contents 4 2 company awards foreword by the chairman of the group executive board 10 innovation 4.0 8 facts & figures 6 34 the group executive board of körber ag 22 logistics systems 14 körber ag worldwide 28 machine tools pharma systems 16 automation 46 tobacco 40 tissue 56 growth targets & corporate values 52 overview of the business areas 54 companies of the business areas 58 income statement / balance / key indicators masthead publisher körber ag, corporate communications, hamburg concept, layout, and production bissinger[+] gmbh, medien und kommunikation, hamburg printing beisner druck gmbh & co. kg this annual report is published in german and english.
we are körber körber — a name that stands worldwide for powerful innovations, technological progress and unique expertise — all unfailingly focused on achieving success and satisfaction for our customers. we are global market leaders in all of our business areas. our broad knowledge and experience are our unique selling points in the market. we operate globally without losing sight of local requirements. this benefits our customers across the world. they value our reliability and our specially tailored solutions. the körber group is built on strong foundations — our joint fundamentals and corporate values are the sound basis of our activities throughout the group. they provide a touchstone as we continually update our strategy which is geared towards our target: long-term profitable growth.
company awards a w a r d s a n d a n n i v e r s a r i e s k ö r b e r a g a n n u a l r e p o r t 2 0 1 6 pharma systems rondo rondo and ucb pharma were honored with the german packaging award in the category “function- ality and convenience” for their innovative packaging of the medication cimzia®. machine tools united grinding at the ringier technology innovation awards cer- emony, united grinding china received an award in the category “machine tools for metal pro- cessing” for its walter helitronic vision 400 l high-performance tool-grinding machine. pharma systems werum it solutions werum it solutions was a winner in the asian manu- facturing awards com- petition in the category “best pharma solutions provider” for several reasons, including the advanced development of the pas-x manufacturing execution system. and the winner is… the körber business areas had many reasons to be proud in 2016. 2
automation lti motion lti motion gmbh and heinz fiege gmbh received the innovation award of the sector magazine mm maschinen- markt in the “milling” category for their joint development of the levispin drilling spindle. logistics systems gearl the joint venture godrej efacec automation & robotics, which now operates as godrej consoveyo logistics automation, based in mumbai, india, received the warehousing excellence award for the second time. machine tools schaudt the chinese automobile manufacture industry magazine presented the user’s commendation award to schaudt for its crankshaft grinding machine crankgrind, which it praised for its stability, reliability, and user-friendliness. pharma systems mediseal the consulting firm id-consult has honored the top three participants cited in the study “the influence of modular product systems on corporate success” with the modularization readiness award. mediseal was one of the winners. tobacco hauni 70 years of innovation: on july 14, 1946, kurt a. körber laid the foun- dation for today’s hauni maschinenbau gmbh. all of the employees at the plant in bergedorf celebrated the 70th anni- versary of the company, which offers solutions for the tobacco industry. tissue fabio perini fabio perini celebrated its 50th anniversary with a gala dinner for custom- ers in shanghai, china; an in-house exhibition in green bay, usa; an open house in lucca, italy; and colorful festivals for the employees and their families at all the company’s locations. logistics systems inconso ag sap confirmed inconso ag to have sap recognized expertise in the area of supply chain manage- ment/extended ware- house management. this recognition makes inconso ag a qualified service partner for imple- menting logistics solu- tions for the application of sap ewm. 3
foreword by the chairman of the group executive board f o r e w o r d b y t h e c h a i r m a n o f t h e g r o u p e x e c u t i v e b o a r d k ö r b e r a g a n n u a l r e p o r t 2 0 1 6 “we are developing digitization into one of our core areas of expertise” dear ladies and gentlemen, dear business partners, innovations and investments in new and future-oriented technologies and solutions for the benefit of our customers, as well as a high level of customer satisfaction, have always been key elements of our long-term operations, and thus of our corporate success. current developments related to the new technologies and innovations of the fourth indus- trial revolution are transforming entire markets and industries. today concepts such as the smart factory, industry 4.0, the internet of things, and digitization in general are significantly impacting everything we do. business models are changing and expanding in fundamental ways; organizations and pro- cesses are being transformed at an ever faster pace. in order to shape this radical transfor- mation successfully, we consistently think in terms of digital solutions and industry 4.0 applications. at körber, we are convinced that digital and networked products and processes are the cru- cial factors behind our customers’ future success. already today we are providing first-class solutions and products that match our customers’ needs or developing these together with our customers. to this end, we are continuously improving our know-how, our technologies, and their possible applications in the area of digitization into a further core area of expertise across our entire group. in this report you will find interesting examples of “innovation 4.0 made by körber” with which we are already supporting, delighting, and inspiring our customers. they include smart machine components, collaborative robotics solutions, intelligent packaging that makes it eas- ier to communicate with patients, and service technicians who are linked into the action vir- tually and in real time. “innovation 4 .0 m a de by körber” innovation 4.0 made by körber is clearly the logical consequence of our guiding principle “we are körber — strong together for our customers’ benefit.” all over the world, our companies and employees work together closely and act as partners of our customers in their respective mar- kets. our teams are continuously improving their performance in a process of exchange and sharing — always for the benefit of our customers. in parallel, through measures such as our group-wide it infrastructure project global it@körber, we are today creating the prerequisites that will enable us to offer new, innovative, and successful solutions, applications, and products to our customers and partners in the future as well. we are doing so in the areas of industry 4.0 and digitization as well as in our traditional business operations. 4
thanks to the positive results of all of our business areas in 2016 and our good development in the first months of the current fiscal year 2017 we are looking at the future with great con- fidence. in 2016 we received orders totaling €2,357 million. that represents a significant in- crease of more than 7 percent compared to the previous year. our group sales amounted to €2,215 million. the decrease in sales, amounting to approximately 4 percent compared to 2015, is due to changes in the portfolio that took place in the previous year. our consolidated earn- ings (ebita) increased by over 20 percent in 2016, to €171 million. in addition, through our acquisitions in 2016 we further strengthened our focus on growth and technology as well as our global footprint. the danish company qubiqa logistics expands our portfolio and is accelerating the internationalization process at our business area logistics systems. the us company fargo automation supplements our range of services as well as our market presence in the business area pharma systems. in 2016 we also concluded the sales of baltic elektronik and baltic metalltechnik in grevesmühlen. both of these companies were sold to new, more broadly based owners that offer them new opportunities for development and growth. we would like to express our special thanks to our employees and managers, who in 2016 once again contributed to the success of our customers and our group and advanced it with several innovations — all of this with tremendous commitment, responsibility, and their broad expertise. we will continue moving along this successful and future-focused course together in 2017. i would like to sincerely thank our customers and business partners, both personally and on behalf of the entire group executive board and all of our employees, for the trust you have placed in us and for your excellent and successful cooperation. we look forward to actively and strongly supporting your business success in the future as well, with innovations, customized solutions, and the highest possible degree of customer orientation. hamburg, may 2017 s t e p h a n s e i f e r t c h a i r m a n o f t h e g r o u p e x e c u t i v e b o a r d o f k ö r b e r a g 5
the group executive board of körber ag t h e g r o u p e x e c u t i v e b o a r d o f k ö r b e r a g k ö r b e r a g a n n u a l r e p o r t 2 0 1 6 towards the future breaking new grounds together: the group executive board of körber ag harald vogelsang member of the group executive board of körber ag 6 stephan seifert chairman of the group executive board of körber ag
christopher somm member of the group executive board of körber ag michael horn member of the group executive board of körber ag 7
facts & figures fa c t s & f i g u r e s k ö r b e r a g a n n u a l r e p o r t 2 0 1 6 how we create the future to anticipate tomorrow’s trends with tailor-made solutions, you need plenty of innovative ideas and the drive to put them into practice. just like körber. automation 4.0 plug & produce solutions from the automation specialists at lti motion cut machine setup times by up to 70 percent. connected working by the end of 2018 around 11,500 employees throughout the group will become users of a new, higher-performance it infrastructure — and thus of new possibilities for mobile and connected working — as result of the global it@körber project. percent space savings langhammer from the business area logistics systems is presenting a highly flexible complete solution for palletizing different product groups in the form of a robot- supported layer-handling system. it offers a space saving of up to 40 percent compared with conventional layer palletizers. 8
smart sales tools the business area machine tools has developed a sales app that contains several tens of thousands of digitized documents, presentations & films about the solutions and products offered by the individual brands. a virtual reality headset also enables customers to take a realistic trip into the business area’s machines. years of expertise the new be series of blister machines from mediseal was the first of the company’s systems to be developed to be fully modular and has been honored with the “modularization readiness award” as a result. this solution provider from the business area pharma systems has achieved a significant increase in machine availability — for even more productive time. 80 years of expertise in blister technology have paid off once more for the customers. online support the hauni remote service enables the tobacco-industry solution provider’s customers to instantly resolve around 60 percent of all machine faults. the constellation effect during the past year, fabio perini from the business area tissue sold 50 production lines with integrated constellation technology. this innovative winding system raises the quality of the end product and optimizes customers’ production processes thanks to its consistent alignment with the requirements of industry 4.0. 9
innovation 4.0 i n n o v at i o n 4 . 0 k ö r b e r a g a n n u a l r e p o r t 2 0 1 6 connecting knowledge. creating value. digitization and industry 4.0 are revolutionizing all aspects of industrial production — and körber is supporting to shape these developments. r efrigerators that send shopping lists to smartphones, heating systems that are quence of these developments. the catch- word here is industry 4.0, which refers to the growing link between conventional produc- tion systems and state-of-the-art information and communication technologies. digitiza- tion is the primary driving force behind in- remotely controlled with apps, and cars that dustry 4.0, which stands for the fourth indus- park themselves — what sounded like science trial revolution: the first industrial revolution fiction just a few years ago has long since be- took place in the 18th century when the steam come reality. the foundation for this rapid de- engine replaced muscle power; the second velopment is a technological leap that re- revolution saw assembly lines and electricity volves around the internet, data analyses, pave the way for mass production at the be- sensors, and mobile terminals such as tablet ginning of the 20th century. the third indus- computers and smartphones. this digitiza- trial revolution transformed the nature of tion of daily life will continue in the coming work with the advent of electronics, informa- years. for example, according to estimates tion technology, and automation starting in about 50 billion mobile devices will be in op- the 1970s, and the fourth revolution is estab- eration worldwide by 2020, accompanied by lishing a new era by digitally networking the just as many communication and internet-en- entire value chain. abled “objects” — smart household appli- key components of this development are ances, apparel, and mobility solution compo- cyber-physical systems (cps) — machines nents. the “internet of things” continues to and facilities that are digitally networked and expand and is set to change our lives more establish a connection between the physical drastically than ever before. world and the world of data. a cps is a virtual indus try in tr a nsform ation industry is also undergoing a fundamental object in the digital realm that is able to per- ceive its surroundings via sensors and can ac- tively influence this environment using actu- ators, such as drive system elements that transformation — as both a basis and a conse- enable mechanical movements. in an internet 10 internet of things the internet of things refers to the sum of all objects that com- municate autonomously via the internet and carry out tasks or perform individual services for users.
of things, cyber-physical systems will be linked to and communicate with one another. once this occurs, any component involved in a production process will be able to collect in- formation, for example on its own capabilities and current state, and then publish this data hensive networking of complex production and share it with another cps. machines or processes and value chains. this includes the entire facilities will then be able to coordinate establishment of international manufactur- with one another, control each other’s opera- er-independent standards for data storage tions, and move components through the and communication, as well as the develop- manufacturing process with maximum effi- ment of big data analysis techniques that will ciency. data will thus become the essential make it possible to evaluate and intelligently factor in the design of industrial production. utilize the huge amounts of data generated in fac torie s bec ome sm a r t this development will ultimately lead to the production networks. increasing digitization and networking offer tremendous opportuni- ties. for example, a study commissioned by establishment of smart factories and thus a the federation of german industries (bdi) es- production system that largely organizes it- timates that expanding digitization and net- self, utilizing data from procurement, logis- working could increase industrial gross value tics, and sales units, for example, and taking added by €1.25 trillion in europe alone be- account of external factors such as energy tween now and 2025. prices in the process. this will lead to a sig- nificant increase in the efficiency of the value chain and also enable industrial companies körber a s a pioneer the grinding machine manufacturer studer to react to the requirements of markets and offers a good example of how industry 4.0 individual customers much more flexibly and works in practice. the körber company from quickly — for example by providing custom- the business area machine tools is currently ized products and services. implementing its own smart factory. the proj- in order to transform all of this into real- ect is part of a comprehensive digitization ity, experts around the world are working to strategy that körber is using as a basis for ac- develop solutions that will enable the compre- tively creating the future. within the frame- big data big data refers to data whose huge volume and complexity make it impossible to process and evaluate it using conventional methods. work of this strategy, experts throughout the entire group are extensively studying the key technology drivers behind industry 4.0 — ev- erything from smart sensors to 3d printing and holistic software systems for monitoring and controlling production and logistics pro- cesses. the goal here is to exploit the various new possibilities in order to create networked products, processes, services, and new busi- ness models that improve value creation 11
i n n o v at i o n 4 . 0 k ö r b e r a g a n n u a l r e p o r t 2 0 1 6 new and innovative solutions. to this end, körber invests an above-average amount in research and development in order to acceler- ate the development of smart technologies and disruptive business models throughout the group. decisions about acquisitions will also be heavily based on digitization and in- dustry 4.0 considerations in the future. of particular interest, therefore, are research spinoffs, startups, and other companies that can either contribute to the further develop- ment of the körber technology base or else of- fer the group access to new, pioneering busi- ness units. here, internal and external growth go hand in hand within the framework of the digitization and growth strategy. le v er aging s y nergie s a key factor of success here is the creativity of our employees. during the most recent fis- cal year, körber companies applied for 124 new patents, and 216 patents were granted af- for körber customers, and thus offer measurable value added. broa d technology ba se körber can rely on a broad technology base for its efforts here. with its six business areas ter the normal examination procedures were — automation, logistics systems, machine completed. in order to further strengthen the tools, pharma systems, tissue, and tobacco innovative capability of our employees and — the group can fall back on extensive and exploit synergies in the process, the group is, detailed expertise in the areas of automation, among other things, networking the knowl- sensor systems, software, and mechanical edge of its technology experts across all busi- and plant engineering. the focus at körber as ness areas and locations worldwide. a good the group moves into the digital future is to example of this approach is offered by net- develop and combine existing technologies in work center technology (nct) — a compe- line with the requirements of industry 4.0 so tence network in which specialists from all that a broad range of industrial applications business areas extensively discuss pioneer- can be covered. in addition, the group contin- ing technologies, initiate joint projects, and ues to forge ahead with the development of exploit external expertise in a targeted man- ner. the ten specialist working groups that participate in nct meetings focus on indus- try 4.0 and digitization topics. in may 2016, the nct “sensor” cluster, which consists of experts from the business areas pharma sys- tems, tobacco, tissue, machine tools, and automation, defined the new topics for its work in 2017. a key area of focus here involves smart sensors that support industry 4.0 solutions. körber is also getting its own processes ready for the digital future. in its global it@ körber project, for example, the group is pro- viding all of its locations worldwide with a 12
leading supplier to the tobacco industry, has developed a digital service package with a corresponding tablet app that enables cus- tomers to obtain remote technical support and helps cut production downtime by as much as 30 percent. fabio perini, the leading company in the business area tissue, also of- fers remote technical support in real time with its wearable innovative high-tech high-performance, efficient, and secure it in- helmet. frastructure for all standard (and especially whereas the latter two systems enable the digitization) solutions. all employees at the rapid and efficient resolution of breakdowns, körber group will begin to benefit from these the machine tool manufacturer schaudt by the end of 2018, as the new platform will mikrosa is using a lifecycle monitoring sys- also make mobile and networked working tem to find the causes of machine failures. easier to implement. innovation 4 .0 in parallel with the group-wide initiatives, the software-based machine-condition mon- itoring system offers a benefit in that users can plan for required maintenance intervals in advance and thus exclude the possibility of and in line with the common digitization unwanted shutdowns. schaudt mikrosa is strategy, the business areas are also continu- already taking things to the next level in the ally and intensively developing their activi- ameli 4.0 joint project, which will enable ties and adapting them to the requirements of even better machine-condition monitoring by their respective target markets. cooperation more powerful sensors. with customers is playing an increasingly im- a project at dividella focuses on the vari- portant role, as it enables the business areas ous opportunities offered by human-robot human-robot to learn more about customer requirements collaboration. this swiss manufacturer of and needs, while also making it possible to packaging machines is incorporating a col- incorporate a broad range of information and laborative robot into the process for a flexible data into the development of new solutions. packaging system in a way that enables the one thing is clear: the use of a holistic ap- robot to package medications on its own. an- proach is the only way to ensure that the var- other exciting project — this one from the ious possibilities offered by industry 4.0 and business area pharma systems — is smart digitization can be exploited comprehen- packaging, which the swiss company rondo sively for the benefit of customers. ag is using to establish new interactive com- the following sections describe how the munication channels between patients, phy- business areas are using the intelligent net- sicians, and pharmacies. working of machines, processes, and data to however, the starting point for the jour- help customers. here, innovative products ney into the digital körber world is levispin and services from körber are presented in a — a magnetic-bearing drilling spindle from manner that also offers a preview of the future the business area automation with high-res- of industrial production. examples include a olution sensors that enable detailed process service app from aberle — the system integra- monitoring, and a 6d drilling system that has tor from the business area logistics systems. taken drilling technology a decisive step into this app uses augmented reality to support the future. this innovation was developed in the company’s customers with facility main- a close cooperation between lti motion and tenance and repair operations. two projects heinz fiege gmbh — in line with the motto: at the business areas tobacco and tissue “innovation 4.0: networking knowledge. cre- have similar objectives. hauni, the world’s ating value.” 13 collaboration in human-robot col laboration, people and autonomous robots work together in the same area without protective barriers between them. augmented reality augmented reality appli cations enrich visual depictions of reality with useful additional information.
k ö r b e r w o r l d w i d e k ö r b e r a g a n n u a l r e p o r t 2 0 1 6 14
production product design time additive manu fac turing software sensors
laser c o n n e c t i n g i d e a s the network center technology connects the best minds at the körber locations worldwide. körber established the net- work center technology (nct) in 2009. the center’s objective is to connect the group’s tech- nology experts and so initiate an exchange of knowledge across the business areas and between the körber locations throughout the world. since then, the members of the ten specialist working groups meet more than once a year to make new technologies useful for our customers. it’s a fruitful exchange. numerous joint projects have already been successfully driven forward by the nct. machine safety materials auto- mation
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business area automation 16
business area automation how cooperation between two automation specialists is revolutionizing drilling technology. 17
b u s i n e s s a r e a a u t o m at i o n k ö r b e r a g a n n u a l r e p o r t 2 0 1 6 levispin the name of the innovative drilling spindle is derived from the words levitate and spin. good vibrations lti motion and fiege, two specialists in the business unit motion technology, have jointly developed a fully automated, vibration-assisted drilling spindle that has taken drilling technology a decisive step into the future. g ood ideas tend to release creative forces — as was the case with the development ample, long metallic chips — known as flow chips — are formed and these generate sub- of levispin, an innovative drilling spindle stantial friction on the bore wall and can also from lti motion and heinz fiege. it all started damage sensitive materials such as cfrps. with an unusual idea that was taken up by the “the friction also leads to a very high operat- two companies in the business area automa- ing temperature, and drilling tools break tion, who worked closely together and com- down more quickly as a result,” says markus bined their core expertise to create a new dirscherl, head of global industry manage- drilling technology that is now setting stan- ment machine tools at lti motion. “this of dards around the world. the key here is that course has a negative effect on efficiency and levispin reduces the size of drill chips, thus costs.” enabling a higher level of productivity with better drilling quality and lower costs. the project began in april 2015 with initial basic sm a ll drill chip size s flow chips have posed a problem in drilling testing; the first prototype was completed just processes for decades now. back in the 1950s, one year later. extensive interest in the inno- experts at bauman moscow state technical vative technology was immediately expressed university began searching for a solution. by numerous well-known companies from their research focused on vibration-assisted the aviation and automotive industries, as drilling, which works as follows: along with well as manufacturers of pneumatic and hy- the forward motion of the drill, there are also draulic valves. field-test units are now being overlaid vibrations that are generated axially operated by customers. light w eight de sign trend the new drilling technology is important be- (i.e. in the drilling direction). these break the drill chips and thus keep chip sizes as small as possible. the automation specialist lti motion and cause companies in the aviation and automo- the spindle technology company heinz fiege tive industries are increasingly employing have now achieved a breakthrough with vi- lightweight materials in order to conserve fuel and thus lower co2 emissions as well. combi- nations of various materials are being used bration-assisted drilling by building the world’s first vibration-assisted drilling spin- dle that can be used in fully automated pro- more and more often. for example, the new cesses. this innovation offers extensive mar- airbus a350 contains combinations of tita- ket potential. for example, the drilling of rivet nium and carbon fiber-reinforced plastics holes is one of the most important and de- (cfrps). the increased application of these manding production steps in the aircraft man- composite materials has changed the require- ufacturing industry — several hundred mil- ments for drilling processes. in the conven- lion rivet holes are drilled every year in the tional drilling process with titanium, for ex- airbus group alone. 18
the secret behind the success of levispin has to do with magnetic bearing technology, which makes it possible to superimpose ad- ditional vibrations on the position of the spindle shaft, which is suspended in a mag- netic field. as a result, levispin only pro- duces short chips that cannot do any damage to boreholes or materials. “the drill more or less strips out the bore,” dirscherl explains. “the small chips produced as a result are blown out of the bore with air that is chan- neled to the cutting edge of the tool by “the drill more or less strips out the bore; the small chips produced as a result are blown out of the bore with air” markus dirscherl, head of global industry management machine tools at lti motion innovation team at the business area automation: markus dirscherl (left) and mathias fiege 19
b u s i n e s s a r e a a u t o m at i o n k ö r b e r a g a n n u a l r e p o r t 2 0 1 6 means of integrated cooling bores in blunt, the magnetic bearing will take in more the drill.” levispin’s lower chip friction re- electricity. the machine operator can define duces operating temperatures as compared in advance whether a new tool (known as a to conventional techniques and thus signifi- sister tool) should automatically be used for cantly improves bore quality and the service the next bore in such a situation. in addition, life of drills, especially when drilling deep the machine control system can automatically holes. stop the drilling process if sensors register lti motion and heinz fiege also devel- atypical readings and there is a danger that oped the 6d drilling technique, which gives the component will have to be scrapped due their drilling spindle great freedom of move- to a damaged tool or a loose workpiece that ment. whereas conventional drilling spindles leads to vibrations. 6-d drilling levispin can be programmed for drilling in six degrees of freedom, which means this spindle technology enables 6-d drilling for the first time. basically can only rotate, the levispin drilling the sensors can also detect different ma- spindle shaft can be programmed via a ma- terial layers, which offers a decisive advan- chine control system and moved with five ad- tage when composite materials are drilled. ditional degrees of freedom. “it is therefore “the required process parameters, such as now possible to not only optimally adjust chip forward motion, rotation speed, and vibra- size, chip shape, entry speed, and angle of en- tions vary tremendously among different ma- try to a given drilling process but also achieve terials in some cases,” says dirscherl. “le- for the first time process optimizations such vispin can be programmed in a way that as automatic rear-side burr removal and com- ensures the parameters are automatically ad- pensation of drift when drilling deep holes,” justed when the drill enters a new material says dirscherl. “this offers significant value layer.” added and major potential in terms of produc- tion optimization.” “we complemented each other perfectly. this is exactly what enabled such rapid and successful development work” mathias fiege, managing director of heinz fiege gmbh holis tic s ys tem levispin, with all of its functions, is not just a particularly innovative individual compo- nent. instead, the drilling spindle is actually a holistic drilling system that has the poten- tial to revolutionize manufacturing pro- cesses. in this sense, cooperation between lti motion and heinz fiege shows just what’s possible when specialists apply their expertise in a targeted manner that also con- sistently focuses on customer utility. “the fiege experts contributed their knowledge of various spindle functions, while the spe- cialists at lti motion took care of the mag- netic bearing technology and the drive sys- tem,” mathias fiege explains. “we complemented each other perfectly. this is exactly what enabled such rapid and success- ful development work.” but that’s not all — levispin also makes a ma- it didn’t take long for the joint develop- jor contribution to industry 4.0 in the form of ment to attract attention and praise either, as multifunctional sensors mounted in the drill- the industry magazine mm maschinen markt ing spindle that provide machine operators presented levispin with the prestigious mm with detailed process monitoring data and en- award 2016 in the “milling” category during able them to draw up preventive maintenance the amb international exhibition for metal- plans. for example, if the drill begins to get working in stuttgart. 20
improved drilling the levispin magnetic bearing drilling spindle guarantees reliable and economical drilling processes fast levispin enables more rapid forward movement, higher cutting speed, and the use of pcd tools and drills with three cutting edges. economical customers benefit from a longer tool service life, maintenance- free storage, and less expenditure on coolants and chip removal operations. precise the levispin spindle ensures stable bore quality. extra benefit: no burr formation at the drilling tool exit. efficient process optimization with cutting parameters that reduce tool stress and integrated sensors that identify materials. 21
business area logistics systems business area logistics systems how augmented reality and proof of delivery solutions generate added value for customers. 2222
b u s i n e s s a r e a lo g i s t i c s s y s t e m s k ö r b e r a g a n n u a l r e p o r t 2 0 1 6 deep insight thanks to mobile data two examples from aberle and inconso illustrate just how far industry 4.0 has already advanced in terms of the intelligent networking of machines and people. h umans have always dreamed of being able to see the invisible — and augmented circuit diagrams, detailed images, or work- flows from operating manuals. if desired, reality is now making that dream come true. smart glasses can also be used to provide sup- for example, digitally optimized logistics fa- port in the form of an additional information cilities, such as automated high bay ware- channel. for example, the smart glasses worn houses, now make it possible to view techni- by the service technician at the facility can cal processes that normally would not be send a live video stream to the support team apparent at first glance. service technicians in aberle headquarters. the team then sees at the system integration company aberle everything the onsite technician sees and can now only need a standard tablet, smartphone, provide immediate support to help solve the or laptop to do this. aberle’s innovative ser- problem. vice app provides precise information on the all of this enables a mobility and time-op- operational state of machine and facility com- timized — and paperless — service. “the new ponents while the technician’s on the move. service app makes it possible for our onsite and in the event of a breakdown the app technicians to quickly access all relevant doc- guides technicians through all the steps that uments on the hardware components and it are needed to fix the problem. infrastructure for everything from erp sys- digita l supp or t the secret behind this “x-ray vision” involves tems to programmable logic controllers,” achim aberle, head of development, ex- plains. “this simplifies and accelerates pro- numerous markers placed on specific ma- cesses, improves the quality of our services, chine parts and components. for example, if and reduces machine downtime to a mini- technicians point their tablet at a particular mum.” spot, they will see on their display not only a real image of the machine part they’re point- ing at but also context-related information that can help them with maintenance plan- produc t s olu tion s ta r ting in 2 018 the innovative service app, which has com- ning, servicing, and repair operations. the prehensively demonstrated its effectiveness service app makes use of the principles of internally at aberle since the beginning of augmented reality here by delivering live im- this year, will be rolled out as a product solu- ages along with useful additional or back- tion for the system integrator’s customers in ground information such as operating hours 2018. “after the market launch, our custom- to date, service intervals, and the latest error ers will be able to acquire the app for use by messages. their own service staff,” says andreas ebert, depending on the specifics of the work or- the aberle managing director responsible der, the mobile device can also display digital for sales. 24 erp system enterprise resource planning (erp) systems help companies plan and manage the use of resources such as personnel and production materials.
the tablet as a problem solver aberle’s innovative service app reduces machine downtime to a minimum. a look inside when technicians point a tablet at a machine part, the service app provides them with detailed informa- tion on its current operational state. paperless service the aberle service app allows users to access digital circuit diagrams, detailed images, or workflows from operating manuals as needed. step by step the service app guides technicians through all the steps for fixing a problem. among other things, live images of machine com- ponents can be displayed along with useful additional or background information. 25
b u s i n e s s a r e a lo g i s t i c s s y s t e m s k ö r b e r a g a n n u a l r e p o r t 2 0 1 6 mobile assistants: tablets provide relevant information in real time. a typical feature of this industry 4.0 im- electronic shipment tracking with digital plementation project involves the use of mod- documentation of all transfer points in the de- ern and cost-effective features of tablet com- livery chain is really nothing new. indeed, puters and smartphones in order to optimize anyone who has received a package by mail is business processes and project steps. in addi- familiar with the process of digitally signing tion, digitization has been taken to its logical for it on a mobile device. even before the pack- conclusion in that no paper whatsoever is re- age is delivered, it is possible to track it on the quired at any of the stages of the value and service chains. this isn’t just good for the en- vironment, as it also enables all relevant in- formation to be accessed via the system in its most up-to-date version in real time. these two benefits are also offered by another sys- tem from the business area logistics sys- tems — the inconsopod proof of delivery solution developed by the software company “we are able to ensure seamless data integration from the customer’s erp system to the driver’s mobile device” inconso. wilfried pfuhl, member of the inconso board of directors 26
internet, locate its position in the delivery pro- conso board of directors member responsible cessing chain, and obtain an estimated time for project and product development. “for ex- of arrival. however, the system that europe’s ample, a wide variety of sensors for measur- leading logistics software provider, inconso ing temperature or humidity in cargo areas or ag, has developed can do a lot more. detecting doors that have been left open could the cloud-based app solution known as be incorporated into the process.” inconsopod particularly displays its strengths when it’s used by industrial and re- tail companies that often operate with a com- gre ater t r a nspa rency inconsopod thus makes the delivery process plex mixture of their own vehicle fleets and more transparent and reduces the number of external transport capacity purchased from administrative tasks that have to be per- shipping companies. one such inconso cus- formed — tasks that offer very little added tomer, a provider of system solutions for value. however, additional added value is gen- roofs, has been using the app for a little over erated by the provision and use of the col- a year now. the customer sends the inconso lected data at the inconsopod portal, where pod transport platform the latest informa- customers can use portal dialogs to check the tion from its erp system (enterprise resource status of their delivery and download delivery planning) on all the day’s delivery runs. all notes containing all the latest data immedi- of the drivers have the associated app on ately after delivery if they need to have such their mobile devices — for example their documents in writing. senders can also see smartphones. proce s s -rele va nt inform ation the app not only displays the delivery trip whether a delivery is running late and then implement any required measures. the infor- mation collected at the portal can also be used to initiate follow-up processes or manage complaints. plan and the associated itemized delivery the app is available for use with all three lists; it also provides information on whether common smartphone operating systems (ios, empty pallets need to be collected at a deliv- android, and windows). “it has an intuitive ery site, whether a delivery note needs to be interface, so it can be used spontaneously at issued or if an electronic signature is suffi- any time in tightly synchronized delivery op- cient, and whether a photograph of the deliv- erations,” pfuhl explains. “with inconsopod, ered cargo needs to be taken at the construc- we are able to implement seamless data inte- tion site in order to document its damage-free gration from the customer’s erp system to the condition, for example. inconsopod trans- driver’s mobile device, with the possibility of forms the mobile devices it’s used on into mul- carrying out numerous real-time analyses tifunctional units that can display all the along the way.” above mentioned information with just a few clicks. the consignment data for the individual shipments is scanned with a smartphone high degree of data securit y all of this data is stored in the cloud of a ger- camera when a delivery is made, and images man data-management company certified in and signatures are also digitized and for- accordance with the country’s exceptionally warded to the consignment sender, which stringent and continually updated security then has access to seamless documentation of standards. this is crucial, because in systems all transports, including time stamps and gps that form the foundation of industry 4.0 — i.e. data. “we can even go a step further and use where devices exchange information with other smartphone functions such as blue- one another and with their human operators tooth to collect additional process-relevant — it must be ensured that sensitive data never information,” says wilfried pfuhl, the in- gets into the wrong hands. 27
business area machine tools 28
business area machine tools how schaudt mikrosa is preventing unplanned machine failures by means of planned downtimes. 29
b u s i n e s s a r e a m a c h i n e t o o l s k ö r b e r a g a n n u a l r e p o r t 2 0 1 6 the maintenance inter- vals for the kronos s 250 can also be planned in advance with the life cycle monitoring system. comprehensive monitoring unplanned machine and facility downtimes are very expensive. schaudt mikrosa is now preventing them with a system for comprehensive condition monitoring of grinding machines. 30
c ompanies can’t make money with a machine that isn’t working. this might the system also helps schaudt mikrosa cus- tomers to diagnose and repair faults. if a dis- sound like a simple idea, but for a long time it ruption occurs, the machine operator’s screen was quite difficult to prevent unplanned will immediately display an incident ticket downtimes, or to plan and carry out required that provides a detailed description of the maintenance work in time. after all, it used cause of the defect. various problems can thus to be generally accepted that technical sys- be quickly eliminated in a targeted manner. tems were unable to provide information on the software also collects extensive data on their current state — and certainly not their future condition. today, however, machines key parameters such as hours of operation and workpieces produced. this information are capable of reporting problems and provid- serves as a solid foundation for developing ing information on which components will measures designed to increase overall facility need servicing in the near future. in order to effectiveness. the software also makes it pos- do this, they need to be equipped with a con- sible for customers to determine which types dition monitoring system such as life cycle of training measures are needed for machine life cycle monitoring from schaudt mikrosa. “our cus- operators. tomers expect their machines to be available an extensive amount of development at least 95 percent of the time,” says paul kössl, work went into the various functions offered head of customer care at the united grinding by the comprehensive life cycle monitoring group, and vice president sales & marketing system. the project for the system was at schaudt mikrosa. “our life cycle monitor- launched in 2002. three years later, in march ing system is an important component for 2005, schaudt mikrosa signed a cooperation ensuring that our grinding machines can con- agreement with the fraunhofer institute for tinually meet this minimum requirement and production systems and design technology thus maintain a consistently high level of pro- (ipk). a team of scientists then began devel- ductivity for our customers.” oping the monitoring software that would the life cycle monitoring system from form the centerpiece of the life cycle moni- schaudt mikrosa is a software-based solution toring system. “we first had to find out which that enables transparent condition monitor- ing. the system will soon be displaying its components could be used to actually enable reliable statements to be made on the current strengths in the automotive and aviation condition of a machine,” kössl explains. “to industry, for example. the principle behind this end, we and the fraunhofer ipk virtually the system is very simple: regardless of disassembled the mikrosa kronos m precision whether the filter for a hydrostatic unit or a grinding machine. that was fairly compli- wiper on a guideway needs to be replaced, or cated when you consider the fact that a grind- if oil simply needs to be changed — customers ing machine has as many as 2,000 different receive a message from the integrated soft- components.” ware program and can then initiate the once they had identified the parts they required maintenance or servicing operation. needed, the experts from fraunhofer ipk the software also documents, evaluates, and began programming the monitoring soft- issues reports on wear and tear for quali- ware. after initial tests were conducted with ty-critical components such as axles and spin- the kronos m, schaudt mikrosa launched a dles. this condition monitoring allows cus- tomers to avoid sudden machine failures and customer project. the results were presented to the german mechanical engineering also enables them to plan maintenance inter- industry association (vdma) in 2008. since vals in advance and integrate them into the then, the company has continually improved production process. or, as kössl puts it, its life cycle monitoring system. one of the “instead of unplanned machine failures, you biggest challenges here involved feeding the have planned downtimes.” software program with data from live 31 monitoring life cycle monitoring is an advanced form of condition monitoring that covers the entire service life of a product. 2,000 single parts a schaudt mikrosa grinding machine has as many as 2,000 different components.
b u s i n e s s a r e a m a c h i n e t o o l s k ö r b e r a g a n n u a l r e p o r t 2 0 1 6 machines in order to enable a compari- monitoring systems of the future within the son between ideal component conditions and framework of the ameli 4.0 project. the goal actual conditions, as well as the generation of of the research project is to improve the mar- statistically reliable statements regarding ket position of german companies in terms of future maintenance requirements, for exam- industry 4.0. that’s why germany’s federal ple. “our software has been running in test ministry of education and research is subsi- operations at selected customers for years dizing it with nearly €4 million in funding. now,” says kössl. “we also have additional “in life cycle monitoring we draw conclu- operational data from the test runs we regu- sions from the data we receive from the cnc larly conduct with our own machines system on the mechanical condition of indi- inhouse.” all of this has led to the gradual col- vidual components,” kössl explains. “in lection of a huge amount of data that has ameli 4.0 we are attempting to take condi- enabled schaudt mikrosa to continually refine tion monitoring to a new level with the help its condition monitoring system and adapt it of a sensor system.” to customers’ actual production processes. here, the partners rely on mems (micro- the system was also employed with more electromechanical system) sensors that have and more machines as development work pro- already proved their worth in automobiles and 30 percent the goal of the ameli 4.0 joint project is to reduce machine mainte- ceeded. today, the life cycle monitoring sys- the consumer electronics sector. such sensors nance, inspection, and servicing costs by as much as 30 percent. tem is so far advanced that it can easily be are considered more intelligent and energy- used with any grinding machine built by efficient than conventional industrial sensors schaudt mikrosa. “we’re currently develop- — and also less expensive. however, they are ing a marketing strategy for our product,” says still not powerful and robust enough to be kössl, “and we’ve already been approached by used in complex industrial environments. customers who want to use our comprehen- researchers in the ameli 4.0 project there- sive life cycle monitoring system.” other fore want to improve the mems sensors. if companies from the business area machine they succeed, the new sensor system they cre- tools — mägerle and blohm jung, for example ate will be able to measure oscillations, vibra- — are also planning to use the software after tions, and sounds inside a machine in real adapting it to their machines. time and compare the data it collects with in the meantime, schaudt mikrosa is get- stored profiles. this type of sensor-assisted ting the life cycle monitoring system up to machine monitoring will reduce mainte- speed for industry 4.0. together with six part- nance, inspection, and servicing costs by as ners, the company is working on the condition much as 30 percent. “as part of our joint project ameli 4.0, we are attempting to take condition monitoring to a new level with the help of a sensor system” paul kössl, head of customer care at united grinding group, and vice president sales & marketing at schaudt mikrosa 32
everything in sight versatile, intelligent, effective: the software-based condition monitoring system by schaudt mikrosa data analysis the software collects business-relevant process data, as well as other data. technical support incident tickets displayed on the screen provide a detailed description of the causes of defects. process control the machine control system sends the machine operator detailed infor- mation on wear and tear on axles and spindles, for example. the data can be used to initiate necessary maintenance activities. 33
business area pharma systems business area pharma systems how two körber companies are making the pharmaceutical industry fit for the future. 34
b u s i n e s s a r e a p h a r m a s y s t e m s k ö r b e r a g a n n u a l r e p o r t 2 0 1 6 smart pack aging a collaborative robot and a folding box that communi- cates with doctors, patients, and packaging machines: this is how dividella and rondo are supporting the pharmaceutical industry as it moves into the future. a factory hall, a rubik’s cube, and a robot form the scenery of a video that can be supplement that will allow us to have the kind of flexibility and efficiency that the market is watched on the internet platform youtube. demanding and to maintain our traditional things start to get exciting at second 32: the high product quality even with small batches.” robot picks up the rubik’s cube, looks at it in many industrial sectors, human-robot from every angle, and starts to turn the mov- collaboration (hrc) is already part of the daily able elements of the cube, using both of its gripper hands. the robot’s movements are routine. however, this solution has not been used so far for the packaging processes of careful and seem highly focused. starting at a pharmaceutical company. dividella now minute 1:08, the speed of the video increases changed that. yumi’s first new workplace will eightfold. finally, at minute 1:30 the robot has be the manual insertion module neotop x. finished its task. the rubik’s cube is once neotop x is a packaging system used at divi- again in its original state, with every side of della which has been directly adapted to in- the cube displaying of a single color. creasing product segmentation and decreas- generations of human players have failed ing batch sizes. in the system, robots work in to reconfigure rubik’s cubes since the 1970s. the same environment as their human col- yumi has turned out to be much smarter — so leagues, directly next to them and in cooper- smart that the pharmaceutical industry is ation with them. there’s no need for a protec- now paying attention. yumi is a “collabora- tive separation wall such as those that are tive” two-armed robot (known as a cobot) used to screen off welding robots in the auto- built by the swiss industrial group abb. to- motive industry. “collaborative robots feature gether with a major customer from the phar- an integrated safety solution — and besides, maceutical industry, the group company di- from a safety point of view they are incorpo- vidella has worked out a way to integrate the rated into an existing machine concept in a cobot yumi into the processes of a flexible completely different way than traditional packaging system. after yumi has completed robots,” messmer emphasizes. “we are current- its qualification process, it is expected to be ly working to clarify these safety-related tech- “permanently employed” by dividella’s cus- nical issues related to yumi and neotop x.” tomer. one of its jobs will be to fill medicine packaging units. “the trend in the pharma- ceutical industry is clearly going in the direc- efficient a nd ac cur ate after this step, yumi will be ready to take on tion of small batch sizes and even personal- its new job from a technological perspective. ized medicine packaging,” says jürg messmer, using yumi has numerous advantages for the head of engineering automation at dividella. dividella customer. thanks to its staying “the use of a collaborative robot such as yumi power, yumi further enhances the efficiency in an automated packaging system is the ideal of the packaging system. in addition, its work 36 cobots collaborative robots are industrial robots that work together with human beings without any protective separating walls.
yumi’s next workplace may be the manual insertion module of neotop x is reliable and accurate. these capabilities are in great demand in the pharmaceutical sector. “if medicine packages are filled manually, there’s a risk that the activities may not be car- ried out as they should be — for example, with regard to the product alignment or the amount of force applied. if deviations like these are not detected in the quality control process, they could well have critical consequences for patients,” messmer explains. by contrast, if yumi is responsible for filling the packaging, many typically human sources of error are eliminated. another huge advantage is the robot’s flexibility. whether it’s blister packs, am- pules, syringes or injectors, yumi can “the use of a collabo - rative robot such as yumi is the ideal supple- ment that gives us the flexibility and efficiency the market is demanding, even with small batches.” jürg messmer, head of engineering automation at dividella 37
b u s i n e s s a r e a p h a r m a s y s t e m s k ö r b e r a g a n n u a l r e p o r t 2 0 1 6 new communication channels rondo brings nfc technology into the pharma- ceutical industry via its talking folding box. innovative pharmaceutical producers can store data and information about a medicine on an nfc chip that is integrated into the folding box. secure the chip transmits the stored data to a terminal with reading capa- bi lity — but only when it is in the immediate vicinity of the packaging. 38 convenient the end user can use the transmitted data to have the information on the instruction leaflet read aloud or to order a repeat prescription via a smartphone.
plug & produce with plug & produce, machines and devices can autonomously configure themselves and form networks with one another. the process is inspired by plug & play, which ensures that a printer, for example, is ready to use directly after it is connected to a computer. place a wide variety of products, intact the pharmaceutical industry shows that the and in the desired amounts, into their pack- topic of smart packaging is a very important aging. dividella therefore aims to go a step one.” there are many possible applications for further by using the robots for additional tasks this type of communication via a product’s in the medium term. one category of these folding box. for example, patients can have tasks is the plug & produce process. as mess- the instruction leaflet read aloud to them or mer explains, “we have a lot of discussions take a look at more detailed information about with our customers about the topic of commu- the right way to take their medicine, for ex- nication and integration. the question is: how ample. in addition, the system can be used to can we provide robots with data so that they automatically order repeat prescriptions or re- can also work with a different machine with- fills of the medicine. out requiring long changeover times? this rondo is continuing its development of possibility offers entirely new opportunities smart packaging. it is currently working on a in terms of flexibility and efficiency.” solution that can automatically remind pa- communication is also the focus of the tients to take their medicine at the right time smart packaging project of the swiss folding or help them to participate in surveys that are box producer rondo ag. in this project, rondo part of clinical studies. an exploration of the takes advantage of the opportunities offered topic of augmented reality is also part of the by the internet of things and uses a technol- project. in parallel, the experts at rondo are ogy that has already proven to be successful tinkering with the interaction between the in the keyless opening of cars as well as cash- folding box and the packaging machine. there free payment: near field communication are numerous promising application possibil- (nfc). thanks to this international transmis- ities for this nfc application as well. for ex- sion standard, data can be shared over short ample, information about the desired packag- distances by means of radio technology. all ing processes can be saved on the chip and that’s needed is an nfc chip and an appropri- transmitted to the machine. as helfenstein ate terminal device such as a smartphone. by explains, “these projects are still new for the contrast to comparable solutions such as rfid pharmaceutical industry, but it’s becoming codes, data transmission via nfc technology clear that there is a need for this technology, functions only over short distances. that so we’re rapidly forging ahead with smart makes it impossible for third parties to read packaging for our customers. we’re being personal or sensitive data unnoticed from helped by the close cooperation between the afar. colleagues in mechanical engineering and in with its smart packaging solution, rondo it — for example, people from werum within demonstrates that near field communication the business area pharma systems.” is also suitable for use in the pharmaceutical industry. the solution: data is stored on an nfc chip, and the chip is subsequently inte- grated into the folding box. users only need to lay their smartphone or another terminal with reading capability on the packaging in order to receive the data that has been stored on the chip. “our folding boxes thus enable direct communication between the patient and the package. they also open up new op- portunities for dialogue between the patient, the doctor, and the pharmacist,” says marc helfenstein, head of packaging development at rondo. “the feedback we’re getting from “our folding boxes enable direct communication between the patient and the package” marc helfenstein, head of packaging development at rondo 39
business area tissue 40
business area tissue how fabio perini is increasing the productivity of tissue paper manufacturing and reducing costs at the same time. 41
b u s i n e s s a r e a t i s s u e k ö r b e r a g a n n u a l r e p o r t 2 0 1 6 creative and customer centered with all-in-one and weareable, fabio perini is creating ideal conditions for tissue production 4.0. r olls of tissues such as paper towels and toilet paper have a long way to go before they appear fully packaged on supermarket tion cost considerable amounts of time during which the facility was shut down. the all-in-one software, by contrast, en- shelves. soft tissue paper goes through a va- ables such switches in production to be auto- riety of production stations during manufac- matically triggered by the push of a button. turing. from the press roll and the winder to the software system is centrally connected to the packaging unit, a wide variety of ma- all the stations of the plant and sends them in- chines in the plant ensure that the right rolls formation to adjust them for the new product. of paper reach the customers at the right time. if a problem occurs in one part of the facility, one of the main preconditions for this is the the system will immediately display it on the existence of an efficient and fault-free produc- screen so that it can be quickly rectified. this tion process. enables the customers of fabio perini to save for manufacturers this means that all of valuable time, ensure that machine down- the machines in the plant have to be precisely times are kept to a minimum, and deliver coordinated with one another and the work- products to their recipients on time. “our cus- flow has to be optimized to make interrup- tomers benefit from all-in-one because it tions in production almost impossible. the simplifies changes of product so that the ef- technicians at the körber company fabio per- fectiveness of the facility as a whole increases ini are working continually to ensure this is sustainably,” explains luca frasnetti, chief the case. their latest innovation is called technology officer of fabio perini. all-in-one. this software lives up to its name because it coordinates all of the production steps and optimally matches the capacities of a lways produc ti v e in addition, all-in-one controls the individ- the individual machines for the processing ual production steps by holistically monitor- and packaging of tissue paper. ing them. in order to optimize the facility’s previously, many work steps had to be output, the software flexibly adjusts the speed performed manually whenever a facility was of the individual machines whenever there is switched to manufacturing another product. a disruption or loads are too high. under the whether the switch, for example, from thin to watchful eye of all-in-one, a roll of tissue thick tissue paper is successful depends, in passes through all of the stations of the plant part, on how efficient the coordination pro- under unvarying conditions. frasnetti sees cesses between the plant managers and the this as a big step forward. “in conventional plant operators are and how well the corre- tissue production, the effectiveness of the sponding machine requirements are met in overall facility used to always depend on the practice. as a result, a big drawback of the pre- skills of the people involved. these skills of- vious approach was that switches in produc- ten vary greatly, and production fluctuated as 42 all-in-one this software compre- hensively coordinates and monitors all of the production steps for tissue paper. as a result, it reduces the number and duration of interrup- tions in the production process.
a result,” he says. “our new it system, on the other hand, guarantees the sustained optimi- zation of the production cycle as well as a con- sistently high level of productivity.” moreover, the monitoring process collects valuable data concerning, for example, the length of interruptions to production when cutting surfaces or rollers are replaced. the software logically groups possible stops, de- pending on when the components have to be replaced and how long this will take. on the basis of these forecasts, the system automati- cally stops the facility at a time when several “our customers benefit from all-in-one because it simplifies product changes so that the effectiveness of the facility as a whole increases sustainably” luca frasnetti, technical director at fabio perini components can be replaced simultaneously. world’s first integrated tissue paper produc- this reduces the number of interruptions so tion line that extends along the entire manu- that production can run unimpeded for a lon- facturing process, from the raw material to the ger period of time. according to frasnetti, this final product,” he says. this feat has enabled innovation has great development potential. the developers at fabio perini to take a big step “all-in-one has enabled us to create the on the way to achieving industry 4.0. fabio perini stands for innovative processing and packaging solutions. 43
b u s i n e s s a r e a t i s s u e k ö r b e r a g a n n u a l r e p o r t 2 0 1 6 “however, our long-term goal is to offer age of what the customer sees to the techni- our customers a comprehensive set of intelli- cian at the other end of the line. instead of gent solutions from which they can select ex- having to laboriously describe the problem to actly the combination of measures that meets the contact person at perini’s technical cus- their requirements,” frasnetti points out. tomer service department, the customer can ta rge ted a s sis ta nce the company also pursues a customer-cen- now simply show it with weareable’s built-in camera. moreover, weareable is convenient because it tric approach in its handling of technical only needs to be put on and can be taken along problems. offering support by phone is often wherever one goes. its further benefit is ex- too complicated and ineffective when individ- pressed by the product’s name: “we-are- ual machines in the plant fail or the entire able.” specifically, this means that customers plant comes to a standstill. that’s because the are provided with targeted assistance through technicians have to know which error mes- the headset so that they can solve problems sage is being displayed and if it’s possible to on their own, no matter where in the world see which part is defective. moreover, it’s of- they may be. the only thing the user needs is ten hard to clearly describe complex technical a good internet connection. weareable en- processes or the positions of machine parts on ables fabio perini to provide remote assis- the phone. as a result, it helps if the assisting tance in real time. the company’s technical technician on the other end of the line can get assistance team is reachable around the clock an impression of the actual situation at the and adapts itself flexibly to the customers’ plant. wishes and suggestions. weareable makes all of this possible. al- as a result, faults can be diagnosed much though it might look like a futuristic pilot’s more quickly and precisely than would other- helmet at first glance, weareable makes it wise be the case. weareable ensures that de- much easier for customer support staff to pro- fects are rectified in a targeted manner. in ad- vide remote assistance when technical prob- dition to reducing stress, it saves valuable lems occur. weareable is equipped with a mo- time that can, for example, be used instead to bile display, a camera with a memory function, further improve the production process. the an audio system, and a data link. as soon as efficient and permanent elimination of faults a customer dons the helmet and switches it also reduces costs because the facility can be on, weareable transmits a real-time video im- quickly put back into operation again. weareable the product name combines the words “wearable” and “we are able.” for fabio perini, weareable and all-in- one are important elements in the continuous optimization of customer service through in- novative solutions. “we are devoted to the continual further development of mainte- nance programs, the creation of training courses, and the improvement of the spare parts service,” explains roberto ferrari, cus- tomer service sales & marketing director at fabio perini. the concept aims to provide a comprehensive range of services extending from the sale of a product to its regular main- tenance. customer orientation and creativity are the forces that motivate the company’s technicians to continuously develop new solutions for their customers’ industry 4.0 requirements. “our approach focuses on the continuous further development of maintenance programs” roberto ferrari, customer service sales & and marketing director at fabio perini 44
high-tech perception weareable provides a perfect view of the situation, enabling remote support in real time. webcam the customer uses a built-in camera to film the defective facility, providing service technicians with real-time video images. headset the built-in ear- phones enable the customer to receive the instructions needed to quickly eliminate the defect. data goggles the technician’s instructions are projected into the customer’s field of vision here. microphone no matter where the facility in question is located, the customer can use the microphone to contact a service technician at any time. 45
business area tobacco 46
business area tobacco how a cigarette manufacturing machine is being transformed into a networked industry 4.0 facility. 47
b u s i n e s s a r e a t o b a c c o k ö r b e r a g a n n u a l r e p o r t 2 0 1 6 the virtual twin with its smart mobile operator support, hauni has developed an intelligent service solution that can significantly reduce production downtimes. s ometimes reality surpasses fiction. for example, the latest innovation from the business area tobacco brings back memories of the classic science fiction film “2001: a space odyssey,” which was directed by stanley circuit diagram of the affected “unit ae-35” in large magnifications and different views. self-a n a lysis en a bled nearly 16 years after that visionary film was kubrick in 1968, and it follows a voyage to set, a very similar process has become reality jupiter. in that movie, the talking onboard — not in space but instead in the world of in- computer known as hal informs two astro- dustry. with smart mobile operator support nauts on a spaceship that their communication (smos), hauni has developed a digital service antenna will soon fail because of a defective package that transforms cigarette manufac- circuit. hal’s service-oriented electronic turing machines into a networked industry brain also shows the two astronauts the digital 4.0 facility that continually analyzes itself 48
hauni’s smos solution can be used with all cigarette manufacturing machines built from 2005 on — e.g. with the protos-m4. is not behaving normally. the designation of the protos-m4 is highlighted in red, which means that the machine has stopped operat- ing. an explanatory message in the red field on the display says, “stop: tube wheel too high.” in other words, the service technician knows at a glance which machine has a prob- lem and which component in the machine is causing it. using the virtual twin, the technician can see all of the current parameters of the ma- chine and immediately determine which functions are affected and which ones con- tinue to work properly. but what does “tube wheel too high” actually mean? to find out, the technician can click on “cause / correc- tive action,” after which a schematic drawing of the module in question appears under the “diagnosis” tab. smos also suggests three possible causes of the fault in this case, e.g.: “tube wheel height set incorrectly.” however, a look inside the real machine reveals that this is not the case. second suggestion: “incorrect tube wheel in use.” a look inside shows that the right version is installed. third sugges- tion: “photo sensor b207s not correctly aligned.” bingo! as the technician discovers, and carries out intelligent communication it was the tiny light-sensitive sensor that with its human operators. for example, if a caused the problem. the app then instructs breakdown in operation occurs, it is immedi- the technician to consult the protos-m4 op- ately digitally identified. the system’s tablet erating manual for information on how to cor- app then notifies the service technician, rectly handle the sensitive component. guides him or her directly to the affected ma- chine, and even describes reasons for the fault using keywords. once the technician has ar- pa perle s s libr a ry “this is actually already standard procedure rived at the machine, he or she is guided for us up to that point,” says andreas eckroth, through the steps required to eliminate the who is the group manager responsible for the problem with the help of a “twin” machine basic development of automation technology that is displayed in real time on the tablet at hauni. “now we get to the real innovation.” screen. smos can also do something that more specifically, until recently thick tomes hal couldn’t: initiate an online order process of paper had to be located on their shelves, for any required spare parts that are not di- carried to the machine, and consulted — and rectly available. focusing on pa r a me ter s a simulation demonstrates more clearly just perhaps turn out to be outdated. this doesn’t happen with smos, which has three addi- tional buttons for choosing between “circuit diagram,” “manual,” and “spare parts cata- what the system is capable of. the app shows logue,” all of which are stored digitally in the a schematic diagram of a cigarette production system and can be accessed in their most re- hall with a large number of machines, one of cent versions at any time. 49
b u s i n e s s a r e a t o b a c c o k ö r b e r a g a n n u a l r e p o r t 2 0 1 6 “an order of spare parts can be placed directly with the app” andreas eckroth, group manager automation & drives at hauni 30 percent smos can reduce output loss by as much as 30 percent. the service technician can thus first ex- to send the hauni expert live images of the de- amine the circuit diagram and zoom in on fective machine. there’s also a whiteboard the wiring schematics or select another ex- that both the technician and the hauni expert cerpt from the documentation as required. can use to draw sketches and provide graphic the defective b207s sensor is immediately support for possible solutions. “and the best marked in red by the system. a click on thing is that both parties remain completely “manual” then takes the service technician mobile with their tablets,” says eckroth. in to the corresponding digital documentation other words, the technician can walk around — on the right page and in the right section the machine and send detailed images of ex- for the sensor. the latter is already marked actly the perspectives or details of the ma- in the digital spare parts catalogue, along chine that are needed to show where the prob- with a message that there are two such sen- lem originates. all of this saves customers a sors in the machine in question. if a replace- lot in terms of downtime, as eckroth explains: ment sensor is not immediately available, a “we believe the system can reduce output loss b207s unit will have to be ordered from the by as much as 30 percent.” that would mean spare parts warehouse, which is no problem around one third less downtime due to ma- at all. “the order can be placed using the chine failure. app,” eckroth explains. the technician can review the installation procedure explained in the manual while waiting for the photo- fire wa ll sepa r ation the app runs on a windows tablet that uses sensor to be delivered. all of this is done wifi to log into one of two possible networks. without having to use a single sheet of either the customer’s service technician uses paper. remote a s sis ta nce however, what happens if the customer’s the company’s own network or a hauni expert directly logs into the system of the machine in question after receiving authorization from the customer in the form of a password. the technician is unable to resolve a complex machine’s system is separated from the rest of problem alone at some stage of the repair pro- the customer’s network by a firewall. all mod- cess? in that case, he or she will be given as- ern cigarette manufacturing machines built sistance remotely. here, the technician uses from 2005 on can be retrofitted with the smos the remote service (rs) module in the tablet program package. to launch an “rs session” with a hauni ex- extensive interest has been expressed in pert. a chat window that enables a live dia- the app solution by potential users, whose logue then opens — or alternatively the tech- suggestions have also been incorporated into nician can talk to the expert using a headset. smos — a system that would make even hal the technician can use the tablet’s webcam from “2001” jealous. 50
solution via livestream smart mobile operator support makes it possible to solve problems effectively. in more complex cases, a hauni expert can be called in to provide remote support in real time. company network security a firewall prevents external access to the company network. hmi network customer tablet the smos tablet app guides the user to the machine whose operation has been disrupted and ex- plains the steps that need to be taken to solve the problem. the app can also be used to order spare parts. machine network 51 customer service tablet during a remote service session, a hauni expert can log into the affected machine’s net- work and provide the customer with valuable informa- tion and tips for fixing the problem.
overview of the business areas o v e r v i e w o f t h e b u s i n e s s a r e a s k ö r b e r a g a n n u a l r e p o r t 2 0 1 6 o u r b u s i n e s s a r e a s in its business areas the körber group unites the technologically leading companies with more than 130 production, service, and sales companies. a u t o m at i o n the business area auto- mation develops, produces, and markets high-quality, innovative products and services for international markets in the fields of motion technology, sensor technology, and energy technology. its three busi- ness units — motion tech- nology, sensor technology, and energy technology — are renowned for their technologically leading products and set new stan- dards to guarantee their customers long-term competitive advantages. lo g i s t i c s s y s t e m s the business area logistics systems offers its customers high-quality, intelligent, and efficient logistics solutions along the entire value chain. these range from project planning and consulting services through software, materials handling, palletizing and warehousing technology, down to compre- hensive systems integration for production, distribution, and transport logistics. thanks to their expertise, experience, and top stan- dards of quality and service the business area’s six companies — aberle, aberle software, consoveyo s.a., inconso, langhammer, and riantics — offer customized logistics solutions that boost their customers’ sustained success. 52
machine tools the business area machine tools unites leading global suppliers of precision ma- chines for grinding, eroding, laser finishing, combined finishing, and gauging. with its eight brands — studer, schaudt, mikrosa, walter, ewag, mägerle, blohm, and jung — the business area has the broadest application know-how, the largest product portfolios, and the most comprehensive range of services in the international market. tissue the business area tissue is synonymous with innovation, state-of- the-art technologies, and end-to-end solutions for processing and packaging machinery and equipment for toilet paper and paper towels. outstanding inno- vations and a systematic customer orientation make fabio perini a technology and market leader in the sector. pharma systems the business area pharma systems offers solutions for safe, efficient processes in the manufacturing, inspection, and pack- aging of pharmaceutical products and pharmaceutical traceability. this business area’s unique combination of process know- how and cutting-edge technology makes it one of the leading systems providers to the pharmaceutical and biotech industries. it brings together leading international companies — dividella, fargo automation, mediseal, rondo, seidenader, and werum it solutions. corporate ventures the körber group plans to continue its growth in the years ahead. that includes expanding its strategic investments. the group is therefore focusing on key future technologies and mar- kets. the business area corporate ventures offers the ideal framework for those companies that represent new territory for the group. tobacco the business area tobacco, comprising the hauni, borgwaldt, borgwaldt flavor, decouflé, garbuio dickinson, and sodim brands, is the leading supplier to the international tobacco industry, thanks to its comprehensive product range and global presence. at locations around the world, the companies in this business area support customers in the fields of tobacco processing, filter and cigarette manufacture, and measuring and analy- sis equipment, as well as flavorings. 53
companies of the business areas c o m pa n i e s o f t h e b u s i n e s s a r e a s k ö r b e r a g a n n u a l r e p o r t 2 0 1 6 companies of the business areas körber unites technologically leading companies around the world with more than 130 production, service, and sales companies. busine s s a re a au tom ation · dressel gmbh, unna/germany · heinz fiege gmbh, röllbach/germany · körber automation gmbh, lahnau/germany · lti austria gmbh, wels/austria · lti motion deutschland gmbh, lahnau/germany · lti motion gmbh, lahnau/germany · lti motion gmbh, wasserburg/lake constance/germany · lti motion italia s.r.l., settimo milanese/italy · lti motion schweiz gmbh, rüti/switzerland · lti motion (shanghai) co., ltd., shanghai/china · lti reenergy a.s., van/turkey · lti reenergy co., ltd., hsinchu city/taiwan · lti reenergy gmbh, unna/germany · lti usa ltd., mechanicsburg/usa · sensitec gmbh, lahnau-waldgirmes/germany · sensitec gmbh, mainz/germany busine s s a re a logis tic s s ys tems · aberle gmbh, leingarten/germany · aberle logistics gmbh, siegen/germany · aberle software gmbh, stuttgart/germany · consoveyo s.a., moreira da maia/portugal · consoveyo singapore pte. ltd., singapore/singapore · godrej consoveyo logistics automation ltd., mumbai/india · inconso aktiengesellschaft, bad nauheim/germany · inconso beteiligungs gmbh, bad nauheim/germany · inconso sasu, lyon/france · inconso software, s.l., sant cugat del vallès/spain · körber logistics systems gmbh, bad nauheim/germany · langhammer gmbh, eisenberg/germany · langhammer gmbh, freiberg/germany · riantics, arden/denmark 54 busine s s a re a m achine tool s · blohm jung gmbh, hamburg/germany · blohm jung gmbh, göppingen/germany · ewag ag, etziken/switzerland · fritz studer ag, steffisburg/switzerland · fritz studer ag, biel/switzerland · irpd ag, st. gallen/switzerland · mägerle ag maschinenfabrik, fehraltorf/switzerland · schaudt mikrosa gmbh, leipzig/germany · studertec k.k., tokyo/japan · united grinding gmbh, moscow/russia · united grinding gmbh, india branch office, bangalore/india · united grinding group ag, bern/switzerland · united grinding méxico sociedad anónima de capital variable, querétaro/mexico · united grinding north america, inc., miamisburg/usa · united grinding north america, inc., fredericksburg/usa · united grinding (shanghai) ltd., shanghai/china · united grinding (shanghai) ltd., branch office beijing, beijing/china · united grinding (shanghai) ltd., branch office chongqing, chongqing/china · walter ewag asia-pacific pte. ltd., singapore/singapore · walter ewag do brasil – importação e exportação de máquinas ltda., são paulo/brazil · walter ewag italia s.r.l., bregnano/italy · walter ewag japan k.k., anjo city/japan · walter ewag uk limited, warwickshire/united kingdom · walter maschinenbau gmbh, tübingen/germany · walter maschinenbau gmbh, garbsen/germany · walter s.r.o., kur�im/czech republic
busine s s a re a ph a rm a s ys tem s · dividella ag, grabs/switzerland · fargo automation inc., fargo/usa · körber medipak américa latina soluções farmacêuticas ltda., são paulo/brazil · körber medipak systems ag, winterthur/switzerland · körber medipak systems gmbh, hamburg/germany · körber medipak systems machinery s.r.o., kur�im/czech republic · körber medipak systems na inc., clearwater/usa · mediseal gmbh, schloß holte-stukenbrock/germany · mediseal gmbh, shanghai representative office, shanghai/china · rondo ag, allschwil/switzerland · rondo obaly s.r.o., ejpovice/czech republic · rondo-pak, llc, camden/usa · rondo-pak inc., norristown/usa · seidenader maschinenbau gmbh, markt schwaben/germany · werum it solutions america inc., parsippany/usa · werum it solutions america inc., cary/usa · werum it solutions america inc., san francisco/usa · werum it solutions gmbh, lüneburg/germany · werum it solutions gmbh, hausach/germany · werum it solutions gmbh, sankt augustin/germany · werum it solutions gmbh, allschwil branch office, allschwil/switzerland · werum it solutions k.k., tokyo/japan · werum it solutions pte. ltd., singapore/singapore · werum it solutions sarl, toulouse/france · werum it solutions ltd., bangkok/thailand · wpg pharma gmbh, heidelberg/germany busine s s a re a t is sue · engraving solutions s.r.l., lucca/italy · fabio perini germany gmbh, neuss/germany · fabio perini indústria e comércio de máquinas ltda., joinville/brazil · fabio perini japan co. ltd., shizuoka/japan · fabio perini north america, inc., green bay/usa · fabio perini (shanghai) co., ltd., shanghai/china · fabio perini s.p.a., lucca/italy · körber engineering (shanghai) co. ltd., shanghai/china busine s s a re a tobac c o · asl analytic service laboratory gmbh, hamburg/germany · baltic metalltechnik gmbh, hamburg/germany · borgwaldt flavor gmbh, hamburg/germany · borgwaldt kc gmbh, hamburg/germany · borgwaldt kc, inc., richmond/usa · decouflé s.à.r.l., chilly-mazarin/france · dickinson legg, inc., richmond/usa · dickinson legg limited, winchester/united kingdom · garbuio dickinson group holding s.r.l., paese (treviso)/italy · garbuio (shanghai) trading company limited, shanghai/china · garbuio s.p.a., paese (treviso)/italy · hauni do brasil máquinas e equipamentos para tabaco ltda., são paulo/brazil · hauni do brasil máquinas e equipamentos para tabaco ltda., uberlandia/brazil · hauni far east limited, hong kong/hong kong · hauni far east ltd., kunming representative office, kunming/china · hauni hungaria gépgyártó korlátolt felelösségü társaság, pécs/hungary · hauni japan co., ltd., tokyo/japan · hauni (malaysia) sdn. bhd., shah alam/malaysia · hauni maschinenbau gmbh, hamburg/germany · hauni maschinenbau gmbh, dubai branch, dubai/united arab emirates · hauni primary gmbh, schwarzenbek/germany · hauni richmond, inc., richmond/usa · hauni singapore pte. ltd., singapore/singapore · hauni south africa (pty.) ltd., cape town/south africa · hauni st. petersburg ltd., st. petersburg/russia · hauni teknik hizmetler ve ticaret limited sirketi, izmir/turkey · hauni trading (shanghai) co. ltd., shanghai/china · isis s.r.l., paese (treviso)/italy · pt. garbuio dickinson indonesia, jakarta/indonesia · sodim s.a.s., fleury-les-aubrais/france · universelle engineering u.n.i. gmbh, schwarzenbek/germany 55
growth target & corporate values g r o w t h ta r g e t & c o r p o r at e v a lu e s k ö r b e r a g a n n u a l r e p o r t 2 0 1 6 our strategic long-term growth target our clearly defined long-term growth target for the period until 2025 is an ambitious one. we will achieve this growth by continuing to impress our customers on a permanent basis. we intend to more than double our total earnings by comparison with 2013 through organic growth and strategic acquisitions. our körber vision the future is ours to create! we are technology leaders, strong together, and inspire our customers and partners as sector experts in all business areas. our körber mission as an international technology group with a strong regional presence, we create measurable benefits and added value for our customers. as a reliable, solid partner, we develop and supply pioneering, innovative solutions and perfectly tailored services worldwide with and for our customers. 56
our group-wide corporate values our group-wide uniform corporate values form the foundation of everything we do. they make clear what strengthens and connects us across all the companies and functions in the group and what we pledge to uphold in all our dealings with one another and third parties. customer satisfaction we are körber and we add value for our customers by inspiring our customers and partners as industry experts. as a solid, reliable partner, we develop and supply pioneering, innovative solutions and perfectly tailored services worldwide with and for our customers. we are körber and we create innovations by putting our experience, expertise, and creativity to work for our customers. we defend our technological leadership through tireless innovation and the improvement of our products, services, and business processes. innovation connecting people and knowledge we are körber and we connect people and ideas by recognizing and leveraging the full breadth of our know-how and experience. we encourage and require everyone within our international group to share ideas and experiences in order to apply all our knowledge to developing efficient, best-practice solutions. responsibility we are körber and we take responsibility by putting our corporate values at the heart of everything we do. we keep our promises and act reliably toward employees, partners, and customers. our success depends on close, long-term relationships with our employees and business partners. focus on the future we are körber and we strive for sustained and profitable growth by viewing long-term success and financial independence as a motivating challenge. together, we develop profitable, sustainable solutions. we count on our employees worldwide and support everything they do with modern, attractive work conditions. 57
income statement / balance / key indicators i n c o m e s tat e m e n t / b a l a n c e / k e y i n d i c at o r s k ö r b e r a g a n n u a l r e p o r t 2 0 1 6 consolidated income statement from january 1 to december 31, 2016 in thousands of euros sales increase in finished goods and services and work in progress other own work capitalized total operating performance other operating income cost of materials cost of raw materials, consumables, and supplies, and of purchased merchandise cost of purchased services personnel expenses wages and salaries social security, post-employment, and other employee benefit costs of which in respect of old age pensions depreciation, amortization, and writedowns of intangible assets and tangible assets other operating expenses income from long-term equity investments of which from affiliated companies income from other securities and long-term loans among the fixed assets other interest and similar income of which from affiliated companies writedowns of long-term financial assets interest and similar expenses of which to affiliated companies consolidated earnings before taxes on income taxes on income consolidated earnings after taxes on income share of non-controlling interests in consolidated earnings consolidated retained net profits 2016 2015 2,214,577 2,317,277 48,159 3,890 5,576 2,573 2,266,626 2,325,426 129,734 180,397 731,458 136,586 697,520 139,206 26,014 104,750 466,267 116 116 33 765,954 128,816 741,500 159,953 38,972 108,274 515,639 2,422 2,422 33 7,156 21,585 496 100 26,425 4 101,353 41,650 59,703 –1,386 58,317 782 1,389 21,920 8 86,418 52,679 33,739 –912 32,827 58
consolidated balance sheet as of december 31, 2016 in thousands of euros assets fixed assets intangible fixed assets tangible fixed assets long-term financial assets shares in affiliated companies other long-term equity investments other loans current assets inventories receivables and other assets securities checks, cash on hand, and bank balances prepaid expenses deferred taxes goodwill arising from asset offsetting balance sheet total equity and liabilities equity accruals liabilities prepaid expenses balance sheet total 59 2016 2015 248,937 337,035 17,937 9,577 10,396 37,910 268,976 351,510 18,101 4,920 8,888 31,909 623,882 652,395 676,347 549,748 813,967 658,074 604,393 516,282 511,015 877,276 2,698,136 2,508,966 6,833 96,097 8,916 6,197 65,060 8,775 3,433,864 3,241,393 1,814,776 1,769,121 329,535 332,908 1,286,505 1,138,488 3,048 876 3,433,864 3,241,393
i n c o m e s tat e m e n t / b a l a n c e / k e y i n d i c at o r s k ö r b e r a g a n n u a l r e p o r t 2 0 1 6 körber group key figures in millions of euros operating business incoming orders sales ebita1 return on sales (ebita)1 net income after taxes2 cash flows from operating activities3 capital expenditure on tangible fixed assets research and development expenses research and development ratio balance sheet indicators as of december 31 reporting date equity balance sheet total equity ratio4 employees as of december 31 reporting date employees5 1 earnings before interest, taxes, and amortization of intangible fixed assets (ebita) from acquisitions 2 includes scheduled amortization of goodwill in accordance with the hgb 3 since 2014 according to drs 21 4 equity as a percentage of total equity and liabilities 5 including unconsolidated companies 2012 2013 2014 2015 2016 1,965 2,004 229 11.4% 151 138 48 99 2,252 2,194 222 10.1% 137 218 54 120 2,320 2,342 258 11.0% 150 167 58 129 4.9% 5.4% 5.5% 2,191 2,317 141 6.1% 34 244 65 145 6.2% 2,357 2,215 171 7.7% 60 181 46 127 5.7% 1,470 2,194 67.0% 1,578 2,352 67.1% 1,727 2,535 68.1% 1,769 3,241 54.6% 1,815 3,434 52.8% 9,553 11,190 11,950 11,578 11,246 60