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Herbert Eibensteiner is the new CEO of the voestalpine Group

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Herbert Eibensteiner, who succeeded Wolfgang Eder as CEO of the company today, joined the voestalpine Group exactly 30 years ago. After graduating in mechanical engineering and business management from the Vienna University of Technology (TU Wien), he started his career at the age of 26 as an engineer working in maintenance at the site in Linz. As early as 1993 he assumed management functions at voestalpine Stahl in the cold rolling mill, quality management, workplace safety, and environmental protection.

Eibensteiner Interview

"I’m looking forward to continuing to develop the Group from this positive basis, working together with my colleagues as we proceed along our chosen path. Where we are successful, we want to improve further. We will press ahead with internationalization, work ambitiously on developing new and innovative products, and drive digitalization. We will achieve all this on a step-by-step basis."
Herbert Eibensteiner, Chairman of the Management Board of voestalpine AG

 

Head of the Metal Forming Division

In 2000 Herbert Eibensteiner was appointed the Technical Director of voestalpine Krems. This was followed by further management positions in the former Profilform Division and other precursor companies to the Metal Forming Division of which he became the head when the division was founded in 2012. During this period he played a key role in the drive to internationalize the automotive segment.

Herbert Eibensteiner

Herbert Eibensteiner at Annual General Meeting 2019

Return from Krems

In 2014 Eibensteiner returned from Krems to Linz, becoming Head of the Steel Division, the Group’s largest revenue generating division. Here Herbert Eibensteiner also launched far-reaching initiatives: over a billion euros was invested in state-of-the-art production technologies. The technological basis for the coming years was laid with the construction of a new continuous casting line, the relining of blast furnaces A, 5, and 6, and the building of a hydrogen pilot plant. Eibensteiner has also been a Vice President of the European Steel Association, EUROFER, since 2014.

In June 2018 it was decided that Herbert Eibensteiner should take over as the new Chairman of the Management Board of voestalpine AG as of the Annual General Meeting 2019. This appointment became effective today.

"I’m consistent, I’m clear, and I’m fair. I’m known for the satisfaction I get from moving things in the right direction, and that’s key. By the way, that’s also what I expect from our employees."
Herbert Eibensteiner, Chairman of the Management Board of voestalpine AG

 


voestalpine Talk with Herbert Eibensteiner

voestalpine at the world’s largest air and space trade show

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All renowned representatives and suppliers of the aerospace industry attended the trade show at Paris’s Le Bourget Airport from June 17 to 20, 2019. This trade show, which takes place every two years, is considered both one of the industry’s most important exhibitions and a venue for many meetings with customers and suppliers and for closing contracts.

Aerospace ExhibitionSuccessful trade show for voestalpine

voestalpine BÖHLER Aerospace—the aerospace industry’s leading provider that specializes in the production of hard-wearing drop forge parts made of titanium alloys, high-alloyed steels, and nickel-based alloys—was very successful at the trade show. It negotiated and closed two contract renewals: the company has been supplying titanium structural parts for the flap tracks used in the world’s most widely manufactured family of medium haul planes. Given the consistent and reliable quality as well as the performance of voestalpine BÖHLER Aerospace, the company’s client renewed the EUR 60 million contract. Another contract package regarding the supply of structural parts made of titanium and nickel-based alloys for civil and military helicopters and airplanes was renewed as well. This means that this voestalpine company was very successful at the trade show.

Industry’s key exhibition

Besides facilitating major contracts totaling USD 140 billion, the Paris Air Show 2019 also drew more than 300,000 visitors. Airbus announced a super long haul version of its A321 neo bestseller at the show. This aircraft, the so-called Airbus A321XLR, is supposed to fly up to 4,700 nautical miles (8,700 km) and thus is suitable for flights from Europe to the Americas or India, for example.

More on the Paris Air Show: https://www.siae.fr/en/

 

Employees as the basis for success

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It is the vested interest of employers to make every effort to attract the best employees, initially by convincing them to join the company, and then to retain them over the long term. Reliable and committed skilled employees and specialists are scare commodities, not only because many of today’s youngsters no longer consider apprenticeships, instead favoring an “academic path.” Once qualified and looking for jobs, it is the task of the company to present itself as an attractive employer. What makes this more challenging than previously is that employees’ demands, needs, and individual expectations, as well as the social framework conditions, are subject to ever-accelerating change.

Nurture and motivate

Nowadays, companies are forced to question their own attractiveness to both their customers and employees more often than ever before. This attraction is measured in more than just adequate remuneration. In the hierarchy of needs, money comes way down the list. Employees place greater value on how they can fulfil their potential and develop their careers, whether their activities are valued and recognized, whether their social needs are considered and, finally, workplace safety.

"A winner mentality means delighting in success. We are involved in an international competition, and competitions are things you want to win. And I think that for us this means bringing the best innovations, having the most efficient processes, taking a solution-oriented approach to customers, and quickly adapting to new challenges. Our employees are well trained, motivated, and pulling in the right direction."
Herbert Eibensteiner, CEO voestalpine AG

Buzzword “work-life balance”

Although these values are not new, it is in demand more than ever before, and also needs to be broadened for the younger generations. A key consideration for young people in this context is the concept of a work-life balance. They attach great importance to having free time, allowing them to adapt their working hours in order to reflect their personal needs where possible. This shouldn’t be confused with a lack of willingness to work, but rather the philosophy of everything at the proper time.

New recruitment methods needed

In view of these shifts, personnel departments, today’s HR, are faced with major challenges. It is no longer sufficient to simply place an advertisement when searching for new staff; today a skilled metal worker is usually found in a different place than an IT employee. And the process is different in Austria to that in China or the USA. Whether a logistics expert in Africa, a skilled worker in Austria, or an IT specialist in China, a company like voestalpine is confronted with the entire spectrum of the global jobs market. Which means it is no longer enough to state “We’re a great company.” An appropriate answer needs to be found in each individual case if the company wants to be seen as attractive.

Eibensteiner Interview

Increasingly, solutions to the question of how a life-phase-related workplace can be designed must be sought, one which meets the needs of both employees and the company, whatever the country, and often on the basis of completely different framework conditions. The answer lies in hundreds of different work time models, offering everything from attractive shift work to home office time. Offering employees personal development perspectives is now far more important than it once was. However, these and many other wishes and offerings all depend upon understanding an important point: in return employees must treat the company—their employer—and the voestalpine brand with loyalty and respect.

Training and continuing education

Today training and continuing education is an essential element of long-term success. More than ever, it is unrealistic to expect that employees will arrive at a company fully trained. Apart from the increase in educational deficits amongst school leavers, the demands on today’s workforce are changing so fast that ongoing professional development is a must in order to secure the required level of qualifications over the long term. Well-functioning in-house professional development, with competent and external support as required, is essential for everyone, from skilled worker to executive.

"The thirst for knowledge and pleasure in excellent performance are extremely important drivers of the innovations which make us a success in our markets. That’s what I expect from our employees."
Herbert Eibensteiner, CEO voestalpine AG

Conclusion: Nowadays, companies are permanently faced with new developments and challenges in the personnel sector. They have to create incentives, motivate, and react promptly. They have to take employees’ worries seriously, including the recurring question of the consequences digitalization will have on the future of the workplace—“my workplace.” In a fair and open working relationship it should be clear, however, that demands are also made of the employees as a means of ensuring effective cooperation over the long term, because where something is being offered, it is not presumptuous to expect commitment, quality, flexibility, and the will to succeed in return.

However you view it, in the end the more the interests of the employee overlap with those of the company, the greater their shared future success.

 

voestalpine high-bay warehouses for storage parks

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What happens when your EV battery runs out of power and only recharges to just over three-quarters of its original capacity? Then it is time to replace it and let it live a second life elsewhere. There are numerous existing programs and initiatives for developing a complete, sustainable value chain for battery cells, such as the Battery 2030+ EU initiative. And automobile and battery manufacturers are continually establishing battery alliances.
The increasing demand for optimized storage racks for EV batteries is another field of activity for voestalpine Krems Finaltechnik, a global specialist for high-bay warehouses.
Auch für die voestalpine Krems Finaltechnik, weltweit Spezialist für Hochregallager, ist der steigende Bedarf an optimierten Lagerregalen für Antriebsbatterien ein weiteres Betätigungsfeld.

Second life for batteries

Before it goes into storage, however, the EV battery spends its first life fulfilling its primary function in electric cars. But after approximately 100,000 kilometers, which equates to about eight to ten years of use or around 4,000 charging cycles, it has to be replaced. By that point, the battery loading capacity has dropped to approx. 75 to 80 percent. Even though that is no longer good enough for electromobility, it offers sufficient capacity for practical (intermediate) storage of large quantities of electricity. Second life is the name of the next phase for EV batteries.

Regal Use of batteries in storage parks

Thousands of EV batteries spend their second life in battery parks where energy is stored—primarily from renewable sources (e.g., photovoltaics and wind power)—and released again when needed, for example during power peaks or to stabilize the grid. Daimler AG and its partners in Lünen, Germany, are a good example. In a storage project that has been running for two years now, around 1,000 lithium-ion batteries from electric Smart cars have been providing a total capacity of 13 megawatt hours—enough to cover the electricity requirement of an Austrian household for about three years. Their power offers additional economic advantages, because primary control power (electricity to compensate for short-term grid fluctuations) from these parks can often be sold to grid operators at very good conditions.

Storage parks with voestalpine know-how

voestalpine Krems Finaltechnik has already proven its know-how in many areas with its application-optimized rack solutions in high-bay warehouses, from frozen food logistics to car tire logistics. The high-quality voestalpine warehouse structures with significantly more than 100,000 storage locations can easily handle pallet weights of more than 1,000 kg. From a technical point of view, the company is ideally equipped to handle a load of 1,000 battery packs plus control electronics.
voestalpine Krems Finaltechnik has many years of experience in the construction of temperature-controlled, well protected high-bay warehouses.

"This gives OEMs who want to follow this new trend in the electricity storage market together with us a considerable advantage. Because just like in electric vehicles, the new ‘stored’ battery requires optimum operating conditions in terms of connectivity, ambient temperature, and fire protection in its second use phase in storage parks."
Peter Häckel, Head of Innovation Management and Structural Analysis, voestalpine Krems Finaltechnik
AKL Stahlgruber

Warehouse know-how by voestalpine Krems Finaltechnik—also for storage parks

The third life: recycling

EV batteries contain valuable substances. After their first life in vehicles and their around ten-year second life in stationary storage, their raw materials are recycled. In 2018, the BMW Group, Northvolt, and Umicore formed a technology consortium in order to work closely together on the continued development of a complete and sustainable value chain for battery cells. The Volkswagen Group is currently setting up a pilot plant for battery recycling that will make it possible to recycle 72 percent of all raw materials—the long-term goal is nearly total recycling of raw materials. Modern recycling processes expect to soon see a recovery rate of 95 percent—especially for the strategic raw material lithium.
These high values will have a positive impact on the life cycle assessment (LCA) of electric vehicles. But there is still not enough practical experience—it will take at least 10 to 15 years before the beginning of a noteworthy second life era, when more e-vehicles are on the road and have been in operation for a decade.

Battery added value circuit

Battery added value circuit of Daimler and partners in Lünen (© Daimler AG)

 

Thanks to successful voestalpine European races: Vergne is once again winner of ABB FIA Formula E Championship

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Sebastian Buemi (Nissan e.dams) and Lucas di Grassi (Audi Sport ABT Schaeffler) took second and third place in the overall standings. This means that the first three places were taken by still active Formula E champions—what an extraordinary race of champions this memorable season five championship has been.

The big winner: Jean-Eric Vergne, European.

With victories in Monaco and Bern and a third place in Berlin, “JEV” has earned 68 points in the last three of the voestalpine European races. He decisively outstripped his rivals Buemi (46), Di Grassi (28), Frijns (0) and Evans (26) considering that the lead in the ABB FIA Formula E Championship at the end of the season is just 17 points. And that Vergne lost the two final races in New York, dropping out of one and reaching seventh place in the other. As far as points, he clearly lost there to Buemi at 6:43.

The best team of the season: DS TECHEETAH

On Saturday in New York, it was still tough going for the French-Chinese team. The two pilots Vergne and André Lotterer were involved in two collisions at the same time. But despite another dropout by Lotterer, Vergne’s seventh place on Sunday was good enough for the DS TECHEETAH to win the prestigious team title. A great triumph for the team led by Mark Preston, especially in light of the fact that no other motorsport series in the world has so many participating car manufacturers. Another former Formula 1 driver was also pleased: Pedro de la Rosa, once with teams such as McLaren, Jaguar in Formula 1, and a close friend of Alexander Wurz, is under contract as a driver consultant to this team.

Great diversity: victories for Buemi and Frijns

Saturday was (finally) the day—after a two-year break, the great Formula E legend Sebastien Buemi racked up another win. It was the first victory for Nissan e.dams in the ABB FIA Formula E Championship and the first for the team since Nissan took over the entry from Renault. This means that eight (!) of eleven teams have won races this season, a sensational diversity that also extends to the drivers: there were nine different winners, and Envision Virgin Racing was the only team to have two winning drivers. After Sam Bird’s victory in Santiago and the success of Robin Frijns in Paris, it was once again the Dutchman who won the second race in New York thanks to a really great overtaking maneuver against Alexander Sims (BMW i Andretti Motorsport). Once again, Frijns demonstrated his extraordinary courage.

Spectacular visions: Porsche and Mercedes are coming

When season six of the ABB FIA Formula E Championship (the second year of the impressive Gen2 era) begins, two new and well-known manufacturers will be at the start: Porsche and Mercedes-Benz. Behind the scenes, the planning phase is in full swing for the Generation 3 cars that will be used as of season 9 (from 2022).

The outlook for the sixth season and the voestalpine European Races 2020

With the provisional calendar being released in June, the new season starts with two races on November 21 and 22, 2019 in Ad Diriyah, Saudi Arabia. The voestalpine European Races will take place in Rome, Paris, Berlin and twice in London. The two races on July 25 and 26, 2020 in the British capital will be the final races of the ABB FIA Formula E Championship. The other new addition to the calendar is a race in Seoul. There will be some rule changes—the driver who has set the fastest lap of each of the qualifying group will score a point in the championship. And a technical change—only one motor will be allowed in the future—the twin-motor solution that Nissan e.dams used to win in New York will be banned.

 

New talent at voestalpine in the UK

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Its collaboration with training providers and schools in the local area gives the opportunity to demonstrate to young people the benefits and rewards of working in the engineering sector. The company’s ongoing efforts were recently rewarded at The Ladder for Birmingham Apprenticeship Awards through a nomination and its second place win in the category, Medium Employer of the Year. To reduce the skills gap over 20,000 qualified employees would be needed annually for the engineering industry in the West Midlands, the central part of England around Birmingham therefore voestalpine High Performance Metals UK has been promoting new talent in this engineering region of the UK for many years. “We are convinced that the training we offer is of great value to the company but it’s not easy to recruit new talent into engineering,” Bev Smith, Head of Human Resources, explains. The challenges the company faces in the recruiting process are related to candidates’ frequently poor education, low social skills and lack of awareness of engineering and the range of role related to the industry.

voestalpine High Performance MetalsUK Apprentices

Trainees of voestalpine High Performance Metals in the UK.

Getting to know each other

voestalpine High Performance Metals in the UK is well on its way to recruiting new talent for itself. Over the last few years twenty six apprentices have completed an apprenticeship with 13 going on to occupy full-time positions.“This success is due to our cooperation with a number of agencies that help us in our recruiting efforts,” Smith explains. These agencies build platforms for engineering and manufacturing companies in the Midlands with the aim of reaching young people and engineering students at local technical colleges. To kindle students’ interest in a career in engineering and help them develop a passion for the field, the students are invited to gain some experience at the company through workshops, internships and plant tours. The company also participates in workshops and networking events at local schools and training academies. The company most recently had a local school, the RSA Academy, visit.

Experience and theory

The company offers trainee opportunities for new talent throughout the business, including areas such as the Service Centre (warehouse), Business Administration, Marketing and Facilities Management. Theory and practice are imparted to the trainees using the learning-by-doing approach. As a rule, one experienced employee is assigned to each trainee with the trainees also spending one day a week at the college. All trainees must take a final apprenticeship exam at the end of their 12 to 18-month training. The training programme is considered wholesome and extremely valuable says Courteney Cleverley (22), Purchasing Assistant, who completed her training in 2016:

"It enabled me to develop professionally, academically and personally because the company gave me both the space and the support to do it."

Joe Stevens (18), who is being trained as a Quality and Technical Engineer since September 2017, had this to say: “What I love about the training is that there’s always something new to learn and the job never gets boring. The company’s attitude toward its trainees is fantastic and it treats everybody fairly and respectfully.” voestalpine High Performance Metals UK also runs a successful graduate training program; three graduates of the program have already been offered full-time positions.

Nice reward

Whilst the workforce in Oldbury largely comprises of long-served employees, according to Bev Smith, “the company knows that new talent is the lifeblood of a successful company’s future.” Currently, the focus is on recruiting four trainees for the Service Centre, who will be trained the “voestalpine way.” voestalpine’s UK team was recently rewarded for its commitment in respect of this as it was nominated for this year’s The Ladder for Birmingham Apprenticeship Awards in the category, Medium Employer of the Year. This prize is given to the best trainees and the people who help them succeed. The UK team won second place on July 4th at the Edgbaston Stadium—an excellent result! “We firmly believe in the value of the training and will continue to really push it,” says Bev Smith happily.

Nominated in the Medium Employer of the Year category

A great achievement for both the trainees and their trainers on July 4th at the Edgbaston Stadium in Birmingham: The nomination and the second place win in the category, Medium Employer of the Year, at The Ladder for Birmingham Apprenticeship Awards.

 

Silicon Austria Labs Launches Collaborative Project with voestalpine and Infineon

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The collaborative Radar Tomography project of Silicon Austria Labs, Infineon DICE & voestalpine Stahl serves to push the use of radar sensor technology in industry.

It was officially launched with the signing of the cooperation agreement by SAL, Infineon DICE, and voestalpine on Tuesday, July 16, 2019, in the new LIT Open Innovation Center on the campus of Johannes Kepler University (JKU) Linz, Austria. Not only does the project bank on the novel use of intelligent radar sensor technology for industrial applications, it also serves as a showcase for the increasing digitalization of Austria’s industry with the help of collaborative, cutting-edge research.

“SAL aims to conduct leading research worldwide for electronic based systems along the value chain, from the production of components all the way to industrial uses of electronics. We have succeeded in doing precisely that through the Radar Tomography research project,” says Thomas Lüftner, SAL Division Head for RF Systems and Site Director in Linz. “Bringing Linz-based Infineon (a worldwide leader in the development of radar chips) and voestalpine (a leading manufacturer worldwide of high-tech products made of steel and other metals that is headquartered in Linz)—two leading technology companies from very different industries—together with our top researchers will generate entirely new thought patterns and approaches to solutions that will be able to make a difference in the world market.”

Tomography Vertragsunterzeichnung

Research as guarantor of global innovation

The collaborative project entails harnessing the radar technologies in the automotive industry, which are already leading globally, for industrial applications also, turning the key concept—Industry 4.0—into reality:

“Thanks to its development center for high-frequency components in Linz, Infineon already is a trailblazer in the field of radar for automated driver assistance systems. With more than 100 million 77 GHz radar chips sold, Infineon is the technology and world market leader in this segment,” Manfred Ruhmer and Peter Zeiner, Managing Directors of Infineon DICE Danube Integrated Circuit Engineering GmbH & CoKG, are happy to report. “Research and development are key requirements in this connection to ensure that we will be at the forefront of global developments in the future too. In SAL, we’re getting a new, important partner within the nexus of science and economics. Our joint research in collaboration with SAL and voestalpine in the Radar Tomography project will open up new applications and generate new momentum for Linz as a center for high frequency research,” is how the two describe SAL’s role as a research partner for the industrial companies.

Jointly tap into digitalization opportunities

voestalpine also banks on intensive research and development activities.

"The key word here for voestalpine’s success globally is innovation. With a current research budget of more than EUR 180 million, we are one of the most research-heavy companies in Austria."
Franz Androsch, Head of Research of the voestalpine Group

“The research cooperation agreement with SAL and Infineon enables us to develop answers to the future requirements of digitalization in a number of fields—whether sensor systems, high frequency, autonomous systems, machine learning, or smart factories. Going forward, the build-up of know-how in the long term through such high-value alliances will help us as a technology group to continue strengthening and expanding our leading position in the industry,” Androsch adds.

SAL’s research model thus is an important tool for tapping into the digitalization opportunities for the Austrian industrial ecosystem by working jointly with partners on the development of innovations.

By 2023, SAL will employ about 80 top researchers at the Linz site, who will conduct research on key technologies for high frequency technology in the mm wave area for radar and communications, embedded artificial intelligence, and smart factory communications.

 


Steel as Material for a Sustainable Automotive Industry

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Climate protection is the key driver of developments in the automotive industry that have triggered the current boom in the electromobility market. In terms of emissions, however, it is a fact that matters such as battery production and recycling still impose an enormous burden on battery-driven electric vehicles (BEV). The improvement in both the technologies for manufacturing batteries and their energy density is aimed at noticeably reducing this burden. But it is also a fact that the advantages of an electric vehicle (EV) in emissions terms grow, the greater the percentage of eco-electricity in the product mix. The climate balance sheet of an electric vehicle is totally unsatisfactory if fossil fuels are used to produce the requisite materials and if the electricity at the charging stations is not from renewable sources. Ecologically speaking, the success of electric mobility hinges in large part on the success of the energy transition. Yet the type of materials used should not be ignored in this connection either. Steel offers particular benefits compared to aluminum or carbon, because its production requires less energy from the get-go and because it can subsequently be processed and then recycled without any loss in quality. The study, “The Role of Steel in Electromobility” (original German title: Die Rolle von Stahl in der Elektromobilität), which the Handelsblatt Research Institute prepared at the behest of voestalpine, confirms as much.

Life Cycle Steel

voestalpine steel guarantees sustainable automotive construction

Therefore, those who conceive of electromobility as a way to resource conservation, energy efficiency, and emissions reduction must deal with steel. This concerns not just the fact that engines require electrical steel strip. Indeed, consistent consideration of issues of sustainability in automotive engineering means turning to solutions that involve high-strength steel. voestalpine is an important supplier of auto manufacturers worldwide thanks to both its range of high and ultra high strength materials and the automotive components it makes from these materials. The advantage of these materials lies in both the weight reduction they bring about and the fact that they are infinitely reusable—in contrast to other lightweight construction materials such as aluminum and carbon.

The fact that life cycle assessments take issues of recyclability into account underscores the value in the long term of state-of-the-art steel solutions for automotive engineering. Estimates carried out by worldsteel (the World Steel Association) show that the construction of a component made of aluminum, whose performance is equal to that of one made of high strength steel, generates 6.5 times the amount of CO2, and one made of carbon even 7.5 times the amount.

automotive components

Stella—the sustainable future of the automotive industry

The Steel Division has launched a website that addresses the issue of sustainability and corporate responsibility in the automotive industry. Stella—a virtual vehicle with a personality—provides lots of information on questions of sustainability: What materials are used? How does voestalpine ensure transparency in the supply chain? How environmentally friendly is the production of steel at voestalpine? How do lightweight construction steel grades help the customer achieve CO2 savings?

You can find all information on these questions at https://www.voestalpine.com/stella/en

 

The digital revolution

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Digitalization has become a magic word, usually uttered in the same breath as revolution. If that really is the case, then it is a creeping revolution—or, more accurately, one which has long since crept in—and one whose impacts and consequences can often only be guessed at. Automation is one form of digitalization which has been around for a long time. Even so, digitalization is something quite different again. It goes much further, and is very clearly perceptible, as in the new voestalpine wire rod mill in Donawitz. Here wires are manufactured on eleven separate rolling paths at throughput speeds of up to 400 km/h. The 700-meter long facility is controlled via an innovative monitoring system with more than 2,000 data acquisition sensors and over 15,000 continuously recorded parameters which the plant uses to optimize its operations on an ongoing basis.

"We view digitalization in terms of the opportunities it generates. The fact is that digitalization has allowed us to hugely improve our processes and services, and make them highly efficient. Big data, deep learning, and artificial intelligence are topics we already deal with routinely, and this also creates new and interesting jobs for current and future employees. And I believe that we clearly need to stay on this path."
Herbert Eibensteiner, CEO voestalpine AG

New opportunities bring added value

Here the complexity of the digital world suddenly becomes clear, showing how it helps to faultlessly manage incredibly complex procedures, coordinating the quality and optimizing the efficiency of long value chains. Controlling all these aspects creates many ways in which we can benefit from digitalization. However, it also requires the will to understand, manage, and consistently implement digitalization. At the same time, extracting the maximum benefit from everything digitalization makes possible is the key prerequisite for continuing to enhance our technological leadership.

The potential applications are virtually inexhaustible. Another example is provided at the site in Linz where, after 8 years of development and realization, a key digitalization project is now in the final stages of implementation. During the entire process of production, starting with the blast furnace, and through to the final automotive component delivered to the customer, all types of information, in every desired correlation, can be called up—costs, efficiency, cycle times, and all product specifications. It is the perfect combination and use of data. The skill lies in recognizing and applying the relevant information, i.e., entirely excluding data which is irrelevant. In this way, digitalization becomes artificial intelligence.

In the end, the question for the long-term future is whether it is possible to completely digitalize the entire production process, from raw material extraction, perhaps in Erzberg or in the Ukraine, through to the finished product delivered to the customer. Many of the individual steps have long been at least partially automated, and now they “just” need to be combined to form an overall process.

Digitalisierung

One symbol of the advances in digitalization is additive manufacturing, or 3D printing. Rather than the usual process of milling a work piece from a single block, or assembling it from a variety of different parts, entire components, i.e., the final product, are constructed, layer by layer, using powder. In accordance with its philosophy of sticking to what you do best, voestalpine has specialized in 3D printing in metal and to this effect operates research centers in Düsseldorf, Singapore, Taiwan, and Toronto. The high-quality metal powder used in 3D printing is produced by the Group at its subsidiaries in Sweden and Austria.
Due to the costs involved, 3D printing in metal is not suitable for serial production. However, for one-off complex pieces, small batches, and products with extreme requirements, 3D printing is ideal and opens up new application areas. Consequently, it is a valuable addition to previous production methods. But the vision of complete cars emerging from a printer will remain just that, a vision, even in the future.

Between reality and crystal balls

Not even a crystal ball can reveal how digitalization will shape our future, and the changes it will bring. The past years have seen the emergence of many things long believed impossible, both positive and negative. But in all these considerations one thing remains clear, namely that—although not everyone agrees—people will always have a role to play. However, the nature of this role has long since started to change. There will be less physical work, which incidentally has always been a key goal in industrial manufacturing. Step by step, it will be replaced by new monitoring, development, moderation, coordination, planning-type jobs, and much more. But it is also clear to everyone in the voestalpine Group that we have to consistently adapt our employees’ qualifications and training to reflect this change if we are to ensure a successful transformation to a digital future. This requires flexibility and openness from the company as much as its employees, and above all a constant willingness to keep learning. The wire rolling mill in Donawitz has shown that this major transformation is possible without anyone losing out. The new special steel plant in Kapfenberg is currently proving this once again, despite the claims of dissenters.

 

The microcosmonaut from Düsseldorf, Germany

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Farwah Nahif is the perfect role model for initiatives such as “Girls & Technology”—even though, in her case, such a program wasn’t even necessary to get her interested in solid state physics. Because, even when she was little, she always “played with building blocks instead of dolls,” says this R&D engineer (a native of Germany’s Rhineland), laughing: “My first professional ambition was to be an astronaut.” It is what Nahif actually did: “Except that I landed in the microcosm, not the macrocosm…”

Farwahl NahifLove at first sight

Thin coating technology is the realm this metallurgist and materials scientist has been researching since completing her doctorate at RWTH Aachen University. Nahif’s interest in this field transcends a mere working relationship: “One day, when I was still a student and working as an intern at my later doctoral adviser’s lab, I saw plasma for surface coatings for the very first time,” she remembers. “That was love at first sight, what can I say!” This love turned into a lifelong passion that has carried her since her studies, which she completed in 2013 with a dissertation on the phase stability of particular thin films. The text remains a mystery to laypeople even after reading it the second time … but it opened up lots of opportunities for her in the job market.

The Group’s expert for surfaces & coatings

Her choice to join Düsseldorf-based voestalpine eifeler was not long in coming. “Because eifeler, as part of the network of a worldwide Group, offers a unique opportunity for innovation above and beyond the parameters of pure coating technology. This network has the advantage that, on the one hand, I can work intensely on coatings but, on the other hand, also have lots to do with metals and toolmaking. It opens up my view to both the big picture and the application.” eifeler, the Düsseldorf-based coating specialist in the voestalpine Group, turned out be the ideal environment for this young woman, who was appointed deputy manager of the 16-member team during her first year in the firm’s research & development department. She has headed the department since the summer of last year. That’s a meteoric rise—and Farwah Nahif hadn’t even planned on it: “I never aimed for an executive position,” she says, “all I’ve ever wanted to do was to get things moving.”

A passion for R&D

And that’s what she does at voestalpine eifeler—not least thanks to her team. “What makes us excel as a team is our absolute intention to forge new approaches and develop solution-oriented ideas. But this can only happen in a company that embraces precisely this kind of mentality. In a stagnating company, R&D means doing the same thing over and over again. At voestalpine eifeler, however, we are always working on innovative and cutting-edge topics.”

Like, for example, the novel coating for tools used to form high-strength and thus ultra high-tensile sheet steel, which voestalpine eifeler is in the process of launching under the Duplex-VARIANTIC®-1400 brand name … with the promise that it helps to extend tools’ useful life fourfold, if not more.

A first in San Diego

The engineer’s qualifications have caught people’s attention, not just at voestalpine. In May of this year, she gave the industrial keynote speech at the renowned International Conference on Metallurgical Coatings and Thin Films in San Diego, California, USA. This was the first time a woman had done so in the world-famous event’s 46-year history. To top it off, her presentation departed from established custom at the conference. Instead of limiting herself to another aspect of thin coating technology, she placed coatings as such within the overarching context of the value chain at voestalpine—from the raw material to the finished tool. Using voestalpine as an example, she stated: “Being part of this value chain makes us unique in the field of wear-resistant coatings.”

 

The magic cauldron

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Open ears, a good eye, and bright minds are all essential to successful research. Research is an unlimited field, with ideas emanating from all directions, including customers, employees, competitors, and derived from current trends. Research should affect everyone. Although research is targeted, solutions are often found by accident. Technological leadership can only be achieved when based on ambitious research; no research means no progress.

"The key to voestalpine’s global success is innovation. The Group consistently invests in this key area because it is clear to everyone that securing our future as an international player in the most demanding product segments can only be achieved through specialization, paired with technological and quality leadership. Together with our employees, we will continue to innovate, because we not only want to convince our customers of the quality of our products, but also to surprise them."
Herbert Eibensteiner, CEO voestalpine AG

Any enterprise, such as voestalpine, wishing to continuously develop its value chain, must permanently innovate. This applies to processes and processing technologies, as well as the materials expertise on which they are based. Ideas are first tested. Where shown to be promising, the next stage is development, involving more resources and more funding. The closer the idea comes to being a marketable project, the stricter the implementation process, because the concomitant activities become more expensive and complex.

Forschung Future in Mind

Focus of research at voestalpine

The voestalpine Group is currently researching into four key areas. 1: Additive manufacturing—3D printing in metal—is a complex project involving many new approaches, and with the aim of completely controlling the necessary value chain through to the final product. From today’s standpoint, additive manufacturing makes possible product structures of hitherto uncontrollable complexity. 2: Lightweight construction across the entire mobility sector. The pressure to use energy as efficiently as possible in order to reduce the impact on the environment is forcing the adoption of ever lighter components across a huge range of applications—but with no loss of strength. This opens up excellent opportunities for steel compared to other materials. 3: The main aim on the process side is CO2 reduction. This involves many small steps as well as the major innovation for the distant future, namely using hydrogen in place of fossil fuels. 4: Digitalization and the application of artificial intelligence with the aim of permanently increasing the efficiency of all processes, from the raw material to the final product. There are many ways of achieving this and much more, such as combining our own products with artificial intelligence. One example is the fully automated track system being developed by voestalpine. Sensors embedded in the rails and turnouts throughout the rail network report on any (safety) problems, as well as notifying of any necessary maintenance, with the entire system monitored from a central control room.

Apart from these four focal areas, many other projects are also underway, for example, investigating how various materials can be combined in a meaningful and cost-efficient manner. Here it is important to understand the relationships between materials and processing methods, right through to the final product—a key requirement for true innovation.

The positive culture of failure

Research involves risk. It’s all about things that have never been done. And research is short-lived: what is vital to a customer in today’s market may be of secondary importance tomorrow. That makes efficiency and flexibility essential. And more importantly, research relies on a culture of positive failure. Failure must be permitted. Never failing means taking too few risks, and thus reducing the opportunities for success.

Around 100 projects are being undertaken in cooperation with universities and research institutions around the world, permanently expanding our horizons and optimizing efficiency. A team spirit and the division of labor are the key to success. voestalpine currently has around 3,000 active patents, and many more will follow.

The claim to technological leadership forbids the Group from resting on its laurels. This leadership depends on constant curiosity, commitment, dynamism, and a hunger for success. Implementing this broad innovative mindset within an organization is an enormous management challenge, which is why it needs to be directed from the top. Sitting back and reveling in past successes must never be permitted.

 

The global motor

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Globalization polarizes. It has both positive and negative connotations. It is often more felt than understood. What is a worthy undertaking to some, is to others the ultimate threat. Globalization is derived from the word “global,” and thus impacts the entire world. Whether individuals, companies, organizations, or states, the fact is that we are all connected, interlinked, or networked somehow, somewhere, to someone, whether personally, economically, politically, culturally, or otherwise. But as is so often the case, this feeling is relativized when the facts are taken into account. According to John Pearson, CEO of logistics company DHL Express, in an interview given in April this year, only 20% of global economic output is exported. Only 3% of people live outside the country in which they were born. Only 1.3% of all parcels are sent across national borders. Worldwide, investments made by companies in acquiring, establishing, or expanding international business sectors, i.e., economic globalization, account for less than 10% of all capital investments.

Plus, globalization is not a recent phenomenon. All around the world, trading between continents has gone on for centuries, if not millennia. It is true that technical developments have significantly accelerated this process, through the networking and use of data, the expansion of air, ship, rail, and road transport, and the general increasing variety of relationships between countries, businesses, and people.

The first steps towards internationalization

voestalpine’s first steps into the global markets were what you would call unstructured. In the 1950s and 1960s, it was the success of the LD process, or more specifically the opportunities this created, which opened up business for the Group in many countries around the world. Subsequently, it was economic pressure that drove the company into what was then a scarcely structured process of internationalization, and consequently into risky business activities. The economic consequences are well known.

Once its survival had been secured and now reduced to around 15,000 employees, from 1994 onwards, under the leadership of Peter Strahammer, the company focused on high-tech steels and bringing costs under control. In 1995, that was also the story for the IPO: “Highly specialized and efficient high-tech steel producer in Central Europe with preferential access to the—then still new—Central European market and with the Danube as a cost-efficient transport route.” The only foreign production company in the Group at that time was Belgian Sadef NV, a company manufacturing special sections, which was acquired in the 1990s.

This period also saw a project that couldn’t be realized, and whose failure is now regarded as a lucky escape: voestalpine had wanted to acquire the German steel manufacturer Salzgitter. By the end of 1997 the negotiations were complete, and a signed Memorandum of Understanding was on the table. The Supervisory Boards of both companies were due to sign off on the purchase in January 1998, but the German side failed to complete. The reason: former Minister President of Lower Saxony, Gerhard Schröder, had forbidden the sale. Then, as now, Lower Saxony had a stake in Salzgitter greater than 25%. Schröder wanted to win the state elections in spring 1998 before being nominated as the SPD chancellor candidate for the federal elections. Selling Salzgitter to a foreign buyer, it was thought, could have ruined his chances. Schröder’s plan paid off, and he became the German Federal Chancellor. Although the deal’s failure was a huge setback for voestalpine at the time, from today’s viewpoint it was a stroke of luck.

voestalpine Taiwan

voestalpine location in Taiwan

New internationalization strategy

Back to voestalpine’s process of internationalization. Peter Strahammer’s focus was overwhelmingly national: he had no passion for the capital markets and flying. However, even as early as 2000 the Management Board was seriously considering the future direction of the company. But the first steps towards setting out and implementing a new strategy were only taken after Strahammer’s tragic death in the summer of 2001, under his successor Franz Struzl. “We make more out of steel,” was the new direction, with the goal of transforming voestalpine from a steel manufacturer into what was then referred to as a processing group. It started with the creation of the “motion” business segment, with the intention of fairly radically extending the value chain towards the automotive industry.

From 2002 to 2007, and in a booming economic environment, voestalpine then proceeded to steadily acquire a large number of companies, most, but not all, in Europe. The process of internationalization was progressing rapidly, not only in the automotive sector. Acquiring VAE brought the world’s largest manufacturer of turnouts back into the Group to which it had belonged right up to the 1980s. This was a leap ahead into the railway sector, another focus of the corporate strategy. With nine turnout plants in the USA alone, even at that time the Group was well established overseas.

Acquisition of BÖHLER-UDDEHOLM

The most spectacular takeover, however, was that of BÖHLER-UDDEHOLM in 2007/2008. It was not only the most expensive acquisition by an Austrian company to date, but also a form of coming home as Böhler (also including Uddeholm, even at that time) had belonged to the voestalpine Group right up to the early 1990s. The acquisition brought the leading global advanced special steel manufacturer and service provider under the voestalpine wing. The number of employees consequently climbed to 38,000, with half based outside Austria for the first time. Revenue rose from almost EUR 7 billion to over EUR 10 billion. China and Asia appeared on the map of Group locations, as well as a few new sites in South America.

Today’s focal markets

A company such as voestalpine which leads in its product segments must operate globally. As the quality of its products is in demand worldwide, it makes sense to have a global presence. Thus the search for new markets becomes a constant one. Today there are almost no blind spots left on the voestalpine world map. Europe is the core market. Growth yes, but the potential for further growth is limited as customers have no wish for an overpowering partner. The USMCA area, formerly NAFTA, consisting of Canada, the USA, and Mexico, is a defined growth area offering many opportunities. But, as recently seen, also questionable obstacles. The real growth market for the future is Asia, particularly China and South East Asia.

"voestalpine has made significant investments over the past years: in Texas, the wire rod mill in Leoben, and many investments at the site in Linz. We’ve built our automotive plants in the USA and China, and work is currently going on to construct the world’s most advanced special steel plant in Kapfenberg. In future we of course plan to invest in many other sectors, such as the aerospace industry, additive manufacturing, and the railway infrastructure segment. But first we must create the framework and generate the financing needed for healthy growth and economic success."
Herbert Eibensteiner, CEO voestalpine AG

Globalization is reality, although perhaps taking the form of what could be called regionally focused globalization, rather than de facto full coverage. This regional globalism can be an advantage. Indeed, this is the approach to adopt where the aspiration and ambition is to be present where the economic action is. But everything needs to come together—efficient research and development, driven by the best and the brightest minds, which generates the innovations needed to bring advances in technology and quality, as well as excellent partners for technical and commercial implementation. That makes committed and qualified employees the key to success.

“What if?”

Drive, don’t drift. Be proactive, rather than reactive. Globalization means actively embracing the world. Seen in this light, we can ask where voestalpine would be today if it hadn’t followed this path of internationalization so consistently over the past 15 years. Yes, this is a “what if?” question, but trying to find an answer can help make the concept of globalization—for many a tenuous one—more tangible, while offering a few facts helps turn indifference into positivity. If it had remained purely a steel manufacturer, although a highly specialized one, as it was in the late 1990s, today’s voestalpine would not have had the experience of seeing its products in their end markets. It is the combination of high-tech steel production and processing through to the final product, as used in vehicles, aircraft, and rail networks, as well as watch housings and rocket propulsion systems (yes, voestalpine is a recognized player in these exotic segments too), that provides a priceless advantage in terms of experience and competitiveness. Innovation, without at the same time directly experiencing global developments, is only half the battle. At the same time, the cultural diversity as manifested in the way our employees think and act is incredibly enriching. A voestalpine limited to Central Europe would, in all likelihood, have only been a small player in terms of revenue and profits. And it would have been an affordable conquest and potential takeover candidate for competitors in Europe and farther afield. One shouldn’t forget that the steel enterprises which dominate the mass markets today are the product of acquisitions and mergers, most of which took place during the period 2000 to 2015.

The colorful and diverse world of voestalpine

It is possible that voestalpine in its current form might no longer exist following an acquisition or merger, with all the consequences that it would have for Upper Austria and Styria. It is true that the strategy of moving towards the end customer and end product by lengthening the value chain could have gone wrong. Who knows? Apart from all the planning, success requires courage, an entrepreneurial spirit, and—denying this is a failure to accept reality—an element of luck. Plus the right balance of “head” and “heart” amongst the decision makers. With all this in place, the global world no longer appears so large and threatening, but instead colorful and ripe with opportunity. Because everywhere you go, it is still people and their abilities, with their know-how and commitment—and here a huge “thank you” goes to the 52,000 current employees spread over all five continents—who make voestalpine the global success that it is today.

 

One-stop shop for welding solutions

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It is only logical that a respected global provider of welding equipment should offer complete solutions. In accordance with this philosophy, voestalpine Böhler Welding, represented by its core brands Böhler Welding, UTP Maintenance, and Fontargen Brazing, is gradually becoming a full welding solution provider, offering a unique portfolio of

  • services,
  • consumables,
  • accessories, and now also
  • welding machines.

Otto Schuster, Head of the Strategic Business Unit Welding Equipment, describes this step as a process of evolution, although the move to incorporate equipment into the portfolio has been accomplished very quickly.

"We completed the project in only six months, and now cover all the areas of expertise needed to make us a full welding solution provider in the welding technology sector. This allows us to have a greater impact, and my impression is that we’ll stir up the world of welding a little, and by doing so develop it further."
Otto Schuster, Head of the Strategic Business Unit Welding Equipment

End-to-end solutions for customers

As a full welding solution provider, voestalpine Böhler Welding is now able to offer its custom-ers end-to-end solutions. This is necessary because many customers are looking specifically for partners with the widest possible range of welding technology expertise. voestalpine Böhler Welding achieves this by offering smooth workflows and efficient welding processes: coordinat-ing welding fillers with welding machines is unique within the industry and enables precision welding of hitherto unknown dimensions. “We have adapted the strategy, and until recently have only needed to add welding machines in order to become a full welding solution provider. These we can now also supply,” explains Otto Schuster, and notes that there are only a few manufacturers in the market who also operate as solution providers.

Terra and Uranos product families

The requirements and the demand are there: choosing the correct welding machine and the appropriate filler guarantees increased productivity and maximum process security. This is sym-bolized by the two product families, Terra and Uranos, and their names have been chosen with care: “Terra” stands for earth and represents traditional welding. It is used in harsher environ-ments, such as steel welds in general steel construction. In contrast, the firmament “Uranos” represents the future and perfect welding using innovative materials. This coordination be-tween the company’s own welding fillers and the range of machines is unique. Working togeth-er with metallurgists and electronics technicians, the voestalpine company can extract the max-imum from the process.

Positive feedback

The first responses from the market have been extremely positive. The company’s decision to position itself as a full welding solution provider is seen as a logical development. Accordingly, the business unit has a global presence, with its key markets currently in Europe and the Middle East. Otto Schuster believes that his colleagues have played a special part in the success of this new venture: “I see our employees as being the key promoters as well as highly effective am-bassadors. They embody this new direction, and our customers are accordingly convinced.”

Equipmentshow Open House

TERRA…

…is designed to meet the needs of steel welders. The machine is easy to use, robust, reliable, and features programs especially developed by experts. The compact yet robust construction of these machines make them ideal for use in a wide range of working environments, even in con-fined spaces. TERRA welding machines from Böhler Welding are happiest in heavy-duty use and guarantee long-lasting joins.

Features:

  • Easy handling for the welder
  • User-friendly ergonomics
  • Low weight
  • Ideal for steel welds
  • Flexible use

Find further information on the website.

URANOS…

…is the best choice for any energy-efficient high-tech inverters. The welding programs are indi-vidually adjusted to the company’s own welding fillers. The modular construction and perfectly coordinated components make this a welding system for the future. The premium inverters used in the URANOS series are equipped with numerous technical refinements. For example, welders are inspired by the ability to call up pre-set welding parameters depending on the re-quirements, whilst guaranteeing reproducible and excellent welding results.

Features:

  • Excellent wire feeding properties due to innovative wire feed concept
  • Connection to automation systems and robot systems possible
  • Digital color display for easy process selection
  • Cutting-edge digital inverter technology
  • Cost-saving energy efficiency (even in demanding continuous operation)

Find further Information on the website.

 

Pipelines for deep drilling

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In its global business, quality is a trump card for voestalpine Tubulars, the manufacturer of seamless steel tubes for the oil and gas industry. With their interior coating and customized steel grades, the tubes manufactured in the Kindberg factory guarantee interruption-free oil and gas pumping cycles of two to three years. “It naturally depends on how well the extraction company manages its drill holes,” notes Andreas Schöngrundner who is responsible for sales in Europe and Africa. “When they are not working well, drilling has to stop after six months to check the pipes.” However, this is just what today’s oil and gas companies can no longer afford to do, because every interruption carries the risk that, after temporarily stopping the flow, the valuable energy source will no longer flow up from the depths so abundantly.

Resistant to oil, water, and salt

This is a risk no one wants to take, especially as almost no new deposits are being discovered, and pumping from old boreholes is becoming increasingly difficult. Seven-kilometer-deep boreholes have become more common, and the longer they are pumped, the more water emerges together with the oil or gas. For example, 97% of the extracted medium in some of Austria’s older boreholes is salt water. This is problematic for oil and gas companies, and not only in Austria. “It’s a global phenomenon,” Schöngrundner knows. It’s also a problem, because the water arising from the depths contains high levels of salt and other corrosive chemicals. A cheap, untreated drill pipe could not withstand such an acid attack, in contrast to the interior-coated tubes made by voestalpine Tubulars. These tubes are manufactured using special alloys, and given an epoxy resin coating by an affiliated company in Gladbeck, Germany.

interior-coated tubes

The quality of voestalpine Tubulars interior-coated tubes makes them a popular choice for oil and gas exploration as well as salt mining.

interior-coated tube

Endurance testing for corrosion

The coating even allows the tubes to withstand the effects of pure brine: “The ultimate corrosion test,” as Schöngrundner says. Consequently, his list of customers includes not only oil and natural gas storage operators, but also major saline companies such as one of Europe’s largest producers of technical salts. voestalpine Tubulars has recently resupplied this producer with its tubes which will be used for leaching salt domes on the Dutch coast.

 

voestalpine Tubular Team

 


The model student from Aguascalientes

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In Aguascalientes where Daniel Gonzalez was born, people know how to enjoy life. The city with a population of 700,000 has the same name as the state it is located in. It is known for its many hot springs, which is also the source of its name (“hot waters”), for good food, and for the exuberant Feria San Marcos, one of Mexico’s biggest fairs, which is celebrated in April.
And the people also work hard. Aguascalientes is an important location for the automotive industry.

Attractive working time models

Some of the parts they use are from voestalpine Automotive Components, which is also located in Aguascalientes. In the production halls and offices on Panamericana Street, employee development is a high priority. The company also tries to be very accommodating when it comes to working hours. It is thanks to its flexible working hours that the Mexican voestalpine site was able to hire Daniel Gonzalez. Just over a year ago, the now 22-year-old forklift driver left his job with an international supplier and joined voestalpine Automotive Components.

Daniel Gonzalez 1

Daniel Gonzalez 2

From forklift to office chair

With an ambitious goal. “Daniel came to us because our working time model allowed him to graduate from high school while working,” reports Norma Loyola from the Managing Director’s office. The determination of the hard-working forklift driver also caught the eye of his immediate superior, Jorge Franco. After observing the new employee for some time, he mentioned Gonzalez’s quick intelligence to Logistics Manager Jesus Barba.

It’s not the first career that started like this at voestalpine, as Loyola knows: “Since we are a smaller company, it’s not difficult to notice who stands out.” And so one day at the end of his first year, Logistics Manager Barba spoke to the always cheerful young man about career opportunities within the company.

Daniel Gonzalez 3

Next goal: engineer

“As an administrative assistant, I prepare our shipments in SAP and am responsible for making sure all finished parts are correctly stored and for tracking their inventory,” explains Gonzalez. Computer work is not completely new for him. “I was familiar with this type of work from my previous job. Jorge Franco taught me everything else. He also encouraged me to keep learning.” Something Gonzalez is keen to do. He has completed high school and already drawn up a new plan. “I would like to start training as an industrial engineer. Because I love my work and because I want to be a well-qualified employee.”

 

Flying support on the ground

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In a warehouse covering a good three hectares with 8,000 press tools, it is not easy to keep track of everything. This is the challenge that the voestalpine site in Bunschoten faces. The expansion of production means more tools need to be stored and made available on time.

Drohne_3

Warehouse section from drone viewpoint: 8,000 tools from 60 x 60 cm to 2.6 x 4.5 m.

Digital check

Drohne_BeitragsbildAgricultural land on one side, commercial enterprises on the other, and behind, the company’s production halls—there is limited storage space for the press tools, which usually weigh tons. And with four stacked on top of each other, the third dimension is pretty much fully utilized. In this extraordinary situation, voestalpine Automotive Bunschoten turned to an unconventional solution: In order to find out how and where the space could be used better, a specialist company have been engaged to have the warehouse recorded by drone and processed the 3D data for virtual reality programs.

Virtual warehouse maintenance

The flying support lasted only a few hours, then the measured data could be transferred to the program and processed. The result was fascinating. Equipped with VR glasses, you now have an overview of the stock. You can “walk” through the aisles in all directions, check the arrangement of the tool stacks in detail—and above all locate and measure gaps in the warehouse rows. The virtual tool tour thus opens up many opportunities to optimize the warehouse:

  • a better overview and
  • the ability to use the available space even more efficiently in the future.
Drohne_2

Glasses for effectiveness—a virtual 3D image helps Rubert Dröge check the availability of space in the tool warehouse.

Even now, the experts at Bunschoten expect that their digitally optimized planning will result in a 5% increase in storage space—more than 100 additional tools.

At voestalpine Automotive Components Bunschoten and elsewhere, there are certainly further reserves that can be tapped in this intelligent, time-saving way.

Rubert Dröge

Rubert Dröge digitally oriented to the “real” warehouse.

 

 

What are the coming trends in lightweight automotive construction?

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Lighter vehicles need less energy than heavy ones to gather speed. This principle also applies to electromobility. Hence lightweight automotive construction will play a significant role in vehicles of the future as well.

Trends in lightweight construction

voestalpine Automotive Components Schwäbisch Gmünd, Germany, is one of the Group’s centers of excellence for automotive components. “All automotive segments feel the pressure to work toward economical lightweight construction, albeit to different degrees,” is how Florian Gerstner (Department Head, Tec Center, Prototype Construction, and Small Series Production) describes the current situation, “but the pressure will play an even greater role in the future, absolutely. We’ve been analyzing this trend for a number of years—and we’re prepared.”

Judging from the discussions around developments in electromobility, lightweight construction will be in demand especially for electric vehicles (EVs) in urban centers. The German trade publication, Automobil-Industrie, has done the math: The drive efficiency of a vehicle that weighs 100 kilograms less improves by just under 5.5% during acceleration processes that occur with particular frequency in urban traffic; this is why energy savings of more than 4% may be expected in real-world operations.

Trend_Leichtbaulösungen_2

Mixing is the thing to do

voestalpine’s specialists are also fully prepared for the trend toward materials mixtures in automotive engineering, Marcus Wiemann (Project Manager, Technology Development) emphasizes: “When it comes to mixed construction types involving steel and aluminum, for example, the expertise of our automotive components companies in Bunschoten and Schwäbisch Gmünd is nothing short of excellent. This includes sophisticated joining technology.” He adds that, in the future, too, materials mixes will be driven largely by customers and volume. According to him, there will be a growing trend toward light metal in the small yet very demanding premium segment; equally conceivable is the targeted use of carbon fiber-reinforced components. “The more economical construction method using high and highest tensile steels, in particular, will continue to dominate the small and medium-sized vehicle segment, even in the future; we developed a new lightweight construction solution using steel called phs-directform precisely for this purpose,” says Andreas Sommer (Team Manager, Hot Forming Development).

Individual concepts are indispensable

According to a study titled, “The Role of Steel in Electromobility”, which the Handelsblatt Research Institute (HRI) conducted at the behest of voestalpine, combinations of steel with synthetics to (partially) strengthen structural components will become highly significant in the future. The HRI study does not posit, however, that such combinations will be used across the board; instead, they will be a factor in individual concept solutions. There will be many more of those in the future, because the respective customer requirements in the continental European markets will become ever more differentiated and thus require flexible autobody platform concepts.

But it is already clear at this time that high demand for aluminum will lead to delivery bottlenecks. According to the HRI study, demand for aluminum will rise to up to ten million tons by 2030. Marcus Wiemann: “Intelligent solutions involving steel thus will be in greater demand than ever before.”

Intelligent roll forming for the future of e-mobility

Geometrically sophisticated sections that are manufactured by voestalpine Krems GmbH ensure stable, low weight—even in battery cases. Thanks to intelligent roll forming, crosspieces and contours create complex, high-tensile steel sections. “Assuming identical crash performance and neutral weight, multi-chamber sections also help to generate a cost advantage relative to extruded aluminum sections,” explains Matthias Stumvoll of the Roll Forming Product Development department of voestalpine’s Krems-based company.

Thanks to its expertise in both materials and processing as well as the know-how of its employees, voestalpine is fully prepared for e-mobility’s lightweight construction requirements of the future.

Trend_Leichtbaulösungen

 

Winner of the British apprentice competition

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Sponsored by The Worshipful Company of Tin Plate Workers a.k.a. Wire Workers and celebrating its 20th anniversary, the competition is an annual awards ceremony for apprentices in the metals industry. The award is designed to encourage and reward exceptional personal development and commitment to professional advancement. voestalpine Metsec is delighted that apprentice Abbiegail Hill has won this year’s award. “This success–Apprentice of the Year–once again underscores the high quality of our internal training program and the company’s commitment to developing the full potential of its employees,” comments Training Manager, Steve Giles.

Winner Apprentice of the Year 2019

voestalpine Metsec nominated Abbiegail Hill for the Career Development Award at the professional association. She was able to convince the expert jury that her professional development was exemplary, and won the coveted Career Development Award. The certificate was presented by Peter Wilkinson, Master of The Worshipful Company of Tin Plate Workers a.k.a. Wire Workers.

Great trust

Over some 20 years, the voestalpine Metsec high-quality, structured training program has proven its effectiveness. It combines academic studies with practical skills and diverse professional experience and leads to recognized national degrees. The Oldbury site currently trains eight apprentices in engineering, IT, design, and sales—including Abbiegail Hill, who was nominated for the Career Development Award by voestalpine Metsec for her exemplary performance. After a 6-month, off-the-job intensive course, she successfully completed her BTEC Level 3 Diploma in Construction and the Built Environment. She also completed a national Level 3 Extended Diploma in Engineering Technical Support. “voestalpine Metsec’s confidence in Abbie is so high that she is currently working with steel construction engineers on real life projects,” Giles is pleased to report.

Exceptional development

As one of the finalists in the preliminary round of the competition, Abbiegail Hill convinced the industry jury at UK Steel’s Sheffield office in a 30-minute presentation and an interview. Her path after graduation of finding a job and then attending evening school to become better qualified and find a better job (which led to her apprentice training at voestalpine Metsec) was a decisive factor in her success. “During my training, I learned and am still learning not only about all the functions and activities within the SFS (Steel Framing Systems) division, but also about the products and services we offer our customers. I experience new things every day and have access to many additional training courses that help me develop further in my chosen career,” says Abbiegail Hill, who is looking forward to the new career opportunities the company offers her. Since the beginning of September, she has been studying at Wolverhampton University to obtain a higher degree in Construction and The Built Environment.

Abbiegail Hill_workplace

During her training, Abbiegail Hill, a third-year apprentice in Construction and the Build Environment, works on projects with steel construction engineers.

Top talent factory

Many voestalpine Metsec executives have participated in the extensive training program in recent years. “Next year, at least 20% of the workforce will be apprentices from the program,” says Steve Giles. But the company’s commitment to encouraging and developing young talent does not end with apprentice training. voestalpine Metsec also supports employees who wish to continue their professional development and academic studies at a higher level, for example through (further) qualification by obtaining undergraduate and master’s degrees in relevant fields.

"I’ve never had so many opportunities to improve in my life."
Abbiegail Hill

 

Research and Development at voestalpine

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Research and development are essential to a company’s success. voestalpine can research, test, and bring new product solutions to market solely through the activities of its more than 700 research employees at 76 R&D locations worldwide. In keeping with the concept of a “know-how network,” besides cross-company research projects the Group also banks on collaboration projects with about 100 external, scientific partners worldwide as well as on long-term development alliances with key customers. More than 3,300 patents have already been registered for voestalpine technologies and products.

A record research budget of EUR 184 million was adopted for the current business year 2019/20—an increase of 7.5% year over year. In the business year 2018/19, the company spent EUR 171 million on research and development.

"Innovation is the key to voestalpine’s global success. The current record research budget of EUR 184 million clearly shows that the voestalpine Group gives highest priority to research, development, and innovation. The Group invests consistently in this key area, because one thing is clear: We can secure our future as an international player in sophisticated product segments solely by enhancing our specialization in tandem with our technology and quality leadership."
Franz Androsch, voestalpine’s Head of Research

Mobility and energy drive our research

The company’s research activities focus primarily on mobility and energy—two cutting-edge markets. The following thus draw most of the attention:

  • Ultra-high tensile steels with improved forming properties;
  • Lightweight construction and safety;
  • E-mobility;
  • Trailblazing railway technology
  • High performance materials for aviation and aerospace; as well as
  • High-tech tubing concepts for the oil and natural gas industry.

But our research also focuses on forward-looking areas such as:

  • Digitalization: Digital linking and optimization of production processes across the entire value chain; digital products & services; internal & external collaboration projects as well as training & continuing education.
  • Metal additive manufacturing: 3D printing of complex metal components using additive manufacturing.
  • Sustainable solutions for cutting-edge steel production.

The voestalpine Group is considered the gold standard for both energy efficiency and environmental compatibility. Hence issues of sustainability; environmental compatibility; energy and resource efficiency; CO2 reductions; and zero waste are at the forefront of our work.

Feinste Pulver für eine revolutionäre Technologie

Additive Manufacturing

Here some of the highlights of the voestalpine Group’s innovations:

  • Press-hardened lightweight parts (phs): process used for indirect and direct (in a single process step) hot forming in the production of press-hardened, ultra-high tensile, and corrosion-resistant autobody parts (phs-ultraform® and phs-directform®);
  • Ultra-high tensile steels with improved ductility: advanced high-strength steels with high ductility (AHSS-HD) = multiphase steels with both highest strengths and improved ductility for use in autobody parts relevant to safety;
  • Electrical steel strip and electrical steel stacks: isovac® (non-grain-oriented electrical steel strip) as a high-tech pre-material for compacore® (inline-bonded electrical steel stacks for efficient, next-generation electric engines);
  • Lightweight components made of steel, hybrid materials, and other light metals;
  • Rail tracks and high-speed turnouts optimized for wear resistance, including diagnostic systems;
  • High-performance materials for aviation and aerospace;
  • Tool steels and coatings for tools highly resistant to wear and tear;
  • Sour-gas-resistant pipes and gas-tight pipe joints; and
  • Heavy plate for pipelines that must hold up under the most stringent requirements, temperatures up to minus 60°C, and the most difficult operating conditions.
voestalpine compacore Motor

compacore and isovac

For more information on research & development at voestalpine

 

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