not enough.

Recognising opportunities and chances, embracing risk in a calcu-lated manner – these sensibilities increased over the years. Also I rec-ognised that operating freedom for employees and focusing on the needs of the SFS customers would achieve more than concentrating purely on cost.

What has been your greatest chal-lenge in your time as CEO?

I believe the most significant chal-lenge lies in the field of ongoing

internationalisation. For our company, with such a small domestic market, there was no alternative. Entering new markets, you were always dependent on strong local management. Above and beyond paper qualifications, what’s needed is the same shared understanding of business and the willingness and ability to communicate openly.

Recruiting qualified local manag-ers who were willing to join a small, hitherto unknown, company was not always simple for us. It was gener-ally the "soft factors" which presented differences to the SFS culture. In an effort to break down these bar-riers, we introduced English as our corporate language at the turn of the

century. We then launched a corpo-rate culture campaign emphasising the values we strove to maintain in our internal and external relationships.

Last but not least, this was followed about ten years ago by a comprehen-sive international training programme, with some 200 managers from all parts of the organisation taking part. These steps improved mutual under-standing – a fundamental requirement for good working relationships.

What in your view are the require-ments to stay ahead in the future global market?

There is no patent recipe, otherwise everyone would know just what to do. But I am convinced that the right mix of technological ability, customer closeness, application engineering, customer relationships and a funda-mental will to win within the company form the basis for success. Then all that is required is that modicum of luck which you need for everything in this life.

What do you wish for SFS as your leave the company in 2016?

My wish is that SFS continues to be a good, solid, successful company. SFS should remain attractive to all the various interest groups. That is what would please me, because after thirty-four years, you develop a strong

emotional attachment above and beyond purely material considerations.

What are you particularly proud of?

I believe that would be how we were able to successfully grow the business at SFS year-in, year-out; whether that was for the shareholders or for the many employees and customers. I am also filled with satisfaction to have been able to hand over the reins to long-serving colleagues, both during the generational change of the nine-ties and now again, as I move on.

How have you prepared for your retirement?

I was fortunate enough to be able to reduce my workload when I resigned as CEO in 2014. This enabled me to embrace new activities. My interests are diverse and varied. I am utilising my newly acquired time for winter sports, hiking, golf, reading, travel and

visiting cultural events. I also contrib-ute my time to other institutions and concerns where I can offer the benefit of my experience. I am 66 years of age; as long as my mental and physi-cal health hold out I will be enjoying the next phase in my life.

n Alongside international expansion, the original Heerbrugg press facility (top) was continuously extended from 1980 to its present-day position (bottom).

* All informations correspond to the SFS industry or rather the later SFS intec Group.

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Logistics solutions for Industry 4.0, the strategic initiative towards pioneering IT

The Distribution & Logistics segment in Switzerland markets a comprehensive range of fas-tener solutions, tools, fitting and chemo-technical products under the SFS unimarket brand. As a partner to both the build-ing trade and industrial sectors, SFS unimarket also develops inno-vative logistics solutions. Such storage and ordering systems soon sink acquisition costs whilst increasing the security of avail-ability. One of the numerous customers using the systems is the internationally-active Stadler Rail Group.

When it comes to the supply of C-components, intelligent logistics solutions have been playing a part for many years. C-components are char-acterised by a minimal actual value, in contrast to their disproportionately high acquisition cost. Small parts like screws, washers and sealing rings are indispensable for production. These parts must always be available in the right quantity. The best case scenario would be for them to be automati-cally re-ordered to minimise material management costs.

Industry 4.0 by SFS: towards pioneering IT

This vision is realised in the self-order-ing system turnLOG® developed in 2008. The component containers are divided into two sections and feature

a transponder. If the stock in the front section is used up, the container turns to provide access to the reserve stock. At the same time, the container issues a replenishment order using RFID technology. The solution led to SFS unimarket being awarded the European Logistics Award in 2009.

The system was enhanced and extended by the pushLOG® and weightLOG® systems over the follow-ing years. Bulky items, which cannot be stored in conventional "bins", can be re-ordered at the touch of a button using pushLOG®; while weightLOG® represented another industry first for SFS unimarket, with a fully-automated re-ordering system initiated when a pre-defined minimum weight is reached. The system also offers the added advantage of automated inventory control.

Michael Leitner, Division Distribution & Logistics, [email protected]

"M2M by SFS"

Following years of development, SFS unimarket launched the new generation of logistics support under the name "M2M by SFS" in April 2015. M2M stands for "Machine to Machine", representing the fully automated information exchange between the machines or equipment concerned – in this case among the stores infrastructure, the mobile end-units and the ERP system. The more developed systems feature numerous technical advantages, further addressing existing and future customer needs. These depend on the latest developments in sensor technology and wireless communica-tion developed by the SFS unimarket engineering team.

At the heart of this innovative solu-tion lies the transponder incorporat-ing NFC technology. This enables the customer to call up article details using a mobile end-unit; while the transponder also recognises when

the "bin" content changes and a new label is applied. Bi-directional com-munication is extremely useful. The transponder does not just indicate whether an order has been placed but whether a delivery is already in the pipeline. This information offers increased security to the customer and saves on additional clarification.

Not simply the second generation

Alongside the second gen-eration turnLOG®, pushLOG® and weightLOG®, the new "M2M" range offers another completely new solution. For the very first time, reachLOG® enables another customer need to be addressed; namely a fully-automated ordering system similar to weightLOG®, but without the load cell. The new fill sensor detects levels and automatically releases orders once a pre-defined level is reached. The system is thus ideal for container level situations, making it perfect for work place integration.

eLogistics

eLogistics represents a centralised data bank for all material control procedures within the SFS logis-tics solutions spectrum. Thanks to eLogistics it is even possible to extend the system to products from third-party suppliers; while the software can also be utilised for so-called inbound processes. In other words it is now possible to control material flows from the central stores through component assembly to final product despatch via eLogistics. The same logistics platform can also be used to inte-grate order details into the cus-tomer’s ERP system.

turnLOG® 2Re-ordering by simply turning the bin

weightLOG®Fully-automated ordering as soon as the container level reaches a pre-defined minimum

pushLOG® 2Re-ordering at the touch of a button – ideal for bulky items

reachLOG®Fully-automated ordering via a level sensor

An overview of the portfolio of SFS logistics solutions

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Interview with Philipp Brunner,CEO Stadler Rail AG, Minsk

You created the Belarus plant on a greenfield site. What challenges did you face?

As well as language and various cultural differences, logistics and administration represented the greatest challenges. The Com-monwealth of Independent States (CIS), representing certain former Soviet Republics, has particu-larly high demands in terms of documentation and bureaucracy, which in turn made material flows between Europe and Belarus dif-ficult to manage. This applied both during the start-up and also during the initial project developments in manufacturing.

But technologically, the Belarus plant is the most modern Stadler production site. What are the main differences to the existing plants?

Of course, it’s the most "modern" because it is the most recent Stadler Group factory. We have

deeper value-added activity at other European sites and are at a higher level technologically speaking than in Belarus. One of the critical differences between Minsk and existing Stadler Group sites was that the entire plant was constructed on a greenfield site, so the layout was not compromised by any existing structure. It could be constructed exactly to an ideal design as determined by our produc-tion processes; and it is fully capable of extension to meet future needs as they arise.

Alongside technology, what about the human aspect: were there enough quality staff available in Belarus?

Yes, there are lots of capable workers at every level; excluding highly special-ised employees, we engaged all key staff members locally and have been more than pleased with their input. We have trained very specialised staff like aluminium welders and com-missioning engineers ourselves over many years.

How was SFS able to meet your needs, and what expectations do you have of us going forwards?

We were delighted that SFS was willing to take the risk of launching in Belarus and build up C-component stores over there. SFS supported us completely during the build phase and initial supply, and always reacted rapidly when everything did not always go to plan at the outset.

With the experience and knowledge we now have about the C-component programme and logistics and customs and excise in Belarus, we can antici-pate reducing the buffer stocks to a minimum over the medium term, and getting stocks matched to the theoret-ical optimum. We expect full flexibility going forward, regarding matching our production requirements to the SFS C-component supply infrastructure.

In your view, what are the main advan-tages of the SFS logistics solutions?

Visibility and control versus auto-mation and cost-savings. Unfor-tunately, the SFS solution cannot demonstrate its main advantages in Belarus to the full extent enjoyed by our Swiss sister companies. Due to specific requirements surround-ing monthly and annual reporting mechanisms, both within the Group

and as a customs-free zone, we have to operate certain laborious proce-dures: SFS helps us keep the work to a minimum.

How do you see the economic situation developing in the CIS in the medium term?

We sincerely hope for a demand surge in Russia and the surrounding states, but I cannot really give a prog-nosis. What we are doing is preparing ourselves with adequate capacity during these challenging times to be ready to meet the market needs as they emerge.

Stadler Rail is a Swiss manu-facturer of rolling stock, with the emphasis on regional railways, trams and special made-to-measure rail products. With numerous daughter companies in various European countries, the company employs around 6’100 people, of whom 2’800 are located in Switzerland, 1’200 in Germany and 1’000 in Belarus. SFS unimarket has been supplying the Altenrhein production facility since 2007. Stadler Rail controls some 3’000 separate items on this site across seven central stores, using turnLOG® and pushLOG®.

Following the addition of the Win-terthur site in 2008 with some 2’100 articles in 16 stores loca-tions and a turnover of 3.4 million Swiss francs, Stadler Rail chose SFS unimarket as its C-part partner in 2014 for the new site in Belarus. The Minsk assembly operation is the largest Stadler Rail site. Double decker carriages are produced there for the wide-gauge prevalent in the CIS states. weightLOG® and pushLOG® logistics systems are used in the new plant.

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Valve clearance

The development of new engines is regarded as one of the most impor-tant challenges for car manufactur-ers. It takes a lot of resources, time and money to launch a new series of engines. Therefore car manufac-turers have to be very selective in choosing their partners hence the engine is a very important factor for the mobility.

Delphi Automotive developed an innovative product concept raising the bar on engine efficiencies and power management. In this project the designers faced several challenges regarding design and manufacturing. Delphi therefore turned to the global resources and capabilities of SFS intec. The good relationship between both partners helped to realise the revolutionary product.

The application

The "High Lift Follower" (HLF) is a critical piece of engineer-ing technology that powers the new "Fiat Chrysler Automobiles" (FCA) Pentastar engine used in

the Jeep Grand Cherokee starting with 2016 models. With twelve assemblies per six cylinder engine, the design upgrade will allow the Pentastar engine to operate more efficiently. This means that the work of drawing air into the engine is reduced dramatically. The end result of engineering and production work is expected to deliver a three to five percent fuel economy improvement, which will provide a competitive advantage for all models carrying this engine.

When the engine operates in low to medium RPM, the "Roller Finger Follower" (RFF) is in low mode, opening the intake valve a reduced lift and the HLF moves freely. The RFF transitions from low to high

Stephen Garapic, Division Automotive, [email protected]

mode when the engine begins to operate from medium to high RPM, fully opening the intake valves to optimise air fuel mixture. In high mode, an internal RFF mechanism locks the HLF to the outer rocker arm. This allows the high lift cam lobe to ride on the HLF.

The long road of success

The success story of the HLF application is one that is more than five years in the making. During the pre-production launch process, Delphi revealed that they had little expectation that any supplier would be able to cold form the HLF. Given the complexity of the part and the critical design elements it

Delphi Automotive PLC (NYSE: DLPH) is a leading global tech-nology company for automotive and commercial vehicle markets delivering solutions that help make vehicles safe, green and con-nected. Headquartered in Gilling-ham, U.K., Delphi operates techni-cal centres, manufacturing sites and customer support services in 33 countries.

The cooperation between Delphi and SFS began already in 1999 with the delivery of screws for throttle valves. Since 2003 SFS intec has produced special screws for fuel pumps for Delphi. They fulfil highest tension and cleanliness specifications.

Over the years the partnership has been extended to additional areas of applications. For example, parts for ABS valves or torsion bars have been developed and produced. Today SFS intec delivers over 50 Mio parts to Delphi for various applications.

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Richard B. RoeDelphi AutomotiveEngineering ManagerValve Train EngineeringVariable Valve Lift Products

From the start of the project, the support from SFS intec has been very professional and rewarding. The team at SFS intec provided great techni-cal support in the development of our design, sharing design, gaging and manufacturing con-cepts. Once the project moved forward to an implementation stage, the manufacturing team at SFS intec proved just as worthy and the coordination of activities between the teams at Heerbrugg and Medina was seamless. The ability of Delphi to work closely with SFS intec allowed our design for the HLF to become a reality as a cold formed and machined design as opposed to other higher cost alternatives.

was thought to be a better fit for a slower, high waste and more costly machined process. The collabora-tion between Delphi and SFS intec allowed for an optimised, cold form-able with secondary machinable design of the HLF.

As one of many components in the 2-Step Roller Finger Follower (RFF) assembly, the HLF concept drew upon the industry know-how of SFS intec both in Europe and in the United States to become a reality. Development and pre-production work were performed by the SFS team in Heerbrugg, while the Medina division worked to estab-lish manufacturing resources that would support Delphi’s high demand requirements in subsequent years.

Technical know-how

The HLF touches on a long list of SFS intec in-house capabilities: cold forming, cleaning, tumbling, special-ised machining and heat treatments are all involved. Each internal process is carefully calibrated and controlled to deliver millions of consistent, high quality parts to our customer.

In good collaboration between the Swiss and US colleagues, four additional machining centres were installed in Medina and were ready for operation in the 1st quarter of 2016. After completion of the fin-ished part in Medina, all activities culminate in the final assembly performed at the Delphi facility in Saltillo, Coahuila Mexico.

Innovation and the road forward

The High Lift Follower is the end result of design excellence and pro-duction know-how. The future looks bright for this product and application as FCA has plans to implement it with various designs across a number of other models and platforms. Working together to produce a superior product, SFS intec has distinguished itself again as a reliable supplier to the automotive industry. The realisa-tion of this production capability and added design support has opened the door to new opportunities for shared success between Delphi and SFS intec.

The ability to work in concert with our customer from positions throughout

the triade has proven to be a distinct strength of SFS intec. The company has positioned itself as a technical leader in cold forming capabilities in meeting and exceeding customer demand for this innovative product. The new HLF has opened the door to the next generation of new product development and cold formable design concepts.

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Clear cut

Sandvik Machining Solutions AB, a business area of the Sandvik Group, is the world’s largest manufacturer of cutting tools. The Swedish corporation trusts in the products and services by SFS intec. The two companies have sustained a close collabora-tion over many years. This extends to product development, manufac-turing and logistics; while a new concept is about to dramatically reduce delivery times.

The demands on cutting tools are continually increasing: the reason being ever-more critical applica-tions, such as the use of high tensile materials. The thrust for reduced operating times requires increased cutting and processing speeds, leading to an increased amount and variety of retainer fas-teners for indexable cutting tools.

Long history of collaboration

Sandvik Machining Solutions AB is the business area focused on products and solutions for the metal cutting industry. When it comes to retainer screws for indexable cutting tools, the

corporation has been placing its trust in SFS intec for over thirty-five years. Their preferred partner offer convincing quality and process security. SFS fasten-ers simply meet every require-ment and operate at the limits of technical feasibility.

This close collaboration has developed into a relationship of trust. Both partners operate at many levels, such as in the co-development of new centre-lock fasteners. Development engineers from Sandvik bring their ideas to SFS specialists, who support the project developments via feasibility studies, prototyping and in-house technical seminars.

Paul Zwicker, Division Industrial, [email protected]

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Sandvik Coromant is the world’s leading supplier of tools, tooling solutions and know-how to the metalworking industry. With extensive investments in research and development Sandvik creates unique innovations and sets new productivity standards together with their custom-ers. These include the world’s major automotive, aerospace and energy industries.

Sandvik Coromant has approxi-mately 8’000 employees and is represented in 130 countries. It is part of the business area Sandvik Machining Solutions within the global industrial group Sandvik.

How can SFS intec make contribu-tion to Sandvik Machining Solu-tion’s (SMS) success?

All suppliers are important to SMS’ success. SFS intec can contribute in the way of delivering the right product at right time, right place and with right quality. Apart from this, continued improvement is essential as well and working with us in proactive and coopera-tive way. It is a good example we work together in setting up a new logistic model.

What was the driver behind the new logistic model?

The initial drivers were reducing time to deliver, improving stock availability, to utilise SFS intec’s capacity and to reduce cost by giving possibility to plan and produce more flexible and optimal.

How do you see SFS intec?

SFS intec is a very important supplier for SMS, and has very good knowl-edge in screws supplied to us. We need to utilise the company’s know-how knowledge more and continue in working together closely.

Innovative logistics

Sandvik benefits from the simple, easy ordering procedure for every group affiliate, while the jointly- conceived packaging concept offers further customer benefit. Parts are packed and labelled in small units according to individual requirements. SFS currently sup-plies approximately 400 different products with a high delivery perfor-mance to Sandvik.

In order to respond faster to cus-tomer and market needs, shorter and more reliable replacement times are called for. The two companies have thus been jointly engaged on a new concept. The driver is a massive reduction in

delivery times, and the first very promising strategies have already been implemented.

Together towards one goal

This is aided by reproducing Sand-vik’s customer order frequency at SFS intec. Using value stream analy-sis, we ensure that the right part is available in the right quantity at the right time. The exact quantity of fasteners required by the customer is produced. This results in a notice-able concurrent reduction in inven-tory and work in progress. As soon as they are ordered the parts can be despatched, or at least be already in production, and hence available at short notice.

The project will be extended to the entire range. Above all, close collabo-ration between the two companies is the critical factor. Once again, SFS intec offers a positive contribution to develop the Sandvik’s position as a market leader.

Interview with Yan BevissSandvik Machining SolutionsSupply Chain / Purchasing

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Mémorial ACTeCité du Vin

Cité du Vin

Mémorial ACTe

"Turn ideas into reality." – customers’ visions come true

Architects’ powers of imagination seem limitless. Their heads are filled with fantastical concepts for new designs, sizes, colours and surfaces. Impressive examples of the new wave of architectural creativity are the Paris Pompidou Centre, the Museum of Modern Art in New York or the Petronas Twin Towers in Kuala Lumpur; all of which are among the most significant structures of our time.

Unfortunately, not all architectural designs can be realised quite as conceived. Reality sets certain limits on how ideas are put into practice. These are determined by physics and by available technologies, materials and budgets. However, choosing the right partners certainly represents the best chance of achieving the vision. Companies with truly innova-tive products and new ideas can do a lot to overcome natural barriers.

Fastening is often a minor, periph-eral consideration; perhaps almost neglected during the planning phase; even though a suitable fastening system can be the key to realising an architectural dream. That’s why SFS intec has coined the phrase "Turn ideas into reality." as their core principle. With many years of

Sonja Oesch, Division Construction, [email protected] experience in fastening techniques, SFS intec specialists are able to offer application-specific solutions time after time.

The objective is always to convert customers’ ideas, or those of their architectural advisers, into reality. The following five key elements come into play:

nKnow-how: understanding pro-cesses and technologies enables customer visions to become reality

nComprehending: local presence, close to the customer helps us truly appreciate local needs

nCreativity: a solution-focused men-tality throughout the organisation embraced by every employee can only result in maximum customer benefit.

nMovement: SFS intec strives for continuous improvement in every area.

n Trust: our strong business relation-ships make us the partner of choice for all our customers.

Here are some real-life projects where SFS intec can show how these

Behind every imposing structural triumph lies the creative energy of an architect. Oftentimes the technical challenges which new buildings have to meet are not self-evident – whereby quality, highly-refined fastening techniques often help to achieve extraordinary designs. Many of them have been accomplished in close collaboration with SFS intec.

fundamental drivers have truly helped creative architectural visionaries to "Turn ideas into reality."

Cité du Vin

On the left bank of the Garonne in Bordeaux, the Cité du Vin is a sort of museum-meets-leisure complex. For the architects Anouk Legendre and Nicolas Desmazières, their design objective was a playful celebration

of wine for the nose and taste buds. So they constructed a 55 metre-high tower as the main central building out of reflective aluminium plates. The resulting design symbolised several concepts; whether it be the ebb and flow of the Garonne, the turning and swirling of wine in a glass or the knurled and gnarled form of a grapevine.

The somewhat unfamiliar design of the building presented the developers

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Expo Milano

Expo Milano

Musée des Confluences

Musée des Confluences

with numerous complex, technical challenges. The core timber frame-work of the museum was held together by WT-T double-threaded fasteners and fully-threaded WR screws. The structure was pro-tected by a synthetic sealing film and glass-fibre thermal insulation layer. The installers attached every-thing using R75 and R45 polymer sleeves in combination with TS-T25 timber screws.

This sub-frame formed the basis for the secondary aluminium structure, to which sandwich panels were finally attached. Types SA, SN and SX3 screws were ideal for the job; whereby the SX3 with their visible heads were subject to a further

design imperative. Their iridescent gold finishing served to produce a chameleon effect.

With their comprehensive know-how in construction applications, SFS intec represented the perfect partner for such a challenge; offer-ing broadly-based application solu-tions and a depth of experience in building design consultation.

Mémorial ACTe

The Mémorial ACTe in Guadeloupe was opened in July 2015. It was to be a memorial to slavery and the slave trade. It contains a collection of images and writings aimed at

reflecting the past and thus healing old wounds. For this reason the memorial wing was constructed as a black box representing the many lost souls.

The aluminium plates were attached to the metal sub-structure using MEGA GRIP® strutural blind rivets. Systems thinking led to the supply of the best installation equipment in the form of PowerBird® setting tools, enabling efficient, ergonomic assembly work. Direct supply to site from SFS production helped meet the extremely tight timing plan.

Musée des Confluences

The Musée des Confluences was opened in 2014 in Lyon. Located directly at the confluence of the Rhone and Saône, the spectacular building was conceived by the Vien-nese architects Coop Himmelb(l)au. It consists of a glass foyer designed like a crystal, symbolising its openness to humanity. The windowless exhibition areas attached are cloud-like, reflect-ing the concept of a spaceship on its journey through technological space.

A particular challenge was presented by the fastening of the external

stainless steel skin to the unusually thick aluminium structure. SFS intec developed an individual solution for this project with the customer, SMAC Vaulx-en-Velin: the self-tap-ping screw type SN7-S can penetrate 7 mm, making it just about ideal for this application.

Expo Milano

The Expo 2015, which ran in Milan from May to October, was a truly world fair. The event was guided by the tagline: "Feeding the planet; Energy for life" The site was the spe-cially-built Fiera di Miliano exhibition arena, opened in 2005 – the brain-child of the architect Massimiliano

Fuksas. Participating nations were provided with areas of between 500 and 4’500 m², with the require-ment that 50 % was to be covered in greenery.

The construction of the individual pavilions was the responsibility of the participants. SFS intec prod-ucts were used extensively both in the themed buildings (cocoa, rice, desert, island, etc.) and also in the country pavilions of the USA, Japan, Switzerland and others. The IWF fastening system was widely used to fit heat insulation elements and flat roofing membranes to timbers; while many architects chose the adjust-able TIA system for roofing featur-ing tapered insulation. Numerous

installers also chose to place their trust in SD, SN and SX screws for attaching metal cladding.

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Unisteel is the leading manufac-turer of components for hard disk drives (HDD). These are subject to exacting requirements in terms of cleanliness. Multiple clean-sing and analytical procedures help ensure that the industry’s requirements are met. Meanwhile special packing solutions maintain the quality of the components during transportation.

Hard disk drives have become a part of our daily lives. For most users, they represent storage facilities for data files, photographs and videos or music collections. In contrast, the extreme requirements placed on the drives, particularly those on the surfaces of internal components, are little known.

As clean as can be

A disk drive stores data on highly sen-sitive magnetic discs. These rotate in use at speeds of up to 7,000 revs per minute and beyond. The read / write head traces over the surface at a distance of three nanometres, making it imperative that no particle contami-nant is present.

For this reason, every component manufactured at Unisteel for use in drives, be it a spring, screw or clamp, is rigorously cleaned. This task is accomplished using heated liquids consisting of tensides and de-ionised water; while the cleansing process is supported by ultrasonic vibrations, helping to remove stubborn stains from every component. The whole process takes place under Class 100 cleanroom conditions.

Extensive checks

Electro-polishing further enhances the cleanliness of the components. Where necessary, special coatings are also applied to smooth the surfaces of the parts concerned. Every process is also environmentally friendly, further

A clean drive

Calvin Ng, Division Electronics, [email protected]

extending the boundaries of what is technically feasible.

Numerous quality control checks follow, including ion chromatography, Fourier transform infrared spectrom-etry and liquid particle count methods. These tests ensure that all compo-nents meet the cleanliness require-ments of the HDD industry – often even exceeding them. Of course the laboratories themselves have in turn to be closely monitored.

Proper packing is crucial

Following the cleansing processes, the parts are first dried and then packed. These processes also have to adhere to the same cleanliness requirements. The parts must not

come into contact with contaminants during their journey to the customer; so special packing is needed.

If the products were poured into a container and able to move about, they would rub against each other during transportation. This would result in the generation of particle contamination, which is addressed by vacuum packing. All the parts are held in position within their poly bags.

Ultra cleanliness supports the HDD producers

Using these state-of-the-art clean-ing processes places Unisteel in the position of industry leader in the

manufacture of parts for the hard disk drive industry. The number of individ-ual ultra-clean components produced annually for the industry meanwhile exceeds the billion mark; but few computer users realise quite what extreme cleanliness requirements are concealed in that box.

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Ever-increasing numbers of sensors

Assist systems are on the increase, with lane departure warning and braking assist playing a major role in current road safety. Meanwhile, auto-mated parking makes life so much easier. Even autopilot has become a reality.

Over recent years the number of sensors built into cars has increased massively, with many more vehicle categories equipped with such sensors as standard. It means things like park distance sensors have become almost standard, from small cars to luxury models. The trend has also moved beyond Europe and America to the mega automotive markets of Asia.

Major challenges for Valeo and SFS

The vast number of sensors now required represents an enormous chal-lenge to automotive system suppliers.

Carefree parking

Sensors are being used ever more widely in vehicles. This represents a major challenge to first tier companies like Valeo. The French group has carried out extensive design and production optimisation work in collabo-ration with SFS intec, increasing productivity and reducing costs.

Matthias Germann, Division Automotive, [email protected]

The Valeo Group, for example, with its HQ in France, with around 80’000 people employed worldwide, is among the largest suppliers of assist systems. The rapid increase in popularity and resulting downward price pressure has required a funda-mental overhaul of their assemblies.

For a number of years Valeo develop-ment personnel have been working closely with SFS intec specialists. Collaboration in the area of driver comfort and driver assist systems has been particularly close. Among other things, SFS intec manufactures filigree mesh membrane components for park distance sensors, responsible for accurate sending and receiving of ultrasonic signals; making them a core component of the overall system.

Cost reduction via improved design

In previous generations, the blanks were produced on cold forming machines. These would then be

clip-cleaned and subsequently machined. Looking for potential cost savings, reducing the number of oper-ations was targeted. The associated design changes would of course have influences on the membrane.

SFS intec achieved a one-step process to produce the membranes. From the original complex, multiple-process manufacturing route, the membranes were further developed with the system trimmed down to a single cold forming operation: the parts coming off the press ready-to-fit. This has resulted in a significant cost reduction.

FEM simulation for optimum design parameters

The use of FEM simulations played a big part. This enabled both the component geometry and the tooling elements to be optimised. Two con-siderations were central during this development: component strength

and cost issues. Tooling elements were therefore designed to minimise wear and simplify maintenance.

To keep the production process as lean as possible, cellular manufacture was introduced. Every process from raw material preparation through pressing to fully-automated inspec-tion and packing are managed by one team. The main advantages are short communication channels, rapid decision making and fast action throughout the manufacturing route.

Interfaces are also eliminated. This reduces waste and down-time and increases productivity.

Ship-to-line, ready-to-fit parts

The result of these measures has been the achievement of technical production and commercial targets. Of course, the visual and functional criteria were maintained. Ready-to-fit components are supplied in return-able blister packs directly to the Valeo

production line. There the sensors are finished, ready to ship to every well-known vehicle maker in the world.

n Components produced at SFS in Flawil are assembled into ready-to-fit systems by Valeo.

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The heart of the matter

The new sensor from Suunto, which measures heart rate, places extreme demands on the associ-ated fastening technology: the parts have to offer a snap-fit, convey the signal current and be water-tight. Working in close collaboration with SFS intec, an optimum solution was developed meeting all these requirements. The use of cold forming techniques ensures absolute repeatability.

Manfred Frei, Division Industrial, [email protected]

and lifestyle watches. When a fastening solution for a new heart rate monitor was needed, the very positive experience during previ-ous projects soon led to the col-laboration on product development being continued.

In this case the heart rate moni-toring sensor is located either in a chest strap or in the user’s clothing. The transmitter sending the data is located in a separate housing. This is clipped to the chest strap with a snap-fit mecha-nism which can be readily released again. A further criterion was to make the housing water-tight so that the heart rate could be monitored underwater – perhaps during swimming.

Suunto Oy is a leading manufac-turer of advanced, high-quality measuring systems. The Finnish concern, founded in 1939, has long been recognised as a pioneer in the field of compasses; while the product range has since been extended into diving instru-ments and multi-functional sports watches.

Numerous applications

When it comes to fastening technology, Suunto trusts in the know-how of SFS intec. For over ten years now, the two companies have been collaborating on solu-tions for various applications in the field of diving, pulse-monitoring

Every function combined in a single fastener

These numerous requirements placed heavy demands on the fastening technology. SFS intec specialists, however, soon developed a multi-functional stainless steel fastener featuring

the REMFORM® II"F"- thread. This could be directly inserted into the plastic housing, holding it together and feeding the signal current from the sensor to the transmitter. It also

featured a spedcaps ® coating to achieve the required water-tightness.

The geometry of the fastener head presented an enormous challenge, as this was to be used in the snap-fit closure of the transmitter, offer-ing both a secure attachment to the chest strap and the capability of easy release. The design also had to be optimised for cold forming; a technology enabling extreme repeat-ability and an economical manufac-turing route for mass production.

Joint development in record-breaking times

The ambitious timing plan from Suunto foresaw a market launch within six months. The result-ing collaboration was intensive in order to achieve the specified

requirements – particularly the fastening function on the compo-nent head. SFS intec produced numerous test prototypes for the snap-fit mechanism. This helped ensure that both opening and closing, as well as the signal transfer, all functioned perfectly. An optimum solution was rapidly developed to meet the numerous requirements concerned.

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Value analysis opening up new markets

Pascal Gonon, Division Automotive, [email protected]

Automatic start-stop systems aimed at reducing fuel consumption have increasingly become a feature of modern vehicles. The automotive systems sup-plier, Electricfil Automotive, manufactures sensors for such systems, which can for example recognise the exact position of the crank shaft. When it comes to keeping these delicate components in their exact predetermined position, Electricfil Automotive relies on the know-how and fastening technol-ogy of SFS intec. Their specialists have developed a screw with a complex geometry to meet these exacting requirements.

For many customers, economy and environmental considerations are the main criteria in the purchase of a new vehicle. So manufacturers place great emphasis on the reduction of exhaust emissions and fuel consumption when developing a new model. That’s why most of the current generation of internal combustion-driven vehicles feature start-stop functions. These shut the engine down automatically when it is inactive – for instance when standing at the lights.

Secure sensor fixing

One of the best-known manufacturers of such systems is the first-tier auto-motive supplier Electricfil Automotive of Lyon, France. For the latest

generation of its start-stop automation, the company has developed a sensor which sits directly on the crank shaft. The information on its exact position is needed by the ECU (Electronic Control Unit) to precisely control the injection phasing. Only then can the vehicle be rapidly restarted.

The extreme conditions surrounding temperature and vibration in the engine area present particular demands on sensor retention. The screws used have to be extremely robust and meet exacting tolerances. For these reasons, Electricfil Automotive involved their partner SFS intec from the initial development phase of the project. The two companies have been working closely together on injection systems since 2008.

Joint development

At the launch of the development programme, SFS intec organised a technical seminar on cold forming and fastening techniques at the Electricfil Automotive site, following which the two development teams carried out a value analysis exercise on the various potential solutions available. Their analysis examined and compared various existing basis technologies for anchoring sensors. It became obvious that available methods were too com-plicated and thus too expensive for this application.

Recognising this fact, SFS intec specialists developed a revolutionary manufacturing process where the

component is produced completely by cold forming with no secondary machining operations. Among the greatest challenges were handling the cold formed preforms, maintaining the length and concentricity tolerances and achieving the overall repeatability required. Only by controlling these factors could a feasible, stable and economically advantageous manufac-turing process be achieved.

Captive screws for fastening the sensors in position

The jointly-developed screw is manu-factured using cold forming, follow-ing which a thread is rolled on the lower shaft section. The shaft is then re-rolled to reduce its diameter.

n The captive screw (right) is produced in three production steps (left).

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Groth Development GmbH & Co. KGHyatt International LLCFreightliner TrucksBosch RexrothSchneider Electric Industries SASOSC Lille MetropoleGirondins de BordeauxOlympique LyonnaisOGC Nice, WILMOTTE et associés, F.VigourouxAS Saint-Étienne, Chaix et Morel AssociésStadler Rail AGFiat Chrysler AutomobilesSandvik CoromantXTU Architects + G. AriciqueMusée des confluences, Quentin LafontValeo Comfort & Driving AssistanceAmer SportsPSA Peugeot Citroën

M. Routurou, how would you rate your collaboration with SFS intec?

SFS intec is a very production-focused company. Its specialists possess the requisite thirst for knowledge to really get to grips with the function of the product in question. With this know-how they are in a position to create a competitive advantage for their cus-tomers. The technical guidance from project start to finish clearly reflects their care and capability. SFS intec engineers meet any responsibility pre-sented to them. SFS intec test results are also completely transparent. Not-withstanding the fine detail involved in the application, every requirement is always met.

Where do you place particular empha-sis in the choice of suitable suppliers?

Electricfil Automotive is on the lookout for technically qualified vendors ready to embrace chal-lenges. We are pioneers for progress in our field and appreciate having SFS intec as a technically qualified supply partner.

An interview withLionel RouturouAQF Electricfil

The top lip of the assembly sleeve mounted on the engine features a diameter slightly smaller than that of the screw thread. Only the special design of the screw’s flanks enable it to be inserted. Once in, due to the different diameters, it can be loosened but not removed. The ingenious overall design thus achieves a captive fastener solu-tion: the fasteners simply cannot be lost.

A rational, efficient manufac-turing process

The manufacturing solution devel-oped by the SFS intec special-ists makes expensive secondary operations redundant. Any risk of damage to, or indeed breaking of, the screw during machining is elimi-nated. Meanwhile, this co-devel-oped production process offers a high degree of repeatability,

which translates into considerable cost savings.

The new process represents a major step forward in preventing fastener loss. As well as applications in the automotive sector, it is highly suited to a range of industrial situations. That means specialists from SFS intec can offer even more persuasive argu-ments on how they can add value for customers.

Imprint

PublisherSFS Group

Editorial teamStaff of the SFS Group

Chief editorArthur Lenart, [email protected]. +41 71 727 50 38

Frequency of publicationAnnual

Printinggalledia ag, Berneck CH

CoverStade Allianz Riviera, Nice

The following images are courtesy of:

Page 4 + 5Page 8 + 9Page 15Page 16 + 17Page 18Page 22Page 23Page 24Page 24Page 25Page 32 + 33Page 36Page 38 – 41Page 42 – 43Page 44Page 48Page 50Page 52

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