| Safely handling heavy loads |
Demag crane fleet supports vehicle final assembly
DOLL Fahrzeugbau GmbH invested in 16 double-girder overhead travelling cranes from Demag Cranes & Components in connection with a new final assembly shop. The cranes lift and transport vehicles weighing up to 25 tonnes. Since the load capacity of the DR hoists used on the cranes can be increased if required, there are also reserves for even heavier loads.
Established in 1878, DOLL Fahrzeugbau GmbH, based in Oppenau, is managed as a family-owned business in the fourth generation. DOLL is the largest manufacturer of timber transport vehicles worldwide. As a further focus, the company also manufactures special transport vehicles and mobile systems. The latter include catering vehicles for airports, a market segment in which DOLL, together with a partner in Thailand, is the world leader. In Oppenau, the company manufactures complete vehicles, but also kits for final assembly by partner companies in Asia and Africa.
The vehicle manufacturer aims to be the quality and technology leader in its markets. The target is not to be the cheapest supplier, but to offer the best value for money. In this context, DOLL refers to vehicles with added value. They last longer, achieve higher resale prices and have lower operating costs. A strategy that has been rewarded with a special award: Brunhilde Rauscher-Doll, the General Manager of DOLL Fahrzeugbau GmbH, has been nominated Businesswoman of the Year 2006 in the German region of South Baden.
New final assembly shop accommodates strong growth
When DOLL reached its capacity limits after many years of growth, the company had to extend its production area. The construction of the final assembly shop marks the completion of the first milestone to transform the premises. The new building will not only help to secure the jobs of the current 300 employees, but it will also create new jobs in the foreseeable future.
The 4,500 square metre workshop is 60 metres long, 75 metres high and nine metres wide. Four double-girder overhead travelling cranes supplied by Demag Cranes & Components operate in each of the four workshop bays. Together with indexed staging areas, they form the basis for the continuous production line. The six to eleven metre long vehicles are each cycled through the final assembly line by two cranes. Since four cranes are operated in each bay, two vehicles can be moved along each line at the same time. The capacity of the workshop is sufficient to complete the assembly of approximately 1,000 towed vehicles, such as semi-trailers and trailers, as well as truck bodies, for catering vehicles, for example, every year.
Load capacity can be increased
DOLL's primary requirement to be met by the double-girder overhead travelling cranes is to provide sufficient load capacity. The cranes have to be able to lift and turn the 20 to 25 tonne vehicles safely. For this reason, each crane is fitted with two DR rope hoists, which each have a load capacity of 6.3 tonnes. The show-stopper: The DR rope hoists have reserve lifting capacities that enable the load capacities to be increased to eight or ten tonnes. DOLL will need the reserves if very large and heavy export vehicles for oilfield exploration are added to the range.
To enable the DR rope hoists to lift the vehicles on the level, they are controlled in parallel by means of an integrated Can bus. Also connected to the bus are the load display and strain gauge carrier link, which offers the possibility of electronic load limitation and also overload protection.
In addition to the high load capacity, DOLL requires permanent availability to ensure that the Demag cranes operate throughout three -shift operation from Sunday evening to midday on Saturday. In addition, the cranes have to be simple to operate. Further requirements include prompt service. DOLL also expects that the companies which provide equipment for its factory correspond to its "Made in Germany" philosophy and, like DOLL, manufacture in Germany.
Proven consultation expertise
Demag Cranes & Components was awarded the contract to supply the 16 double-girder overhead travelling cranes because the supplier offered the best value for money. For DOLL, the services provided also include the good consultation and the competent and prompt Demag After Sales Service, which ensures that the crane fleet will operate efficiently for many years to come.
Demag was already able to demonstrate its expertise before the contract was awarded, when it was involved in the planning of the workshop by the architect and was therefore able to provide advice and develop the materialflow concept virtually from the very beginning. The vehicle manufacturer's employees were involved in the planning, too. They also spoke in favour of Demag cranes, with which they had had better experience than with a competitor's crane.
Work on the new building started in April 2006. DOLL already moved in in the first week of November. The fact that the tight schedule was kept demonstrates the great commitment by all of the suppliers. To reduce the time required for installation, Demag lowered the cranes through the roof while it was still open, for example.
With its new building, DOLL established the basis for efficient assembly operations, but also created a model solution for ecological building. Compared with the old building, the heating requirement was cut to a sixth, for example. The electricity costs were also significantly reduced, as work can now frequently be done in daylight.
About Demag Cranes & Components
Demag Cranes & Components GmbHbased in Wetter/ Ruhr is a subsidiary of Demag Cranes AG and a supplier of industrial cranes and crane components for material flow, logistics and industrial drive applications. Services, such as spare parts, maintenance and refurbishment services, are another key element of the Group’s business activities. With more than 650,000 “Demag” brand electric cranes and hoists for industrial applications in operation, the company has the largest installed base worldwide and operates in 20 countries with some 4,900 employees.
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Contact:
Corporate Communications
Demag Cranes & Components
Mr Christoph Kreutzenbeck
Tel. +49 (0) 2335 / 92-7333
