Annual Report 2012 - Knorr-Bremse AG.

Report
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Directly alongside the new production plant is the Knorr-Bremse Technology Center India (TCI). Here,
Knorr-Bremse Commercial Vehicle Systems has focused its engineering and development services for
commercial vehicle products specifically for the Asian market. One core activity is software development.
In order to benefit from synergies, a new software development center for the Rail Vehicle Systems
division is being set up in the same building. By 2015 the TCI will be providing work for some 200
employees. Pune is an established hub of IT and software activities in India, which means there is an
extensive local pool of talented software developers.
By setting up this new development center Knorr-Bremse is making sure that the company will have
sufficient resources going forward to meet the growing demand in the Asian market and master increasingly
complex products.
Bendix steps up capacity in Kentucky
In Bowling Green, Kentucky, Bendix Spicer Foundation Brake LLC operates a state-of-the-art manufacturing
site for air disc brakes and foundation drum brakes for the North American commercial vehicle
market. In 2011, the company expanded the size of the facility while also launching a new automated
disc brake line at the location, tripling its assembly capacity and capitalizing on its significant market
gains in foundation brakes. This was followed in the year under review by a further multi-million dollar
investment in a major expansion of production capacity and purchase of new equipment. One key
factor in this decision was new first phase of the US Reduced Stopping Distance regulation enacted in
August 2011. The mandate requires a 30% reduction in stopping distance for new three-axle tractors
with Gross Vehicle Weight Ratings (GVWRs) up to 59,600 lbs. and produced after the August 1, 2011,
implementation date. Tractors with two axles, as well as severe service tractors with GVWRs above
59,600 lbs., must comply with the new mandate by August 1, 2013. To help operators meet this requirement,
Bendix developed the Bendix ADB22X air disc brake and the high-performance Bendix
Extended Service (ES) drum brake. Introduction of the new legislation triggered a sharp rise in demand
for these brakes.
Knorr-Bremse Brazil moves to new plant at Itupeva
In the wake of significant growth in recent years and in anticipation of medium-term growth in the
South American market, Knorr-Bremse decided last year to expand and relocate its current Brazilian
production plant – the biggest joint facility for the rail vehicle and commercial vehicle divisions in the
Group. The location selected was the city of Itupeva, only 85 km from the current plant in São Paulo.
The process of transferring operations began at the end of 2012.
The company’s São Paulo plant had reached the limits of its capacity and could not accommodate any
additional product lines. Space restrictions also meant that production processes could not be brought
up to modern standards. As the land surrounding the plant was increasingly being used for residential
purposes, there was no scope to expand the existing site.
The biggest joint
facility for rail and
commercial vehicles
will in future be
located in Itupeva,
Brazil.
The new plant will manufacture brake control systems, bogie equipment and onboard systems for rail
vehicles, but some 70% of its production will be for commercial vehicles, covering the entire product
portfolio for the local truck market, including brake control systems, air supply and treatment systems,
brake cylinders, disc and drum brakes and torsional vibration dampers.
The move to the new location has enabled Knorr-Bremse to significantly extend its capacity not just in
volume production and equipment refurbishing but also in the fields of surface treatment, functional
and torsion testing and vehicle testing. The focus during the design phase of the new facility in Itupeva
was on optimizing layout and production processes and introducing a modern logistics concept.
The result should be significantly reduced throughput times in the various production processes.