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How to set up a Porsche GT3 for the
Porsche Mobil 1 Supercup challenge
Of f i c i a l L o c t i t e

Cu s t o me r Ma g a z i n e no.
10 10
Leading in Health & Safety
Our contribution to your safety at work.
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at work | no. 2/09 at work | no. 2/09
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Cdric Berthod
Dear Readers,
Welcome on board. Once again, we are going to take you on a trip behind the scenes of some the worlds most
famous and successful companies. In this second issue of our customer magazine at work, we will take you to
the desert, where the iconic Porsche 911 raced down the track in Bahrains scorching heat. Another destination
is Scotland, where Terex

produces a mining truck of gigantic dimensions. The journey will also take you to Italy,
where Gessi, the exclusive interior design manufacturer opened its factory gates for us.
What is it that powerful race cars, luxurious bathroom ttings and monstrous mining trucks have in common?
They all rely on a technology without which modern life as we know it would be unthinkable, but which remains
invisible for most people: adhesive technology. This is the golden age of glue writes the American author Bruce
Sterling and continues: During the past 30 years, there has been a silent revolution in adhesion. In this issue, we
give a voice to that silent revolution and open the door to our engineers in Munich and Dublin. They'll share their
insights and experiences as a part of Sterlings silent revolution.
In our trend report, we follow up on this theme, taking an in-depth look at the history of maintenance, a topic
closely linked to the development of sealants, adhesives and threadlockers.
Highlight: Porsche Motorsport
Take a look behind the scenes of Porsche
Motorsport and discover exciting details about
the Porsche 911 GT3 Cup car.
Trend Report
Maintenance and repair. The future economic
Reliability Report 3: Terex

100 ton trucks exerting up to 1000 horsepower.

We are paying a visit to the site where these
giants are manufactured.
Reliability Report 4: Gessi
Luxury bathroom design "Made in Italy".
Manufactured by experts skilled in the ne
art of technology.
RD&E Insights
Environmentally compatible threadlockers
set new standards in Health & Safety and
Handy Hints
Insights online let us bring you closer to our
technologies and help you nd the right Loctite

product faster and easier.
Integrated Solutions
Developing adhesive formulations tailored to
the needs of a wide variety of industries. One of
Henkels core competencies.
Some of the topics for the next issue of Loctite

at work.
Vice President
Loctite Industrial Group
Henkel Adhesive
Technologies EMEA
Yours sincerely,
Cdric Berthod
at work | no. 2/09
Editorial | 3
Porsche and Loctite

engineers worked together to nd

exactly those solutions, in the race car as well as in the
series model 911 GT3. Loctite

products are used in the

construction of the engine, the gearbox and differential.
Porsche relies on the proven Loctite

durability when it
comes to threadlocking and ange sealing, ensuring
reliability of these vehicles even under extreme conditions
like the heat of Bahrain. Loctite

243 is used to secure

bolts on the gearbox clamping plate, the xing bolts of
the oil spray tube inside the gearbox and xing bolts of
the sequential gear shift system. While Loctite

574, a
fast curing gasketing product, seals the two-part gearbox
The xing bolts of the differential housing, the stud bolts
of the gearbox housing as well as the xing bolts of the oil
pump housing and the bolts of the mounting frame of a
pinion wheel shaft are secured with Loctite

270. Loctite

products are also used for component manufacturing:

270 for the tappet pins onto the wheel hub, and

243 for the heat protection shield mounted to

the brake caliper protecting electronic sensors from the
brake heat.

is heavily used in the manufacturing of the

vehicles, but it plays a part in their maintenance, too. At
the beginning of the season in March, all 14 cars taking
part in the Supercup were provided with a full set of

threadlocking, gasketing and cleaning products.

The cooperation between the two companies goes a lot
further than that, however. Engineers of the two rms are
in constant contact and Porsches demands often spur
innovation in the Loctite

labs in Dublin and Munich.

On a race circuit in Bahrain, a parade of tiny dots
whizzes by in the blistering heat. The icons on parade are
the cars that make up the eld of the Porsche 911 GT3
Mobil 1 Supercup. The Porsche 911 is a legendary vehicle
and a physical symbol of brand awareness rivalled only by
a select few. It is one of the few products that have become
a globally recognizable symbol, like Coca-Cola.
However, what is not as well known as the elegant, curved
shape of the 911 GT3 that just raced by under the burning
desert sun is this "minor" detail: the construction of the car
relies on modern adhesive technology. In order to draw
attention to this fact, Porsche and Henkel, with its strong
Loctite brand, have engaged in a partnership to support
the Porsche Mobil 1 Supercup.
The Supercup competition is the overture to Formula 1,
the most popular motorsport event in the world. Porsche
Mobil 1 Supercup races are held on every Sunday before
a Formula 1 race. After the opening event in the Kingdom
of Bahrain this spring, ten more races in different European
countries are scheduled throughout the course of the
The Porsche 911 GT3 Cup cars, which only weigh
1130 kg, boast engines with 420 bhp and a top speed of
290 kilometres per hour. This lightweight co nstruction is
made possible using alternative materials like aluminium
and composites, which is where adhesives come into
play. Since aluminium and composites dont lend them-
selves to thermal welding, alternative solutions needed
to be found.
Porsche Motorsport
and Henkel:
a winning team
Partner status:
Ofcial Technology
Partner to the Porsche
Mobil 1 Supercup.
Ofcial Partner to
Porsche Motorsport
First participation:
Main technical
Engine, Transmission,


Flange Sealing:



Winning together

and Porsche Motorsport start their technical partnership at full throttle

at work | no. 2/09 at work | no. 2/09
| 4 Highlight
This commitment to the high-end of innovation and quality
represents only two of the values that Henkel and Porsche
share. The fact that both rms are family businesses that
maintain long-term relationships with their employees is
one of the similarities in company culture that facilitates
Both companies are used to being consultants as well as
manufacturers. Loctite

provides its customers with high-

tech solutions and individual support. Porsche actually
started as an engineering consulting company and has
retained that feature until today.
High-speed engineering for professionals
The Bahrain story of the German driver Ren Rast makes abundantly clear how crucial good engineering and maintenance
is to succeeding in the Supercup. Ten minutes before the start of the race, Ren Rast wanted to drive out of the garage,
but suddenly there was a loud crack! His chances of making it to the grid in time didnt look good. One of the two drive
shafts had gone. Seven mechanics instantly swarmed the car and managed to do the impossible: within only 8 minutes
and 23 seconds they had replaced the shaft, using threadlocker Loctite

243 to secure the six bolts holding the shaft

to the gearbox. The change of the drive shaft was done in just over eight minutes, says engineer Frank Funke, proud
of his team Veltins MRS Racing, in an interview with I owed this result to my boys, a grateful Rast said
after the race. He came in second, beaten only by Bleekemolen. Richard Westbrooke, Supercup winner in 2005 and
2006, achieved a third place on his comeback to the Supercup.
Bernd Homberg is the Loctite

Sales Engineer responsible

for the cooperation with Porsche Motorsports. It can go
both ways: either we have a new product and approach
the Porsche engineers, they test it and check whether its
helpful for them. Or, Porsche hits on a problem that can
be solved with adhesive technology and they turn to us
for assistance. He explains the way the partners work
together. At the moment, Porsche is testing Loctite

as a gasket for the differential housing. When they were
looking for a way to attach a stopper to the tank we were
able to solve the problem with high temperature resistant
two-component epoxy adhesive Loctite

Hysol 9492, he
One of the interesting features of what the American
author Bruce Sterling calls the silent revolution in adhesive
chemistry is the fact that adhesive technology doesnt
always receive a great deal of attention in academia.
Groundbreaking research and innovative ideas are often
a result of business needs and take place in companies
rather than natural science faculties. Henkel is trying to
remedy this situation, however, and is making its long
years of experience and extensive know-how available
to universities in a number of cooperation projects. As a
professional partner to young engineers and a product
supplier to their racing teams, Loctite

has been part of

Formula Student for several years.
Threadlocker Loctite

high strength for extreme loads
Threadlocker Loctite

Health & Safety counts
Threadlocker Loctite

vibration resistant, removable assembly
Flange sealant Loctite

fast cure speed
at work | no. 2/09 at work | no. 2/09
| 5 Highlight
Hard work
Siberia, minus 50 C. A giant truck rumbles along the gravel of the coal mines, with the
powerful determination of an angry rhino. The giant used in the Siberian mines was
manufactured in Scotland, just like its twin brother doing hard work in copper mines
under the blazing Mexican sun.
The factory in Scotland Ready for delivery A wheel as big as a man Wheel suspension of a 100 ton truck
at work | no. 2/09
| 6 Reliability Report 3
These trucks, used for heavy mining work in some of the world's
most treacherous areas, are produced by the American company

. Vehicles exposed to the full force of extreme climates and loads

rely on high-end technology in combination with solid engineering to get
the job done. This is where Loctite

products make an impact, and the

two companies have a long standing business relationship.
22 bolts are secured with Loctite

at work | no. 2/09
| 7 Reliability Report 3

markets more than 50 brands covering a broad range of equipment

for the construction, infrastructure, quarrying, recycling, surface mining,
shipping, transportation, rening, utility and maintenance industries. Henkel
had the chance to send a lm crew to the Terex

plant in Glasgow, Scotland

to see Loctite

products in action.
The enormous power the Terex

machines wield requires the reliability that


adhesives and sealants can ensure. Locating studs locked with

high strength anaerobic compound Loctite

648 allow easy and fast

xturing of the differential, a crucial construction part exposed to strong
forces. The rigid anges of the differential housing are sealed with Loctite

518. Besides instant seal, Loctite

518 guarantees the reliable long-term

performance because there is no gasket relaxation, and correct clamp load
is maintained throughout the life of the assembly. This is a perfect example
of how Loctite

products provide optimisation in production.

Inspiring strong feelings
How do you measure a companys appeal? Is it the level of brand awareness?
The market position? Customer loyalty?
There is another way of doing it, by asking a simple question: whose
products will inspire more excitement in a conversation amongst school
children? Applying that measure, even Porsche and Ferrari will have hard
time competing with Terex

. The American rm is the manufacturer of the

biggest digger and the strongest crane in the world.
The list of awe-inspiring products from Terex

doesnt stop here. At the

Scottish location, gigantic coal-mining trucks and other heavy duty
applications are assembled. To get an idea of how big these trucks
really are, just picture a wheel that is as tall as a grown man. Terex

produces seven different models of these trucks, with loading
capacities up to 100 tons.
Attention to detail and emphasis on good craftsmanship are the
attributes that Terex

and Loctite

engineers share. Jackie is always

just a phone call away, says Steven Macholecki, a supervisor at
the Scottish Terex

plant in a video documenting the use of Loctite

production. Jackie is Jackie Marshall, the Loctite

sales engineer responsible

for Terex

in Glasgow.
Marshall spends at least one day a week at the plant in Glasgow, and
the cooperation with the Terex

engineers seems to be working well for

both parties. Im involved in nding adhesive and sealant solutions for new
designs, but Im also there when they encounter maintenance problems,
he explains.
A wheel
as big as a man
at work | no. 2/09
| 8 Reliability Report 3
Globally, Terex

is a well-known name when it comes to

equipment for the construction, infrastructure, quarrying,
recycling, surface mining, shipping, transportation, rening,
utility, and maintenance industries. Among its portfolio is an
impressive range of heavy duty vehicles including cranes,
dumpers, excavators, digger derricks and rollers, as well
as both rigid and articulated trucks.
The company has built a reputation for providing high
quality products that do their jobs with efciency, explains
David Brown, Technical Support Engineer at the Terex

base in Motherwell, Scotland. The differential ange
must be sealed in a way to ensure long-term reliability by
eliminating leak paths.

already used a number of Loctite

products on its
vehicles for a variety of applications, so it was natural to
call in the local Henkel sales engineer, Jackie Marshall, to
recommend a solution.
The answer was to use a liquid gasketing product, states
David. It was recommended that Loctite

518 was trialled

for the purpose and this provided the solution we were
Liquid anaerobic gaskets conform totally to the ange
surface, lling all gaps and irregularities. Bolts, ange, and
gasket act as a unit, sharing operational stresses. Loctite

518 is designed for sealing rigid ange faces not only on
vehicle differentials, but also on gearbox, axle and engine
anges such as timing covers. It provides an instant seal
against low pressures, lls gaps up to 0.25 mm, and is
effective at temperatures ranging from -55 C to +150 C.
The size of the ange surface meant that application
techniques needed to be taken into consideration. We
are talking about a two-inch wide lm on a three-foot
diameter ange, declares David. With such an area to
cover, normal application methods such as the use of a
standard dispensing gun were not really suitable. Again,
Henkel through its Loctite

products was able to help.

That help came in the form of the Loctite

Trax Roller.
This is a roller (similar to the one used for painting) that is
attached to a dispensing gun, allowing the gasket material
to be applied quickly with a very even lm over the whole
Since we have put this solution into practice, we have
never experienced any problems with leakage," concludes

Provide a long-lasting
seal on a three-foot
diameter rigid ange at
the rear axle differential.


at work
Long-life, reliable
gasketing solution
The rear axle shaft ready for further
22 bolts holding the differential to the
rear axle are retained with Loctite

Cleaning the ange of the rear axle
differential with Loctite

Transmission and wheel suspension are
Rear axle ready for the next assembly
Differential is ready for assembly
Transmission assembly in a 100 ton
Sealing the ange of the rear axle
differential with Loctite

Source: Terex

case study
at work | no. 2/09
| 9 Reliability Report 3
Dening sustainability
Environmental awareness has come a long way. Once
the domain of bearded men wearing Birkenstock sandals,
they have now arrived in corporate boardrooms all over
the world. Sustainability has become a buzz word in the
business community. What exactly does sustainability
mean to you, though?
That is the question that Henkel Product Manager Erik
Edelmann and his team asked their industrial customers.
For most customers it is rather difcult to clearly dene
sustainability. The term generally encompasses energy
and climate, materials and waste, water consumption,
health and safety, as well as social progress. However, the
primary focus is clearly on occupational health and safety
and environmental responsibility, says Edelmann.
A clean sheet
This was not an entirely new challenge for Henkel, as the
company has always placed great importance on non-
hazardous substances and minimal eco-toxicity in the
more than one hundred years of its history. With the new
threadlockers Loctite

2400 and Loctite

2700, Henkel has

broken new ground in occupational health and safety. The
medium strength threadlockers Loctite

2400 and the high

strength threadlocker Loctite

2700 are a leap forward,

because they both have a white MSDS (Material Safety
Data Sheet).

A white MSDS means that according to the tough
regulations of (EC) No. 1907/2006 - ISO 11014-1 both
threadlockers do not carry any hazard symbols, risk or safety
phrases. In addition, they do not contain any declarable
CMRs (Carcinogenic, Mutagenic and Reproductive toxins),
explains Edelmann and continues: You will be surprised
to see that your ordinary dishwashing agent or all- purpose
cleaner carries more hazard symbols than these industrial
Never sacrice performance
As usual, the Henkel specialists in the Dublin Technology
centre were working together very closely with their
customers during the development process. In the case
of Loctite

2400 and Loctite

2700, we were collaborating

with two large customers in France, says Edelmann. His
professional background is in chemical engineering, a
training which greatly facilitated the communication with
leading developer David Condron in Dublin. The customers
took a very cautious approach and insisted that not even
the decomposition products should be hazardous, says
Not willing to sacrice performance, Condron and his
colleagues worked for more than a year on the project
and nally made it happen: they developed products that
retained the customary high Loctite

performance with a
white health and safety bill.
We were lucky to have the chance to cooperate with
highly sophisticated and demanding customers, says
Medium and
high strength
Added benet
of enhanced
occupational H&S
No hazard symbols
No risk phrases
No safety phrases
No declarable CMRs
at work
The evolution of new adhesives
RD&E Insights
David Condron
Senior Chemist, Product Development Europe,
Dublin, Ireland
at work | no. 2/09
| 10 RD&E Insights
The medical ofcers in France took a personal interest
in the project and gave direct feedback on the various
prototypes. By meeting the customers needs, Loctite

engineers set a new standard in the realm of industrial
threadlocking. I have to say that we are proud of this
achievement and the fact that we were able to reafrm
Henkels position as a technological industry leader,
Condron stated at the end of the interview.
Because safety matters: Loctite

lockers with a white health and safety bill
Quality and responsibility have always been important issues
at Henkel. Continuously striving to improve the Health & Safety of
its products, the company breaks new ground with the medium strength
threadlocker Loctite

2400 and high strength threadlocker Loctite

2700. These
two products retain the same outstanding level of performance customers have come
to trust, with the essential added benet of enhanced occupational health and safety:

2400 and Loctite

2700 require no hazard symbols, no risk phrases and no
safety phrases on Material Safety Data Sheet complying with the tough EU regulations
They do not contain any declarable CMRs (Carcinogenic, Mutagenic and Reproductive
They do not require any entries in sections 2, 3, 15 and 16 of the MSDS according to
(EC) No. 1907/2006 - ISO 11014-1
No compromise on performance
Medium strength threadlocker Loctite

2400 is uorescent blue with a viscosity of

3000 mPas and a shear strength on steel of 9 N/mm
. The high strength Loctite

2700 is
uorescent green, has a viscosity of 500 mPas and a shear strength of 18 N/mm
. Once
cured, both products offer excellent resistance against most industrial chemicals. They
achieve good thermal resistance, withstanding continuous operating temperatures up to
150 C.
at work | no. 2/09
| 11 RD&E Insights
A perfect
What do cars, aeroplanes, syringes, shoes, trucks, water taps, arrows from ancient
Mongolia, spaceships and tunnel boring machines have in common? The answer is:
the use of a ubiquitous, yet rarely noticed technology- adhesive engineering. Even
though the use of glue can be traced back to the Neanderthals, the last 30 years
have seen an enormous increase in its reliability as well as in industrial adhesive
According to Stefan Frisch and Hermann Handwerker from Henkel in Munich, this
is not only a fact normally ignored by the layman; even engineers and academics
dont give adhesives the credit they deserve. University courses only touch briey
on adhesives, one of the youngest joining technologies, if they include them at all,
says Frisch, an application technologist. A lot of the research and the innovation
results from companies like Henkel who are trying to meet customer needs," adds
Stefan Frisch
Application Technologist
Henkel Engineering Adhesive
Hermann Handwerker
Manager European Technical
Service, Henkel Munich
at work | no. 2/09
Integrated Solutions | 12
Handwerker, who holds a PhD in chemistry, continues:
After university, I didnt even think about the adhesive
industry as a possible employer. And I think its the same
for most engineers, too; using adhesives is somehow seen
as second best, something to be avoided, he explains.
This is of course completely unjustied, according to Frisch
and Handwerker, who almost seem like missionaries for the
adhesive cause during this lunch-time interview, their zeal
hardly allowing them to nish their meals.
Standard or tailor made?
They might have a point, as a look around the Henkel
test centre in Munich demonstrates. Just behind
the entrance there is a showcase displaying a
variety of items produced with the use of
adhesives: Loudspeakers, syringes and
infusion bottles to name just a few. The
centre in Munich is one of the places
where Loctite

specialists conduct
the research that Handwerker
and Frisch referred to during the
Frisch points to a differential
gear in one of the rooms and
explains: This is a project weve
been working on for more than
a year. A customer from the
automotive industry wanted us
to nd an adhesive solution for
putting together the parts of this
differential. This is one of the benets
of working for Henkel: Finding and
testing solutions is a service that Henkel
offers as a support to customers in their
development process.
But nding or creating the right product is only the
rst step; the second step is applying and dispensing
the product in the right manner. This is the area that
Frisch specialises in. We offer a large variety of standard
equipment, both for manual and automatic dispensing, he
says. Again, the Loctite

engineers work on a problem until

they have come up with a solution that will stand the nal
test of continuous use on an assembly line or in a factory
workshop. If no combination of standard equipment will
do, we have a team responsible for designing tailor-made
solutions, Frisch continues.
One of the advantages of being the market leader for such
a long time is the wealth of experience and know-how the
team in Munich has accumulated. The customer gets the
right product and the appropriate dispensing equipment all
in one, which leads to very user friendly solutions.
The omnipresent customer need to cut costs is very much
on the minds of the Loctite

crew in Munich. Loctite

adhesives offer benets not only in manufacturing, but
also for maintenance and repair. Loctite

engineers have
developed solutions that emphasise prevention rather than
repair. A good example for this strategy is the gearbox
and shaft package they have assembled: a range of more
than 20 products developed to perform under extreme
conditions. Applying the products prevents fretting and
corrosion, minimises costly breakdowns and extends
service life. Appropriate dispensing equipment is available
for manual as well as other application jobs in the workshop.
And should there be problems: the local sales engineer is
just a phone call away.
Product applications can be found in a wide range of
industries. Special packages have been developed for
applications on pump, centrifuge, power plant, shaft and,
last but not least, water treatment which by all accounts will
be one of the growth industries of the 21st century.
Is there further room for development when it comes to the
use of industrial adhesives? Silly question: Of course there
is, says Handwerker. This is a relatively new technology
and we have just scratched the surface of whats possible.
This sentence almost exactly echoes a statement made
by his colleague featured in the rst issue of this magazine
about the Tear Down Centre. There, an interdisciplinary
team of specialists looks at each component of a nished
product to see whether the value of the product can be
enhanced or the cost of manufacturing can be reduced.
All these efforts help to spread the word about the power
of adhesives and sealants.
at work | no. 2/09
Integrated Solutions | 13
the invisible power of development
Since humans first began developing tools, there has always been a need to maintain
them. The careful maintenance of an economic production process was often a
necessity for survival, especially in times of scarce and valuable commodities. The
road to implementing modern industrial maintenance was a long one. Given the
developments ahead of us, we are still at the beginning of that road.
at work | no. 2/09
| 14 Trend Report
The history of maintenance is also the history of culture and
an allegory to the industry's conception and philosophy.
Effective and efcient maintenance is, more than ever, vital
for development, particularly in times of nancial crises and
reduced turnover, increasing costs for energy, commodities
and labour.
Today, Maintenance, Repair and Overhaul (MRO) costs
more than 1,500 bn per year in the EU alone, and
more than 7,000 bn worldwide. Over 50 million jobs
are directly related to MRO, and 150 million jobs are
indirectly related. However, requirements for MRO are
increasing and, especially in times of nancial crisis
and reduced budgets, are difcult to meet. Laws are
tightening the scope to respond to these requirements,
as well as meeting customers demands, incorporating
new technologies, and considering economic and ecologic
necessities. However, modern industry would not be able
to work efciently without up-to-the-minute and innovative
methods of maintaining tools and equipment.
The early years of industry maintenance by
In the early stages of industrial development, breakdowns
were commonplace due to the means of production and,
consequently, down-times were high.
The symbol of early maintenance was the man with the
oil can. And, beside this basic service, one simply had to
repair the damage as it occurred. There were no monitoring
systems available at that time, and the analysis of probability
of failure was in the early developmental stages.
The transformation of failure based on preventive
maintenance began with trafc engineering; initially from the
railways, and later with aviation technology. The immediate
danger to human life and the difculties encountered on the
way to carry out maintenance work were the driving forces
in the development of preventive maintenance.
Prevention is better than a cure preventive
The reorientation of preventive maintenance in the industry
did not start in Europe or the US, but in post-war Japan.
In an exemplary manner, industrial production was
transformed after World War II. The simple concept was
to follow manufacturers recommendations about the
controlled care and maintenance of machines and devices,
which was not so usual in the 1950s. It was part of the
Japanese Kaizen philosophy, which means (in this context)
continuous improvement toward the better.
Looking into the crystal ball predictive
By the 1960s, increasing competitive pressure led to a
steady improvement and continuity of production plants.
Consequently, the reliability of equipment and the probability
of error intervals became predictable, depending on load
and production time. This knowledge led to the increasing
quality standards of used materials and manufacturing
processes. Predictive maintenance was not able to
foresee occurrences caused by incidence or failure but
this approach led to distinct statistical knowledge, which
was reused by modern technology and software.
at work | no. 2/09
| 15 Trend Report
Optimising the I/0-ratio risk-based smart
The goal of Risk-based Smart Maintenance is to monitor
the conditions of equipment to calculate the probability of
a breakdown and to perform maintenance when it is most
Therefore, the comprehensive and sensitive Condition
Monitoring (CM) of the load on the parts of an installation
is essential to gain the data for risk calculation. Modern
CM systems meet the highest demands on sensors, data
collection, forwarding and automatic processing, analysis
and diagnosis, as well as plant-specic knowledge.
Risk-based Smart Maintenance also offers the greatest
potential for cost savings. The life of critical machine
elements can be almost fully exploited while, at the same
time, necessary maintenance activities can be scheduled
in coordination with the production plan.
The challenges of this strategy can be seen in:
The search for appropriate sampling and sensors
Finding the relevant parameters (state variables) for the
damage to the components of interest
The signal analysis and pattern recognition
The enormous ood of data
Data-analysis and models for risk assessment
Behind the scenes maintenance technologies
of the future
Smart Monitoring is only possible as a result of advances in
technology in the elds of mechanics, acoustics, systems
theory, electronics and computer science. Sensors in thin
lm technology, which can be placed directly onto the
Putting the pieces together total productive
At the start of the 1970s, globalised competition required
a further increase in production efciency to reduce costs.
The Japanese Institute of Plant Engineering merged US
maintenance concepts to create a new standard. The core
of the new concept was autonomous maintenance. The
key to its success was the knowledge and experience of
the facility operators.
Based on this new philosophy, maintenance became
part of the entire production and development process.
Prerequisite was to improve all aspects of production
and maintenance; from the planning and development of
systems to their care and beyond. The unique element of
this concept was Zero Goals, which means no unplanned
downtimes caused by preventable failures and, as a nal
objective, ensures that Total Productive Maintenance (TPM)
is a continuous improvement process.
Itaip: the largest hydro-
electric power plant on
earth. Some of the 20
tubes leading water to the
turbines at Itaip dam on
Paran river, located on
the border between Brazil
and Paraguay.
















at work | no. 2/09
| 16 Trend Report
military-driven development is able to provide very useful
information. Currently, some US universities are developing
Knowledge-based Augmented Reality for Maintenance
Assistance. These systems are tentatively using a
head-mounted display to explain maintenance information,
construction plans or sensor data.
New materials for a new world
In 1912, the Krupp company developed a new kind of
steel (a mixture of iron, chromium and nickel) with excellent
strength and durability against corrosion. At that time, it was
a signicant step toward reliability. Today, new materials
with outstanding properties are available to enable new
applications. Plastics, composites and carbon bre have
been available for some time now and are widely used in
numerous industries, from tunnelling to aviation. Along with
these new materials, new maintenance requirements will
be sent to the suppliers of MRO.
Currently, self-healing products with the ability to partially
repair damages are in development, but are not in
commercial use. Another approach to future maintenance
are the amazing capabilities of nano-tech materials with a
high capability of increasing the stability of equipment by
improved components and processes.
From the outset, the goal of maintenance has been to
increase prot by reducing losses in productivity. Plants and
production of the future will have to be far more complex
than they are today. Highly sophisticated maintenance
technologies are part of the solution.
structure to be monitored, allow a precise data on critical
zones. It also enables Smart Monitoring, which balances
activities and controls measures.
Downtime in a highly-effective plant can cost enormous
amounts each minute. A modern power plant, for example,
produces up to 1,500 MW from each turbine. Large power
plants, such as Itaip in South America, have 20 lines.
Measured by international energy spot market prices, each
minute of downtime costs the plant roughly 1,500. Far
more error-prone in production is the automotive industry.
Here a line has clock rates of less than a minute. So each
minute of downtime could exceed the total amount of one
cars gross prot.
RFID smart objects everywhere
Smart tagging by RFID technology is another approach to
realise cost-effective maintenance for complex industrial
machines and plants. RFID enables the implementation of
a smart object from planning to construction, assembling,
maintenance, disassembly and reassembly. Maintenance
will be much easier with self-monitoring smart objects,
which are able to store their data history, to communicate
with a CMD, to stimulate necessary steps automatically,
and to lead service teams to the area where the work
is required. In this context, the concept of ubiquitous
computing will lead to a new approach in dealing with the
growing complexity of plants and technology.
Mobile maintenance communication services
In order to avoid downtime, the 24/7 availability of all
required service parts has to be guaranteed. Successful
and fast operating logistics is a key factor of efcient
maintenance. Requirement and delivery times will be
reduced to a minimum through mobile communication
systems. In connection with RFID technology, specications
of work pieces, maintenance instructions, technical details
and construction plans of even the most complex systems
will be available at any time and place.
The chemistry of maintenance
For a long time, maintenance has been seen primarily as
a matter of material technique, handcraft and physics.
With the development of complex and sensitive plants,
chemistry has increasingly found its way into processes.
Today, a maintenance team not using numerous chemical
aids such as lubricants, metalworking uids, protecting
sprays or silicone speciality products is inconceivable.
Improving maintenance is imperative to cost-effective
production. Given to a standard industrial net prot ratio, a
reduction of 1 % in maintenance costs may have the same
effect a 33 % increase in turnover. Even in times of lower
turnover, the demand to reduce the cost of labour (which
covers 60 % of MRO spendings) will meet maintenance as
well as all other aspects of production. Therefore, the smart
replacement of procedures, such as the substitution of
welding by bonding technologies, will be able to contribute
an important share to this goal.
See, feel, learn augmented reality
Augmented reality deals with the combination of real-world
and computer-generated data, where computer graphics
objects are blended into real footage in real time. This
Increase prots through increased
maintenance efciency
Share of maintenance
Return on sales
Prot increase by
Source: MCP GmbH
at work
100 m
3 % ROS
8 %
3 m 4 m
4 m
7 %
8 %
100 m
4 % ROS 4 % ROS
133 m
billions 1 billion =
millions 1 million =
Megawatt = 1,000,000
Total Productive
Condition Monitoring
Central Maintenance
Radio frequency
identication by
transponders with
integrated circuits
Return on sales
at work | no. 2/09
| 17 Trend Report
The poetry
of added value
A slight, but unmistakable scent of vanilla pervades the hallway, and the attention of
the visitor is captured by the nostalgic beauty of some antique Italian motorcycles
decorating the room. What seems like the entrance to an exclusive spa or a fancy
hang-out for motorcycle enthusiasts actually leads to a showroom for water taps and
showerheads. But if you associate water taps and shower heads with the appropriate
aisle in the DIY store, you need to think again.
Gessi company headquarters in
Vercelli, Italy
Entrance to Gessis showroom Design meets reliability: Rettangolo
Colour water tap
Raw material ready for processing
at work | no. 2/09
| 18 Reliability Report 4
Pre-applied coating of water taps
at work | no. 2/09
| 19 Reliability Report 4
Reecting on the morality of objects
Both Gessis and Henkels company philosophies emphasise the
importance of beauty. Since its foundation in 1876, Henkels mission
statement has remained to produce products to make life easier, better
and more beautiful. Beauty, not just the beauty of products, also plays
an extremely important role in the Gessi philosophy, which sometimes
reads like an artistic manifesto and dazzles with sentences like these:
The core value of the business system is beauty. Beauty does not refer
exclusively to the aesthetic value of the product since its a dimension
that pervades every aspect of the business.
The average DIY store customer will probably be astonished to learn that
a manufacturer of water taps believes that the true added value of a
brand is its poetry content and its respect for the world. Therefore, the
manufacturer hasem barked on a mission to create artistic consumer
goods, goods that are meant to induce a reection on the morality of
Manufacturing beauty
Gessi, however, doesnt only talk the talk; at the plant in Serravalle
Sesia, it walks the walk: We dont want to compete with low price
manufacturers in China. We deliver the highest quality, both in design and
functionality and its working very well for us, explains Andrea Renna,
the Quality Assurance Director. This is no exaggeration: the companys
turnover grew by a stunning 23 % in 2007.
Gessis coloured light taps are a good example of this dedication to
beauty and functionality. The Rettangolo Color tap lines feature the
trademark minimalist elegance, relying on geometrical shapes: in this
case an open rectangle. When water passes through, a temperature-
sensitive LED lights up in different colours blue, purple, or red
according to the water temperature.

has been a partner to Gessi from the very beginning, and Loctite

threadlockers play an important role in the manufacturing process of a
large number of Gessi products. We use Loctite

products for every

screw that needs to be secured and watertight, explains Andrea Renna.
Be it the extraordinary square showerheads or the huge water taps for
industrial kitchens, Loctite

always plays a vital part in ensuring the

durability of the ttings.
Elegant production
The plant in Serravalle Sesia, which is just across the road from the
showroom, is another reection of the companys emphasis on beauty
and design. The production facility resembles a giant lab styled in the
company colours orange and black. Every worker wears a shirt or a
sweater with the company logo. The preferred means of transportation
within the plant are bicycles. These are, of course, black and orange
and bear the company name as well as the name of the user or the

at work
Locking and sealing
exclusive sanitary
accessories for a whole





2701 is put to use on

passive metal surfaces
Assembly of plated parts with Loctite


638 is used for locking and

sealing of threaded parts, even at room
Bagno Small is ready for use
at work | no. 2/09
| 20 Reliability Report 4
Gessi is the leader in bathroom and kitchen sanitary ware and accessories.
As of today, we are a worldwide reference for the Made in Italy seal as
a company whose products are featured in the most exclusive hotels,
in the best wellness spas and on the most expensive yachts. Although
it is a designer product, it is, above all, a quality product.
Quality of production, quality of the working environment, quality
in the way we produce our appliances and the way we choose our

is a partner which fully meets our philosophy.

Even though Gessi sells its products to business and private customers
all over the world, the entire production process takes place in the
Serravalle Sesia plant. Producing in a high-wage region like northern Italy
is not seen as a liability, but as an integral part of a company philosophy
which emphasises quality and a high standard of human relationships.
Modern times havent stopped at Gessis doorstep, however. The factory,
which is clean and orderly to the point of sterility, belying all stereotypical
perception of Italian chaos and laissez faire, employs robots and other
advanced production technology wherever possible. The yellow robots
in their metal cages with their graceless, yet effective, movements feature
prominently, especially at the beginning of the assembly line.
We automate where we can, says Renna. But due to the sophistication
of our products, a lot of work has to be done by hand and this will
continue to be the case. While showing us through the plant, Renna
points to red Loctite

bottles that can be seen on top of many of the

work benches inside the facility. Gessi handles, soap dispensers or
mirrors all rely on the performance of Loctite

Creative solutions
However, the collaboration between Henkel and Gessi transcends the
usual supplier-customer relationship. As companies whose success
depends heavily on a continuous process of innovation and the ability
to respond quickly to global market demands, Gessi and Henkel have
entered a relationship that can be best described as a form of partnership.
Quality Assurance Director Renna recalls the case of a soap dispenser
that Gessi sold to Russia. Because of the temperature differences, the
regular glue we used gave out and broke the glass. We were able to
solve the issue by making use of the exibility built into certain Loctite

products, says Renna.
If there is a challenge where we can assist, we take care of it
immediately, says Massimigliano Moneta, Loctites Technical Sales
Consultant responsible for Gessi. Loctite

maintains a laboratory in
Milan and the response comes within a matter of days.
Up to now, we have always been able to nd a
solution, normally by pointing out an alternative
use for one of the products from our range,
says Moneta. Even if that shouldnt be the
case at some point in the future, there is
always the European Technology Centre
in Dublin ready to take on the task of
nding a creative adhesive for a creative
Andrea Renna,
Quality Assurance Director,
Gessi Spa
Assembly of water taps for kitchen
sinks with Loctite

Assembly of water taps for hand
washbasins with Loctite

Quadro High Tech is ready for use Rettangolo Color tap is ready for use
at work | no. 2/09
| 21 Reliability Report 4
The knowledge toolbox
Whether you are designing a new product, or looking to keep existing machines running efficiently,

can help. Discover the complete capabilities of Loctite

anaerobic adhesive solutions and

innovations and find the right product for your application needs. Get connected to Loctite

s web
platform designed for engineers, by engineers:
Find your specific product solution for your
threadlocking, thread sealing, retaining and
gasketing applications.
See exciting application
videos and share our
customers experiences.
Order the next issue of at work magazine on:
at work | no. 2/09
Handy Hints | 22
Join us on our trip to Zagreb
where we'll visit Konar Electric
Vehicles Inc. Witness the production of
theses modern low-oor trams, there are over
a hundred which reliably serve the Zagreb public
transportation system on a daily basis.
... coming soon
551 tons of grain within 8 hours. That s the kind of speed
that turned the new generation of New Holland combine
harvesters into the Guinness world record holder.
at work | no. 2/09
Outlook | 23
Henkel AG & Co. KGaA
Adhesive Technologies
Henkelstrae 67
40191 Dsseldorf

Editorial Department
Marketing Department EMEA:
Christian Scholze
Andreas Engl
Beate Schneider
Isabelle Feix
Erik Edelmann
Frank Fischer

Andreas Engl (Project lead)
Phone: +49-211-797-6758

Werbeagentur GmbH
Henkel Limited
Wood Lane End
Hemel Hempstead
Hertfordshire HP2 4RQ
Tel. 01442 278100
Fax 01442 278071
designates a trademark of Henkel AG & Co. KGaA or its affiliates, registered in Germany and elsewhere Henkel AG & Co. KGaA, 2009