The first stage of the maintenance digitalization strategy was the mobile collection and centralization of data in SAP, which was implemented in 2022. This was followed in 2023 by the next stage, the installation of a maintenance board that allows the transparent visualization of availability, fault reports, maintenance activities, official inspections, and budgets for the Cologne, Ulm, and Herschbach plants. There have also been a number of other changes at our sites:

DEUTZ ULM

A new CNC turning machine and several new measuring machines went into operation at the Ulm production site in 2023. Crankshaft production was also reconfigured to achieve better machine availability, and a new tool management system was established. The development of the new PowerTree generation has begun, and the focus of shopfloor management on key figures helps to optimize processes.

DEUTZ HERSCHBACH

In Herschbach, a total of five new milling machines for inhouse production have gone into operation, allowing for more efficient component processing. Another new addition is a special indexing machine for rocker arms, which reduces takt time by up to 50 percent and ensures even better quality and process stability. A new logistics concept using a block storage system will further improve logistics processes.

DEUTZ COLOGNE

In Porz, the upgrade of core assembly on assembly line 3, with new tightening technology, measuring stations, and sealant application units, marks the first step toward the installation of assembly line 6. New automated guided vehicle systems were installed for the engine assembly in hall 41. Some crankshaft production processes have been automated by introducing a robot, which has resulted in increased productivity and greater efficiency. Automation has also reduced the physical strain on employees. In camshaft production, two automated processes have taken over component handling, successfully supporting production operations. The concept of ‘bin picking’ is also being used at DEUTZ for the first time.

DEUTZ AMERICAS

In 2023, DEUTZ achieved record revenue of just under US$ 500 million in the Americas region. Growth in the service business has been particularly strong. The ninth DEUTZ Power Center site was opened in Michigan, and the service team has continued to expand. The acquisition of our former service partner, Mauricio Hochschild, in Chile and Peru has been completed. The integration is proceeding smoothly and initial synergies have been identified to further accelerate growth in the region.

DEUTZ ZAFRA

The DEUTZ plant in Zafra, Spain, has expanded its smart factory concept in the production line for engine components for the 3.6L series. The first phase of the Shared Service Center in Zafra has been concluded successfully, the second phase of extending the Global Service Center has been approved. DEUTZ SPAIN also received a national award from AERCE, the Spanish Association of Procurement, for the best purchasing strategy, as well as a national award for a project by a female vocational student in production.