Newsletter 07/26/2023

From Zero to Hero

The construction of a production area for the new differential bevel gear at Hirschvogel Umformtechnik GmbH in Denklingen was characterized by the motto “From Zero to Hero”. February 2021 saw the start of building work on the extension to Hall 16, and now series ramp-up for these drive-independent components is commencing. Differential bevel gears ensure balanced torque transmission to the wheels when cornering and are found in a wide range of vehicles, from cargo bikes and LEVs to cars and trucks.

 

Hirschvogel invested a substantial sum, amounting to tens of millions of euros, in the new production area. The aim was to achieve the best value stream in the market. On the one hand, this requires having the entire value stream under one roof – in Denklingen, the components are no longer just forged, but also machined and supplied from there in a ready-for-assembly state directly to the customer’s assembly lines. On the other hand, a high degree of automation is necessary. This not only greatly reduces the time from receipt of order to dispatch, but also leads to components of the highest quality.

 

The forging team in Denklingen received support from within the Group during construction work and production ramp-up. Virtual plant design, for example, was carried out together with Usaneers from Munich – a company in which Hirschvogel holds a stake. And a team from Hirschvogel Komponenten GmbH in Schongau contributed its machining expertise.

The differential bevel gears are developed and produced in Denklingen according to a “Green, Lean, Smart” approach. What does that mean in concrete terms?

 

Green: With a view to achieving climate neutrality, the entire differential bevel gear production, including the carburizing furnace, is powered by electricity from renewable sources. Soon, green electricity will also flow in from a solar park, spanning 5.5 ha, that is being built around the Hirschvogel parking lot in Denklingen.

 

Lean: All steps in the process chain are perfectly coordinated in terms of time and space thanks to comprehensive, end-to-end value stream planning. This includes billet preparation, shot blasting, forging, turning, drilling, broaching, hard broaching, case hardening, manganese-phosphating, washing, quality control, and dispatch.

 

Smart: Process control and production are digitally supported and highly automated. This encompasses virtual plant design, electronic worker assistance systems, as well as the fully automated, 100% component inspection which guarantees that no faulty part is delivered to the customer.

Hirschvogel is also happy to take on tasks in advance of production, such as the design validation of the teeth/splines or service life tests for the customer-specific differentials. A test bench for this additional service completes the new production area.

 

We already have a lot to show in terms of successes since starting this undertaking two years ago, namely numerous developments, four major orders and – supported by our customers – a high level of expertise in the production of high-quality differential bevel gears that continues to grow every day.