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[PDF] MAHLE Powertrain â Company Overview - Mahle.com
[PDF] MAHLE Powertrain â Company Overview - Mahle.com
[PDF] MAHLE Powertrain â Company Overview - Mahle.com
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<strong>MAHLE</strong> <strong>Powertrain</strong> – <strong>Company</strong> <strong>Overview</strong><br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd.<br />
St. James Mill Road<br />
Northampton p NN5 5TZ, United Kingdom g<br />
Q4 2011<br />
© <strong>MAHLE</strong>
2<br />
<strong>Overview</strong><br />
OUR COMPANY<br />
INDUSTRY CHALLENGES<br />
OUR SOLUTIONS & RESEARCH<br />
CASE STUDIES<br />
THE DIFFERENCE WE MAKE<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., November 2011 © <strong>MAHLE</strong>
3<br />
Our <strong>Company</strong><br />
<strong>MAHLE</strong> POWERTRAIN<br />
ENGINEERING, MANUFACTURING & TEST SYSTEMS MARKET REACH<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., November 2011 © <strong>MAHLE</strong>
4<br />
Our <strong>Company</strong><br />
<strong>MAHLE</strong> <strong>Powertrain</strong><br />
Wh Who We W Are A<br />
An Engineering and Manufacturing Services Provider<br />
specialising in research, research design design, development development, testing<br />
and production of high efficiency engines.<br />
History<br />
1958 Cosworth founded by Mike Costin & Keith Duckworth<br />
1973 Foundry established at Worcester<br />
1985 Manufacturing established at Wellingborough<br />
1998 Road car division renamed Cosworth Technology<br />
2005 <strong>MAHLE</strong> <strong>Powertrain</strong> established under <strong>MAHLE</strong><br />
2007 <strong>MAHLE</strong> Inline 3 Extreme Downsizing Engine runs<br />
2010 Downsizing g Demonstrator Vehicle presented p<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., November 2011 © <strong>MAHLE</strong>
5<br />
Our <strong>Company</strong><br />
Supporting a Global Customer Base<br />
Detroit (Novi)<br />
São Paulo (Jundiaí)<br />
Wellingborough<br />
Worcester<br />
Northampton p<br />
Stuttgart<br />
Shanghai<br />
Tokyo<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., November 2011 © <strong>MAHLE</strong>
6<br />
Our <strong>Company</strong><br />
Part of the <strong>MAHLE</strong> Group<br />
<strong>MAHLE</strong> Group<br />
One of the top 30 automotive suppliers globally<br />
and a leading powertrain development partner<br />
Engine g Systems y & Components p<br />
Access to development & production know-how,<br />
but independent of actual <strong>com</strong>ponent sourcing<br />
Access to Test & Prototyping Facilities<br />
‘Local’ support options available worldwide<br />
Driven by Research & Development<br />
Leading g edge g of IC engines g and ppowertrains<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., November 2011 © <strong>MAHLE</strong>
7<br />
<strong>MAHLE</strong> - Development to 2010<br />
Sales (billion ( Euro) )<br />
Headcount<br />
5.50 5.26<br />
47,900<br />
5.06 5.01<br />
49,200<br />
50.000<br />
5.00<br />
45.000<br />
4.50<br />
4.00<br />
3.50<br />
3.00<br />
2.50<br />
2.00<br />
1.50<br />
1.00<br />
0.50<br />
0.00<br />
4.12<br />
4.31<br />
3.86<br />
2005 2006 2007 2008 2009 2010<br />
40.000<br />
35.000<br />
30.000<br />
25.000<br />
20.000<br />
15.000<br />
10.000<br />
5.000<br />
.000<br />
37,500 38,600<br />
43 43,500 500<br />
47,500<br />
2005 2006 2007 2008 2009 2010<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., November 2011 © <strong>MAHLE</strong>
8<br />
<strong>MAHLE</strong> – More than just pistons<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., November 2011 © <strong>MAHLE</strong>
9<br />
<strong>MAHLE</strong> – More than just Automotive<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., November 2011 © <strong>MAHLE</strong>
10<br />
Our <strong>Company</strong><br />
Engineering Engineering, Manufacturing & Test Systems<br />
Engineering Manufacturing Test Systems<br />
<strong>Powertrain</strong> Design & Verification<br />
Thermodynamics & Application<br />
Engine & Component Testing<br />
From Clean Sheet to Production<br />
Aluminium Block & Head Castings<br />
Block & Component Machining<br />
Cylinder Head & Engine Assembly<br />
From Prototype to Production<br />
Engineering Testing<br />
Manufacturing Testing<br />
Dealership Testing<br />
From Development to Service<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., November 2011 © <strong>MAHLE</strong>
11<br />
Our <strong>Company</strong><br />
Market Reach<br />
AUTOMOTIVE COMMERCIAL & OFF-HIGHWAY RESEARCH<br />
MOTORSPORT POWER GENERATION GOVERNMENT PROGRAMMES<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., November 2011 © <strong>MAHLE</strong>
12<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Solutions<br />
CO 2 REDUCTION<br />
LOW VOLUME<br />
MANUFACTURING<br />
EFFICIENT<br />
DEVELOPMENT PROJECTS<br />
OPTIMISING<br />
ELECTRONIC & DIAGNOSTIC<br />
PERFORMANCE<br />
TESTING<br />
ACHIEVE FUTURE<br />
EMISSIONS STANDARDS<br />
REDUCING PROTOTYPE POWERTRAIN<br />
WEIGHT & COST SOLUTIONS<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., November 2011 © <strong>MAHLE</strong>
13<br />
Our Solutions<br />
CO CO2 Reduction<br />
Our Solution<br />
Extensive experience in the analysis development &<br />
application of CO 2 reduction technologies across the<br />
entire powertrain<br />
Tools & approaches pp to support pp early y assessment of <strong>com</strong>plex p<br />
control system architectures & proposed solutions<br />
Our Services<br />
Rapid new engine concept development and demonstration<br />
Driveline architecture & controls specification<br />
Engine design, development and testing for series production<br />
Technology benchmarking and research<br />
CASE STUDY<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., November 2011 © <strong>MAHLE</strong>
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Our Solutions<br />
Efficient Development Projects<br />
Our Solution<br />
High level expertise <strong>com</strong>bined with proprietary product<br />
lifecycle and project management system<br />
Interdisciplinary project teams co-located to provide<br />
excellent cross-functional <strong>com</strong>munication<br />
From ‘clean sheet’ concepts to production upgrades<br />
Our Services<br />
Full ‘turn key’ project management (timing, cost and quality)<br />
Detailed and costed proposals for project requests<br />
Clear point of <strong>com</strong>munication and project status report<br />
against customer defined milestones<br />
CASE STUDY<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., November 2011 © <strong>MAHLE</strong>
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Our Solutions<br />
Achieve Future Emissions Standards<br />
Our Solution<br />
Combustion system and aftertreatment expertise<br />
Knowledge based approach for maximum benefit<br />
Flexible methods from engine hardware specification,<br />
integration g and calibration development p<br />
Early assessment of system capability<br />
Our Services<br />
Rapid concept emissions development and demonstration<br />
Combustion system, aftertreatment & controls development<br />
Comprehensive steady-state/transient engine dynamometers<br />
Fully certified, climatic chassis dyno test facilities<br />
TEST FACILITIES<br />
CASE STUDY<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., November 2011 © <strong>MAHLE</strong>
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Our Services<br />
Test Facilities<br />
NNorthampton th t (UK)<br />
Durability, performance & emissions (aftertreatment) testing<br />
12 engine test cells (130 to 700 kW, transient/motoring)<br />
Two 48” 48 single single-roll roll chassis dynamometers rated at 210 kW<br />
Ambient and climatic test capabilities (-40°C to +50°C)<br />
Compliant with Euro 6, LEV2, Tier 2, ULEV requirements<br />
Detroit/Novi (USA)<br />
Durability, performance & emissions (aftertreatment) testing<br />
7 heavy duty diesel test cells (transient/motoring)<br />
12 medium/light duty test cells<br />
48” AWD roll chassis dynamometer rated at 150 kW<br />
Ambient and climatic test capabilities (+10°C to +40°C)<br />
Compliant p with Euro 6, , LEV2, , Tier 2, , ULEV requirements q<br />
Additional Test Facilities (worldwide)<br />
30+ 30 test cells across Germany, Brazil, China & Japan<br />
Two climatic wind tunnels in Germany & USA<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., November 2011 © <strong>MAHLE</strong>
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Our Solutions<br />
Electronic and Diagnostic Testing<br />
Our Solution<br />
Component, subassemblies and vehicle diagnostic testing<br />
and tools at all stages (development, manufacturing, service)<br />
Efficient, agile and cost effective modular test solutions<br />
providing p g an increase in qquality y and customer satisfaction<br />
> 1500 dealers and > 46 production sites on 5 continents<br />
Our Services<br />
Quick identification of concerns in calibration development<br />
Vehicle End of Line and Repair Station test (TestLogiq ® )<br />
In-process testers (e.g. evaporative leakage tester)<br />
Service tool software (ServiceLogiq ® ) and reporting tools<br />
CASE STUDY<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., November 2011 © <strong>MAHLE</strong>
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Our Solutions<br />
Optimising Performance<br />
Our Solution<br />
Experience based tools and approaches to tailor powertrains<br />
to meet customer requirements<br />
Unique engine <strong>com</strong>ponent and systems expertise<br />
Fully y integrated g analysis y led methods<br />
No restrictions in size: city car or supercar<br />
Our Services<br />
'Clean sheet' concept or performance upgrade<br />
Analysis, development & rapid concept demonstration<br />
Low volume production of engines<br />
CASE STUDY<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., November 2011 © <strong>MAHLE</strong>
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Our Solutions<br />
Reducing Weight & Cost<br />
Our Solution<br />
Detailed knowledge of design for manufacture with target<br />
costing methods and unique engine <strong>com</strong>ponent expertise<br />
Philosophy of using simple, practical design features adapted<br />
to specific p customer needs<br />
Innovative approach not constrained by current practices<br />
Our Services<br />
Consultation to advise on feasibility of initial concepts<br />
Clean sheet designs or modifications / upgrades<br />
Structural analysis, rig testing and durability assessment<br />
Target costing and manufacturing support<br />
CASE STUDY<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., November 2011 © <strong>MAHLE</strong>
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Our Solutions<br />
Low Volume Manufacturing<br />
Our Solution<br />
Based on extensive experience in design, manufacturing and<br />
assembly of ‘class leading’ powertrains<br />
Project management and advanced quality planning systems<br />
to promote p fault-free on-time production p and delivery y<br />
Engineering and manufacturing ‘under one roof’<br />
Our Services<br />
High quality aluminium casting foundry using COSCAST<br />
Versatile aluminium and cast-iron CNC machining facilities<br />
Assembly operations and end-of-line testing<br />
Supply chain management and Supplier Quality Assurance<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., November 2011 © <strong>MAHLE</strong>
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Our Solutions<br />
Prototype <strong>Powertrain</strong> Solutions<br />
Our Solution<br />
Rapid new engine concept development solutions<br />
From clean sheet designs to major engine upgrades<br />
To support dyno &/or vehicle assessment / demonstration<br />
Integration g of engine g concept p into carryover y or <strong>com</strong>pletely p y<br />
new concept vehicle architectures<br />
Our Services<br />
Multi-disciplinary teams offer full range of capabilities<br />
Support for engineering, manufacturing, procurement,<br />
engine / vehicle build & testing<br />
<strong>MAHLE</strong> Flexible ECU for prototype control solutions<br />
CASE STUDY<br />
CASE STUDY<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., November 2011 © <strong>MAHLE</strong>
22<br />
Our Case Studies<br />
Recent Case Studies<br />
DOWNSIZING ENGINE OFF OFF-HIGHWAY HIGHWAY ENGINE<br />
TEST SYSTEMS<br />
HIGH PERFORMANCE CALLOGIQ & PROLOGIQ<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., November 2011 © <strong>MAHLE</strong>
23<br />
Our Case Studies<br />
Advanced Downsizing Demonstrator<br />
MMotivation ti ti<br />
Technology demonstrator to showcase<br />
<strong>MAHLE</strong>’s engineering g g & <strong>com</strong>ponent p expertise p<br />
R&D platform to develop new technologies<br />
Highlights<br />
From a clean sheet to a running engine<br />
in only 9 months<br />
50% ‘extreme’ downsizing achieved<br />
2.4l V6 1.2l Inline 3 cylinder with 120 kW<br />
30% reduction in CO 2 emissions<br />
Additional prototype engines produced for<br />
various customer projects<br />
Demonstration car presented in 2010<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., November 2011 © <strong>MAHLE</strong>
24<br />
24<br />
Our Case Studies<br />
Off Off-Highway Highway Engine<br />
Re-design an engine family to meet Tier IV<br />
Inline 4, approx. 1l displacement per cylinder<br />
Concept design (incl. all engine <strong>com</strong>ponents)<br />
Procurement and demonstration engine build<br />
Support OEM production design<br />
Problem solving - Head Gasket Failures<br />
OEM warranty costs ≈ £1m over 18 months<br />
<strong>MAHLE</strong> analysed root cause and implemented<br />
new design Problem “effectively solved”<br />
Highlights<br />
Collaboration with customer including on-site<br />
support through resident engineers<br />
Successful approval of demonstration engine<br />
Fast and effective problem solution<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., November 2011 © <strong>MAHLE</strong>
25<br />
Our Case Studies<br />
Development & Production of Fuel Leak Tester<br />
CCustomer t ttarget t<br />
Fast & cost effective solution to meet 100% leak<br />
test requirement on high volume lines<br />
<strong>MAHLE</strong> Test Systems solution<br />
Fast accurate detection of 00.010 010“ diameter leaks<br />
Typical leak test time of 10 seconds<br />
Designed to integrate easily into line<br />
Highlights<br />
In use at 14 assembly plants and growing…<br />
With several major OEMs<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., November 2011 © <strong>MAHLE</strong>
26<br />
Our Case Studies<br />
High Performance<br />
CCustomer t vision i i<br />
“To challenge the <strong>com</strong>petitors high performance<br />
engine g supremacy” p y<br />
<strong>MAHLE</strong> was a key development partner<br />
Multiple engines / applications, applications including :<br />
450 bhp V8 BiTurbo<br />
650 bhp V10 BiTurbo<br />
MPT involved from rapid concept development<br />
through to production<br />
Highlights<br />
Strong relationship developed with client<br />
Based on <strong>MAHLE</strong> capabilities & many<br />
successful projects<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., November 2011 © <strong>MAHLE</strong>
27<br />
Our Case Studies<br />
Performance Concept Demonstrator<br />
CCustomer t ttarget t<br />
Rapid development of a new high performance<br />
engine concept & demonstration in-vehicle<br />
Project summary<br />
V8 Biturbo, Bosch ME 17 control & many<br />
novel features<br />
Highlights<br />
22 wks ks from project start to first engine rrunning, nning<br />
including design, procurement & build activities<br />
in action - from first running on dyno…<br />
12 wks k tto ffull ll ttorque structure t t vehicle hi l cal l<br />
17 wks to emissions feasibility demonstration<br />
Customer transmission partner <strong>com</strong>ment:<br />
‘… best base calibration they had worked with…’<br />
Power (PS)<br />
700<br />
600<br />
500<br />
400<br />
300<br />
200<br />
100<br />
3.8l Turbo V8 Performance Targets<br />
Power PS<br />
Torque Nm<br />
0<br />
0<br />
0 1000 2000 3000 4000 5000 6000 7000 8000 9000<br />
Engine Speed (RPM)<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., November 2011 © <strong>MAHLE</strong><br />
700<br />
600<br />
500<br />
400<br />
300<br />
200<br />
100<br />
Torque (Nm)
28<br />
Our Case Studies<br />
&<br />
CCalibration lib ti validation lid ti for f an engine i family f il<br />
Multiple engine variants & vehicle platforms<br />
Markets: US, EU & ROW<br />
<strong>MAHLE</strong> used an integrated approach<br />
calibration & simulation tools used to<br />
develop OBD settings<br />
fleet data processing to validate<br />
Maximising benefits of a small vehicle fleet<br />
Highlights<br />
Many subtle issues found & fixed<br />
C Customer reported ’ ’95% % f fewer MILs in 3 years’<br />
’<br />
Exhaust back<br />
pressure<br />
1<br />
0.9<br />
0.8<br />
0.7<br />
0.6<br />
0.5<br />
0.4<br />
0.3<br />
0.2<br />
0.1<br />
0<br />
KFFMSML<br />
15<br />
244.75<br />
30<br />
35.225<br />
40<br />
455<br />
50<br />
69<br />
880<br />
2000<br />
nmot<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., November 2011 © <strong>MAHLE</strong><br />
rl
29<br />
Our Case Studies<br />
ProLogic Secondary Air Flow Error & ‘Fix’ Fix<br />
LLow relative l ti secondary d air i mass flows fl detected d t t d in i ProLogiq P L i IDAA reportt<br />
Root cause confirmed as an error in the back pressure model<br />
Si Simulated l t d iimprovements t ddue tto a new bback k pressure model d l with ith th the same ‘ ‘old’ ld’ ddata t<br />
<br />
<br />
Exhaust back<br />
pressure<br />
1<br />
09 0.9<br />
0.8<br />
0.7<br />
0.6<br />
0.5<br />
0.4<br />
0.3<br />
0.2<br />
0.1<br />
0<br />
KFFMSML<br />
15<br />
24.75<br />
30<br />
35.25<br />
40<br />
45<br />
50<br />
69<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., November 2011 © <strong>MAHLE</strong><br />
rl<br />
880<br />
2000<br />
nmot
30<br />
The Difference We Make<br />
OPTIMISED TECHNICAL SOLUTIONS<br />
REDUCE PROJECT COST BY 25%*<br />
REDUCE PROJECT TIMESCALE BY 50%*<br />
* as per acknowledgement by a customer<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., November 2011 © <strong>MAHLE</strong>
31<br />
Summary<br />
EFFICIENT PROCESSES<br />
TECHNICAL EXPERTISE<br />
FOCUSED RESEARCH<br />
ENGINEERING AND MANUFACTURING<br />
OPTIMISED APPROACH FOR BEST VALUE<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., November 2011 © <strong>MAHLE</strong>
Thank you for your attention<br />
© <strong>MAHLE</strong>
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