EDITORIAL TABLE OF CONTENTS. Dear Sir or Madam,

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1 EDITORIAL Dear Sir or Madam, For you, our customers, maximum availability of our machinery and systems is extremely important. We have therefore optimized our service business. Faster spare parts logistics and a service hotline are just two of the associated measures. With the opening of the service center in Korea, we have added another local facility to our network providing fast and competent support. The Dürr Campus in the United States has been our largest single investment of the last few years. Here in Southfield we can offer you a state-of-the-art test and training center. Our employees from engineering, service, sales and project execution can thus collaborate more closely, and quickly respond to your enquiries. Our North American customers can find all the contacts from four Dürr divisions at this site. Since 2012 we have upgraded, expanded or built new plants at more than 15 Group sites and created additional test and technology centers outside Germany. The associated capital expenditure on expansion in the period 2012 to 2015 came to 110 million. Our clear objective is to adapt our structures and processes to speed up project execution and offer you more efficient products and services. Best wishes, Ralf W. Dieter CEO of Dürr AG TABLE OF CONTENTS Dürr sells 2,000th sealing robot Dürr Group subsidiary Verind takes over service company in Brazil Accurate testing for reproducible quality Dürr opens new US campus The best customized modification Thank you for your positive feedback and your ideas! For great versatility and targeted cost reduction Reliable tracking in a complex production process Innovation creates great demand for training

2 The new EcoRS 30L16S. DÜRR SELLS 2,000TH SEALING ROBOT New model optimizes sealing application in tight spaces Bietigheim-Bissingen, August 2016 The trend is toward fully automatic sealing of welds. Robots are increasingly performing this task in automobile production. Dürr has now sold its 2,000th sealing robot. The EcoRS 30L16S milestone machine will perform rough seam sealing, and it will also be a first. Thanks to its shortened arm 1, the robot is particularly suitable for sealing applications inside car bodies. The robot EcoRS 30L16S will seal the welds inside car bodies at Škoda in Kvasiny. The existing sealing plant is currently being expanded for this purpose. Fully automatic sealing has finally established itself on the market in recent years. More and more car manufacturers are converting their manual sealing stations. One reason is that robots can apply the seams and coatings much more uniformly and exactly than would be possible with manual application, explains Dr. Hans Schumacher, Director of the Dürr Division Application Technology. Dürr has simultaneously tailored the robots to an increasing number of applications. In addition to applying underbody protection and sill coating (PVC and paint), they are also used for liquid applied sound deadener (LASD) application. Robots also play to their strengths when it comes to highly accurate coarse and fine seam sealing, as well as cosmetic seals on doors and lids. Shorter arm for greater mobility Dürr now employs a new model to meet the special demands inside car bodies. Arm 1 of the EcoRS 30L16S is only 800 mm long, making it just over a third shorter than the previous model. This makes it much easier for the robot to enter the car body. It is simultaneously possible to utilize the existing space much more efficiently when converting existing plants. At the Kvasiny Škoda plant, the smaller robot made it possible to dispense with the floor recess normally required. This reduces conversion costs and shortens the brownfield project duration to three weeks. The EcoRS 30L16S is equipped with the latest application equipment. The EcoGun2 3D applicator s streamlined design is free from interfering contours, allowing the applicator with a lance length of 350 mm to penetrate considerably deeper into the car body than before, including into especially tight spaces. 2

3 The electric piston dosing unit EcoShot Meter Double. To make the application of viscous material more efficient overall, Dürr also improved its electric EcoShot Meter piston dosing unit. Available in two sizes, this precise system is suitable for most viscous sealing and gluing materials and covers almost all applications as a standard model. Three EcoRS 30L16S robots operate in the new sealing station at Škoda. Dürr will adapt the existing material supply and conveyor systems to the new system. Škoda will benefit in several ways from the conversion to a fully automatic sealing station: The ergonomically difficult working conditions of manual application will be eliminated, seam quality will improve, material consumption will decrease, and the new robot model is already increasing efficiency thanks to the shorter conversion time, says Dr. Schumacher in summarizing the project. Your contact: Paulo Sentieiro 3

4 Robot teaching will be one the tasks of GT Assistência at the customers sites in South America. DÜRR GROUP SUBSIDIARY VERIND TAKES OVER SERVICE COMPANY IN BRAZIL Focus on Dürr products in the automotive sector Wide range of services for customers in South America São Paulo, August 2016 Highest performance and availability are key requirements for automated paint application and robot technology in the car manufacturing industry. To assure the long-term quality in service, the Dürr subsidiary Verind has now acquired 100% of GT Assistência. This Brazil based company provides a wide range of services for Verind customers in South America. GT Assistência was established in 2009 with the objective of providing a service exclusively dedicated to the automotive sector. Up to now the company has operated independently on the market and has been the preferred business partner of Verind. With the acquisition the focus will lay on Verind customers in South America, such as Fiat Chrysler Automobiles (FCA). Our targets are to improve production efficiency, to guarantee a quick response to customer needs, as well as to provide preventive maintenance to avoid failure and production losses, and to reduce costs at customer sites, explains Dr. Hans Schumacher, President and CEO of Dürr s Application Technology division. Through this corporate takeover we will be in condition to strengthen our service activities. The highly skilled technicians of GT Assistência have many years of experience in painting and robot machinery. The tasks at the customers sites will be installations, robot teaching, commissioning, technical assistance, maintenance, spare parts control and all the others activities related to automated paint application. Since this acquisition nearly 70 employees have been working in the field of paint application technology for Dürr in Brazil. Verind is a subsidiary of Dürr s Application Technology division. It currently employs around 60 people and operates in paint application technology responsible for FCA business in Italy and worldwide. Your contact: Giuseppe Farina 4

5 The x-road Roll/Brake/ABS test stand essentially consists of four roller sets, one for each vehicle wheel. It is used to simulate different driving situations. ACCURATE TESTING FOR REPRODUCIBLE QUALITY Dürr Assembly Products offers complete end-of-line package Püttlingen, August 2016 To ensure the high level of safety and comfort in vehicles, several measuring, aligning and testing processes must be carried out in the end-of-line area. For this purpose, Dürr Assembly Products provides a complete package consisting of testing facilities for wheel geometry measurement, headlamp setting, the setting of driver assistance systems and Roll/Brake/ABS tests. For wheel alignment measurement and setting with maximum precision, the x-wheel alignment stand is the perfect match. From the basic x-wheel mainline model through to complex systems with fully or semi-automatic setting, Dürr Assembly Products has the ideal solution for customer-specific requirements. The x-wheel d test stand, which is a further addition to the portfolio, is used for wheel geometry measurement in rework areas and special vehicle production. The two non-contact measuring systems, x-contour and x-3dprofile (with three-dimensional measuring technology), offer accuracy and reproducibility. In conjunction with the x-tronic balancer for steering wheels, Dürr Assembly Products ensures precise wheel alignment with horizontal steering wheel position when driving in a straight line. Ready to meet current and future demands New headlamp models as well as different legal guidelines require the use of sophisticated setting and testing technology. The x-light headlamp setting system ensures accurate testing and enables the fully or semi-automatic setting of the main headlamps, fog lamps and high beam headlamps. In conjunction with the x-wheel geometry test stand, the headlamps are set by taking into account the wheel geometry data. Thanks to its modular design and great flexibility, the setting station ensures that even future requirements can be met without any problems. Due to the increasing use of driver assistance systems in vehicles, image processing in connection with headlamp setting systems is becoming more and more important. Driver assistance systems based on infrared distance sensors as well as radar systems with auxiliary mirrors can also be set and checked using x-light. 5

6 The x-road Roll/Brake/ABS test stand can be used to simulate different driving situations such as accelerating, braking or hill starts. In addition, control devices for front-wheel, rear-wheel and 4- wheel-drive vehicles in the end of line area can be parametrized and checked. The x-road essentially consists of four roller sets, one for each vehicle wheel. Each roller set is linked to a vector controlled AC motor. The motors are controlled by frequency converters and work individually in a driven or generator mode. Any surplus energy is returned to the grid. Automated test sequences ensure reproducible test results. Freely definable test sequences add to the flexibility of the concept. The x-road combines highly available system technology and accurate measuring technology. Prior to delivery, the quality of the measuring system is carefully checked using the x-cal test device, which has been specially developed for this purpose. End-of-line test systems by Dürr Assembly Products at a glance: Product Area of application x-wheel Wheel geometry test stand x-3dprofile Three-dimensional, non-contact wheel geometry measuring system x-light Setting system for headlamp and distance sensors x-road Roll/Brake/ABS test stand x-contour Non-contact measuring system x-tronic balancer Steering wheel balancer x-dasalign Test stand for driver assistance systems Your contact: Denis Marques 6

7 The new Southfield campus near Detroit was completed at the beginning of On 21,000 square meters Dürr bundles its activities in the fields of painting, assembly, balancing, cleaning and environmental technology here. DÜRR OPENS NEW US CAMPUS State-of-the-art validation, test and training center included Southfield, August 2016 Dürr has opened a modern campus site in the United States for more than 500 employees. The conveniently situated office and technology complex in Southfield/Michigan combines activities which the mechanical and plant engineering firm had previously carried out at three different locations in the Detroit area. The volume of investment amounts to almost 40 million. Ralf W. Dieter, CEO of Dürr AG, said during the opening event: "This investment is a clear commitment to the North American market. From Southfield we can support our customers even more effectively and exploit the growing potential of the US market." Apart from painting and final assembly technology, Southfield also accommodates facilities for cleaning and exhaust-air purification technology as well as the balancing technology business for the automotive industry. These activities were previously housed in Plymouth, Wixom and Auburn Hills. The Southfield campus comprises 11,700 square meters of modern offices. It also includes a 9,300- square-meter validation, test and training center. This is used for product development as well as for production tests and training for customers. 7

8 The US campus in Southfield houses a test and training center with an area of more than 9,000 square meters. Here plant operators can learn how to use Dürr technologies. In addition, it gives customers the opportunity to test and optimize new production processes prior to starting large-scale production. "The campus provides our employees with the ideal communication platform and ensures even more efficient cooperation, for example in engineering, service, sales and project execution. This is a key factor, especially for large system contracts. Our test and training center comes complete with Dürr s latest high-tech equipment, offering customers the perfect environment to run training and tests", explains Bruno Welsch, Head of US company Dürr Systems Inc. Your contact: Astrid Weisseise 8

9 After the modification, the exhaust-air purification system is once again equipped with state-of-the-art technology and offers the operator planning security for years to come. THE BEST CUSTOMIZED MODIFICATION Dürr's Clean Technology Systems division optimizes exhaust-air purification systems Bietigheim-Bissingen, August 2016 Not all modifications are equal. This motto also applies to exhaust-air purification systems. The experts of Dürr's Clean Technology Systems division have extensive experience and have successfully completed a number of complex modernization projects in a short space of time. They know that there is not just one solution which can be applied to all exhaust-air purification systems. At Dürr, detailed preengineering is the key for ensuring the most economical modification, explains Patrick Dippon from the sales team. What are the reasons for modifying existing facilities? Patrick Dippon: The main reason is a change in production, for example when new products are added or the level of production has significantly dropped or increased. What surprises me is how often plants are modified because they were built far too big due to incorrect assumptions. In these overdesigns, the exhaust air to be cleaned is made up of other substances, or the exhaust-air volume is significantly lower than anticipated. The third typical case is a plant that is showing signs of age and is no longer state-of-the-art. What benefits do modifications offer customers? In a nutshell, I would say that customers save resources and end up with an exhaust-air purification system that is perfectly adapted to their current or future production method. The risk of downtime is minimized. The operators have one state-of-the-art plant for which all spare parts are available. What is the standard procedure for these projects at Dürr? We usually follow a set procedure, although we do work out the most economical solution for the operator on a case-by-case basis. At an on-site meeting we analyze the present condition of the exhaust-air purification plant. This means we establish how the plant is run currently and not how it was planned. This is followed by an intensive pre-engineering stage, which consists of an accurate 'as is' survey and detailed concept development. We then present our results to the customer. 9

10 Together we discuss our proposed modification and the associated costs. And we clarify, for example, whether the project will be implemented in one go or step by step. We must bear in mind that there is not a one-size-fits-all solution. We deal with different types of plants and different ages; the customers' objectives can vary a lot, which also depends on their specific national conditions such as legislation and energy prices. Our customers benefit from the experience of our employees in all major market regions around the world. We can also develop suitable modifications for complex cases. Modifications must be completed within a short time frame. Thanks to their skills and experience, Dürr employees can minimize delays in project execution. What particular challenges do you face when carrying out projects? Short downtimes are the main challenge. We usually have around two weeks to complete projects. Downtimes are planned way in advance and cannot be moved one of my customers had planned this period seven years in advance. What this means for us is that we cannot afford any major delays in our preparatory work. Another important point is that a modification project is always an intervention in a functioning system. Process and control are closely coordinated and must now be carefully adjusted. Our intensive pre-engineering enables us to minimize the risk of delays. Your contact: Gilson Silveira 10

11 Give us your opinion" was the motto of the survey sent to all registered users. THANK YOU FOR YOUR POSITIVE FEEDBACK AND YOUR IDEAS! Clear and informative: results of the survey completed by Dürr News readers Bietigheim-Bissingen, August 2016 The Dürr News team received invaluable information during the survey sent to all subscribers to our online magazine. Thank you to everyone who took the time to answer our questions. We have received a lot of information and ideas, which will be incorporated into the content and visual design of future issues percent find Dürr News clear, and 30.9 percent very clear. The large majority of the survey participants think the information content is "good" (56.1 percent) or "very good" (30.6 percent). Features such as videos, picture galleries and infoboxes are rated as "good" by 53.5 percent and as "very good" by 26.1 percent. The overall rating of our online magazine is also very positive: 54.8 percent selected "good", and 34.9 percent "very good". The majority of participants expect Dürr News to present products (26.8 percent) and information on technical trends (25.3 percent) percent would like to learn about the entire Dürr product range rather than just individual areas. What we should improve for you Some of you commented that you would like more photos, videos and diagrams to explain how Dürr products work. Some also suggested specific topics such as articles on conveyor technology, supervisory control systems and Industry 4.0. We will explore these ideas in this and future issues. We will also discuss publishing Dürr News texts in other languages, which some of you have suggested. Your contact: Dürr-News-Team 11

12 The full-vacuum EcoCCompact system can be operated with non-halogenated hydrocarbons or modified alcohols (polar solvents) and can be easily switched from one solvent to another. FOR GREAT VERSATILITY AND TARGETED COST REDUCTION EcoCCompact by Dürr Ecoclean: new compact system for cleaning and corrosion protection Filderstadt, August 2016 Smaller and medium-sized companies, in particular, often face the challenge of having to meet different cleaning demands reliably and cost-effectively using a single system. With this in mind, Dürr Ecoclean has developed the highly versatile EcoCCompact for use under full vacuum. This cleaning system can be operated using nonhalogenated hydrocarbons or modified alcohols (polar solvents) and can be easily switched from one solvent to another. Thanks to its multitude of standard options, it can be adapted to a company's specific requirements: from degreasing and intermediate cleaning right up to fine cleaning. With a footprint of just 4,000 x 1,600 x 2,700 mm (L x W x H), the compact housing can hold one, two or three fluid tanks for cleaning and corrosion-protection processes. Tank two and/or three can also be retrofitted at a later date. The EcoCCompact work chamber is designed to hold batches of up to 530 x 320 x 200 mm in size. Alternatively, with the same footprint, a larger work chamber can be installed to hold part containers with a height of 250 mm. This not only increases throughput but also cuts parts cleaning costs. Optimizing cleaning processes To improve the quality of cleaning or degreasing processes and cut costs at the same time, the movement of the basket can be adapted to the parts to be cleaned by rotating the part container with the help of a variable-frequency drive unit. The advanced vapor degreasing or rinsing option also serves to optimize the process. With this function, the oil-laden solvent is fed directly into the distillation unit, thus minimizing the accumulation of oil in the solvent, or dirt in the flood tank, which in turn improves the quality of the processing fluid. Thanks to the HMI control panel with touchscreen and self-explanatory pictographs for quick and safe operation, the operating mode can easily be switched from cleaning to corrosion protection and vice versa as required. The EcoCCompact also offers an attractive price/performance ratio and a high level of standardization ensuring short delivery times. 12

13 With up to three flood tanks and numerous standard options, the EcoCCompact can be perfectly adapted to specific user requirements. It can be used for anything from pre-cleaning and intermediate cleaning right up to final cleaning and corrosion protection. Your contact: Giancarlo Sidoti Thanks to the EcoEMOS Tracking supervisory control system, an increasing variety of car bodies can be visually tracked in production. RELIABLE TRACKING IN A COMPLEX PRODUCTION PROCESS Dürr's supervisory control system: EcoEMOS Tracking module Bietigheim-Bissingen, August 2016 There appears to be no end to the continuous increase of model variants in the automotive industry. Customers expect great choice when selecting new vehicles. It starts with the color and numerous options for seats and rims and goes way beyond. To track this variety of models reliably in the production line, Dürr combines visual and analytical methods with the help of its supervisory control system, EcoEMOS Tracking. 13

14 The software solution EcoEMOS is a manufacturing execution system (MES) and thus a key element of Industry 4.0 at Dürr. As part of the "digital@dürr" strategy, Dürr offers smart products and smart services, which create added value for the customer through intelligent use of data. The EcoEMOS Tracking module is responsible for the tracking of car bodies in production. Operators can access all necessary information about a vehicle at any time and any place. From the VIN (vehicle information number) to the options ordered a detailed insight into production is only a mouse-click away. Thanks to the RFID read stations (radio frequency identification) or traditional bar code scanners, car bodies can be identified at several points in the line. This enables accurate monitoring of the position and sequence. In the unlikely event of a misrouted item, the system automatically sends an alarm message to the operators and thus prevents production shutdown. This module also ensures efficient storage control and sequence block optimization. The available information provides the necessary basis for EcoEMOS to make specific improvements to the production process and significantly reduce costs. Production cycle times become more flexible, idle times of materials are reduced the principle of just-in-sequence needs supervisory control systems like EcoEMOS Tracking in the production line. The information necessary for this principle must be recorded simultaneously and in full. EcoEMOS Tracking offers the required technological standard as well as the right functions to integrate this concept fully into the production process. Your contact: Wilson Baldin Academy head Andreas Zander (right) with a training participant at the technical center in Monschau. INNOVATION CREATES GREAT DEMAND FOR TRAINING Dürr Ecoclean Academy offers training for parts cleaning in the automotive industry Monschau, August 2016 The SCARA manipulator is the first Dürr Ecoclean robot developed in-house. The first systems integrating this robot, specially designed for the rough conditions in cleaning systems, are now being delivered. For this and other innovations, the 14

15 Dürr Ecoclean Academy in Monschau offers practical training for parts cleaning in the automotive industry, as Academy head Andreas Zander explains in the following interview. Has the SCARA manipulator created a great need for training among customers? Andreas Zander: The response to the new product has been overwhelming. Requests for training range from basic system training and maintenance training through to specialist training on how to program the manipulator. Your training is aimed at the automotive industry worldwide. What are the main topics at the Monschau Academy? Seminars on component cleanliness and cleaning technology are in particular demand. Our program includes "system training for operators", "system operation and troubleshooting", "preventive maintenance" and "robot system operation in cleaning systems". The training is tailored to customers' requirements. All participants receive relevant guidelines, to which they can refer at a later stage as required. What countries have a particularly high demand for training? So far, China is top of the list, followed by European customers. We have noticed that more and more customers are requesting training as part of the package when ordering new systems. Is the majority of the training conducted at the customer's site? What is the percentage of in-house training in Monschau? Yes, most of our training is conducted at the customer's site using their tailor-made system. Inhouse training takes place once or twice a year, compared to 30 to 40 training events at customer sites. How large is the Academy team, and what is the background of your trainers? Our team of trainers currently consists of seven service employees, who have gained an additional qualification as technical trainers in the Dürr Group. When choosing trainers, we always pay close attention to their main qualification be it mechanical engineering, electrical engineering or robot technology to offer customers the best possible expertise. We do, however, ensure that all of our trainers can deliver the basic system content. In our specialist training, we can also draw on the support of our colleagues from engineering. Your contact: Andreas Zander 15