ZKL NEWS · > Technology modernization for the production of spherical roller bearings up to 400 mm...

ZKL NEWSMarch 2014, Issue No. 51

HISTORY REPEATS ITSELF –KOMETA BRNO IN ZKLJERSEYS SHONE AGAIN!

Ultrasonic Automatic Cleaner

Page 4

Central Store of ZKL Bearings Page 6

The continued devel-opment of bearings in NEW FORCE design 0

General Manager Address Page 2

ZKL – Výzkum a vývoj, a.s. in New Decade Page 4

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General Manager Address

ZKL Brno entered the new year with prospect of a new investment with Bottling Printing company called “Laser lettering and completeness inspection of series bearings up to 400 mm diameter by camera vision”. To implement this goal there were projected two workplaces - for bearings up to 250 mm dia. with 20 s cycle time and up to 400 mm with 40 s cycle time. In connection with improved production process both workplaces will be integrated in existing roller track in the series product final assembly in Unit No. 4. The ma-jor purpose of this ZKL Brno investment is to eliminate non-productive and non-uniform lettering as well as to introduce a complex visual data documentation of any complete bearing unit headed to final user. Diminishing certain percentage of claims from the buyers and improving the final product quality by this

measure will again bring ZKL Brno closer to world leading bearing manufacturers.

The facility will be installed at the end of the roller tack, which will be connected with self-con-tained sheltered structure with manipulator for

gripping a bearing and its sequential manipulation into position for lettering of its outer ring by laser device and further into position for optical inspec-tion of its completeness and marking existence.

The technical solution of the installation enables both manual and automatic operation with re-setting time up to 1 minute. For further handling of the product the data of lettered bearing, number of units and production per-son in charge will be recorded. There will be always registered complete data for each piece of bearing from any production batch, bearing photo and order number. The setting permits also to select downloading complete data for each lettered and inspected bearing (demanded by railway industry).

ZKL Brno, a.s.Roman Křivánek, Eng.

Head of Prod. Tech. Preparation

New Investment in Laser Letteringand Bearings Completeness Inspection

Dear Employeesand Business Partners,

The end of year 2013 with Christmas holidays and New Year’s 2014 Festivities is over. I hope you enjoyed Christmas and had a good time at the New Year’s Eve party, took rest among your family mem-bers and friends. That time is said to be the source of gaining new energies and efforts to get prepared for new goals, resolutions and plans for the year 2014.

In a similar manner, in the figurative sense, proceeded the companies of ZKL Group. Production was terminated on De-

cember 23rd, 2013 and launched again on January 6th, 2014 (with exception of automotive production in the daughter company ZKL Hanušovice, a.s., where production started straight after New Year on January 2nd). The be-ginning of the year is always connected with the review the past year´s results and the stipulation of the targets for the upcoming year as well. The figures of 2013 results and plans for 2014 can be expressed in the following table:

Performance Index(CZK thousand)

Reality Projection Index Plán Index

Year 2012 Year 2013 2013/2012 2014/2013

Sales Revenues 1336370 1409063 1,05 1575212 1,12

Added Value 489086 531174 1,09 606784 1,14

Wages and Salaries 389126 411656 1,06 421386 1,02

Performance Result 1006 25079 24,93 54953 2,19

EBITDA 155221 148622 0,96 205741 1,38

Productivity (Added Va-lue/ Wages & Salaries)

1,26 1,29 1,03 1,44 1,12

The table shows that we improved the results in sales, work efficiency and productivity in the range of 5 to 9%, though our goals and plans for 2013 were more ambitious. We anticipated a sales growth around 10 to 12%, labor productivity growth by 15% and EBITDA earnings indication higher by approx. 20%. It is appropriate to raise the question why it was not achieved.

Non-fulfilled plan of sales was substantially caused by sales failure to China in the range from 4 to 5 USD mil. caused by a poor management of our commercial office in China supported by the former head of div. 34 Mr. Hrádek, Eng. Furthermore the negative productivity results involved the

management of ZKL Brno, a.s. in course of 1st six months of 2013, namely the executive director Mr. Janků, Eng. and head of Economic Division Mrs. Mlčochová, Eng., causing a loss of approx. CZK 10 mil. due to an incorrect balancing of capacities in relation to production volume. These are the ma-jor factors for we did not meet the 2013 goals but I am able to say that we managed to eliminate the impacts of these factors in course of 2nd half of 2013. Therefore I expect that the 2014 results will be significantly better, as shown in the 2014´s executive plans. What are the 2014 targets?In the field of investments there will be the following actions:> Completion of the construction and opening of the central bearings whare-

house ZKL_CSL in Brno by March 31st, 2014;> Technology modernization for the production of spherical roller bearings

up to 400 mm diameter and reconstruction of Hall No. 4 in ZKL Brno – start in February 2014, completion in March 2015;

> Installation of technology for the production of cylindrical roller bearings and reconstruction of premises No. 214 in ZKL Klášterec nad Ohří, a.s. – start in Febr. 2014, completion in March 2015;

> Extension of production capacities for automotive program in ZKL Hanušov-ice, a.s. – start in February and completion in June 2014;

> Modernization of technology for production of brass cages in ZKL Hanušov-ice, a.s. – start in April, completion in December 2014.

The above investment projects should result in ZKL bearings´ competi-tiveness elevation and creation of conditions for the supply of ZKL bearings to leading engineering companies in Western Europe, North America and other world´s countries as well as in the Czech Republic.

In the year 2014 we wish to pay attention to employees’ personal advance-ment. Our aim is to reach a level where modern, high-performing machines are attended by qualified, devoted and inspired employees. This assumes, naturally, well paid workers who will be correspondingly proud to be employed at ZKL. This intention started to be implemented in the year 2013 by modifying the reward system of the workers so that their salary is directly proportional to their performance and we prepare another system improvement motivating to reach a higher labor productivity and thus higher earnings.

In conclusion I would like to wish you good health and personal con-tentment in the new year and of course to express you my desire of a good cooperation throughout the year.

ZKL, a.s.Jiří Prášil, Eng. CSc.

General Manager

ZKL NEWS March 2014, Issue No. 51

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Time is relentless, demands to enhance quality and shorten the delivery times of our bearings are escalating. There is no reason to expatiate on quality of our bearings, we all know that ZKL bearings belong among best quality products obtainable on the market. Therefore the main emphasis must be laid on productivity, without degrading the quality no matter how.

The sense of productivity enhancement is understood fi rst of all as elimination of waste and idle time, either in fl ow of individual parts in pro-

duction process or in machines settings. Based on studies oriented to productivity and quality increase gained from experiences in bearing pro-duction there were devised the production lines for fi nishing operations of inner and outer bearing rings. Machinery composition will be identical with those we know while for outer rings there will be a pair of hole grinding machines. One will serve for rough grinding, the other for fi nishing operation, interconnected by automatic manipulation. The line for inner rings will contain a plain grinding

machine and hole grinding machine completed by superfi nishing machine – all processes will be fully automatic, of course. Thus we shall eliminate all times needed for transport of goods between individual technologies. The technology lines will consist of two units – A and B, where Unit A serves for bearings up to 200 mm diameter, B for bearings range from 200 to 400 mm diamater. All machines will be positioned so that the setting-up times are shortest possible. Hand in hand with these machines will come SMED (Single-Minute Exchange Of Die), which is a system based on team work and innovation, reducing signifi cantly time of change and setting-up machines.

Receipt of fi rst of these technology lines is planned to take place by end of 2014 year, fi n-ishing of lines installation in ZKL Brno will be in March 2015. Within the scope of habitual practice this is a technology and process novelty which will contribute to maintaining good name of ZKL brand and establishing new commercial opportunities.

ZKL Brno, a.s.Ondřej Mágr

Process Technlogist

The volume of 2013 execution plan was set to the level of 350 817 CZK thousand, structuring to the receipts of 102 184 CZK thousand in bearing production and 248 633 CZK thousand in automotive sec-tor.

In bearing production fi eld the receipts were fi nally by 753 CZK thousand high-er and the annual sales volume testifi ed that this production assortment in ZKL Hanušovice, a.s. became stabilized.

In spite of 2013 year start being af-fected by 18 months lasting recession of automotive industry, in course of following trimesters gradual recovery of cars sales occurred in Europe. This fact infl uenced signifi cantly also sales in our company and total 2013 automotive sales exceeded the pan by 6 074 CZK thousand.

When inspecting the assortment struc-ture of sales we can see that radical share in the sales overfulfi lling had the pipes in new projects B8PA (Q5/C7), ML 311 and EA 288 which had been prepared for series production conditions in years 2011 and 2012 and materialized in series batches in year 2013.

Identical importance for ZKL Hanušov-ice, a.s. future in 2015 – 2019 period will represent another projects which take place

in the technical division since start of this year - V6TDI Gen2 EVO, BMW i12, EA 288 2,0l MQB BiT, Daimler S-Class, Porsche Spyder 918, EA 288/75, PQ 26.

The professional clients-friendly ap-proach of employees of all trade depart-ments in solution of strenuous assignments and avareness of personal share of each

company member in client’s satisfaction is a foundation of company prosperity in not always favorable conditions of vehicle market utilizing this approach as competing advantage in acquiring new projects.

ZKL Hanušovice, a.s.Petr Scholz, Eng.

Commercial Director

2013 Sales of ZKL Hanušovice, a.s.

ZKL Hanušovice, a.s. – Sales Course in Period 1–12/2005 to 2013 (Figures in CZK)

ZKL BrnoAutomotive IndustryTools & OthersTotally

Introduction of Modernized Grinding Lines


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In second half of 2013 year we procured a new ultrasonic automatic washing machine type UC 5M 230 ZA intended to completely substitute a very obsolete washer PUP 300 with birthday certificate reaching the depth of the past regime. The aim of this purchase is to enhance the washing quality of bearing parts and thus complete bearing units – both in content and size of impurities. The existing washing equipment could not reach the need-ed quality of bearing cleanness and we had to carry out prewashing in a small UZ washer to meet toughened stipulations of some clients.

The new ultrasonic automatic washing machine is destined to clean bearing parts of entire production assortment of ZKL Klášterec and will remove remaining grease and me-chanical particles by ultrasound, which is, compared with the existing installation more powerful and double-phased. The washing

part is equipped with two cleaning vats, the first one has four ultrasonic emitters of 25 kHz operation frequency, in the other one are four ultrasonic emitters of 40 kHz frequency. After that there follows rinsing vat with passivation of parts surfaces and protective vat with hot air drier so that the bearing parts leaving the washer are clean and dry.

Transfer of bearing parts through the washing process is performed by fully auto-matic chain conveyor with 14 manipulation baskets of 100 x 600 x 40 mm size, loading and unloading of parts is manual. All moving parts are located above and behind the vats. The transporting system consists of loading position, unloading position, horizontal and vertical conveyor.

The washing equipment is of two-staff, the used material is purely of stainless steel AISI 304 guaranteeing long service life.

This technology process safeguards not only reaching better quality parameters and thus a satisfied client but gives also guaran-tee of higher capacity and reduction of final product costing.

ZKL Klášterec nad Ohří, a.sJiří Seidl

Head of Technical Section

Owing to growing pressure of manufacturers from low-cost countries the position of research and development platforms of individual compa-nies is permanently strengthening. These groups of professionals ensure to keep and deepen the technical know-how in the enterprise and create also the added value of its products.

In the effort to catch this vital trend the com-pany ZKL – Výzkum a vývoj, a.s. carried out in last 3 years principal changes which have been partly mentioned on pages of this periodical already.

The first great novelty was procurement of the computer program MSC.Marc in year 2010. This program serves for computer simulations by means of Finite Element Method (FEM). There-after the computing analysis of newly designed bearings quickly became an inherent part of the development process. Optimization of inner ge-ometry of bearings assisted by this program is also one of carrying pillars of New Force series.

A year later the system of data exchange and sharing was restructured. This moment was the starting point of database system PLM (Product

Lifecycle Management) project implementation. The first step in frame of this wide project was unification of design setting. After series of nego-tiations the program Creo, known earlier as Pro/ENGINEER was selected. This CAD program is utilized by most of leading bearing companies. ZKL – Výzkum a vývoj, a.s. thus has at disposal an identical software as the competitors.

In frame of procurement new software licens-es the mathematical program Mathcad was ac-quired. This program enabled to interconnect 3D geometry with design analytical computations. In the scope of efforts to automatize and make the development activities more productive thus so called generic models of individual bearing “fam-ilies” started to come into existence. At present ZKL – Výzkum a vývoj, a.s. has around 40 generic models at disposal, which are being conveniently used first of all in creation of bidding drawings for our clients. More productive computations assisted by FEM is then secured by macros ena-bling after entering text data of bearing geometry an automatic generation of computed model.

Today we have macros available for more that 80 percent of standard bearings.

The last phase of PLM implementation is intro-duction of independent database system for ad-ministration of technical data. This phase has been started in the company at the beginning of this year.

The changes in the company carried out in last years did not take place in software facilities only but in the region of organization and pro-cessing as well. A great novelty became creation of Sales Technical Support Dept. Jointly with formation of this department the company inquiry system was changed as well, so that the services rendered to ZKL clients became improved and broadened. In addition of elaboration of bidding drawings the staff of Sales Technical Support Dept. carries out also calculation of bearing ser-vice life or gearbox analysis within the specialized KissSoft program. They also participate in elabo-ration of new catalogues and publicity materials. Last but not least they attend the commercial negotiations and carry out training of new ZKL employees and clients.

The personal changes are the last novelties category. Here the company decided to com-plete the experienced professionals with young technical generation. Starting from year 2010 its ranks were gradually strengthened by 9 new young employees. This “Recruiting Campaign” required to deepen the collaboration with Czech technology universities. In frame of this collabo-ration there was also broadened the cooperation with the academic sphere in the field of basic and applied research, where several projects oriented to research of friction, bearing diagnostics or fatigue strength are taking place.

The sales growth of ZKL bearings and satis-factory responses in clients’ audits corroborate the correctness of the above steps.

ZKL Výzkum a vývoj, a.s.Martin Zbožínek, Eng.

Head of Design Department

ZKL – Výzkum a vývoj, a.s. in New Decade

Ultrasonic Automatic Cleaner


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The existing production premises including for-mer changing rooms between the halls originated in pre-war time. In spite of constant maintenance these buildings are no more capable to compete by their design solution and technical condition the present modern demands for production facilities. In addition to that the structures do not comply with requirements for resistance as regards the weather and load, simi-larly they do not satisfy in respect of energy demands for operation in these buildings. In the year before last ZKL Brno registered in the program of Ministry of Industry and Trade of Czech Republic for support of enterprising and innovations subsidized by EU structural funds with the revitalization project of the production unit No. 4 and succeeded in the contest by obtaining a grant for the anticipated reconstruc-tion. In last year the company ROMEX was selected as implementer in the public tender – this company already proved its ability to meet exacting structural and technological requirements in reconstruction of “New Assembly” in building No. 5.

The core of reconstruction is new solution of roofing including annexes, replacement of skylights glass and complete renovation of floors in major part of the building. In the roofs the porous con-crete panels and damaged beams and joists (most of them were added in course of world war time repairs) will be removed. The entire roof structure will be reinforced to meet new safety regulations.

It will be provided with new load-carrying layer of profiled sheet metal covered with a thick layer of insulating material and protecting foil. Wired glass window panes will be substituted by modern poly-carbonate. These modifications alone will reduce heat losses of the building substantially, will reduce energy demands of the premise and contribute to better working conditions in general.

Floors of grinding shop suffered in course of years similarly noticeable damage. Contamination, damages and pot holes caused by transport and machinery relocations caused that it is no more possible to maintain here a setting worthy of pre-cise engineering and suitable to installation of new precision technologies.

Predominant area of the hall will get rid of re-maining floor tiling and other surface finish and a layer of nearly 10 cm will be removed. A new carpet of highly resistant concrete with a composite will be laid in the same thickness, surface will be treated by grinding and impregnation as we already know it from Hall No. 5.

Certainly it is not all. The most important comes at the end. It would be of no sense to create new modern setting and then to erect here again the existing present technologies. Hand in hand with elaboration of construction documentation there is being prepared a wide program of reorganiza-tion of entire production. Its basis in Hall No. 4

will become automatic transfer lines for finishing the bearing rings. It is anticipated to carry out changes in organization of labor, in functioning of tool and gauges issuance rooms, of production technical support, quality inspection as well as of gauging, pairing and assembly. The last mentioned should be carried out directly in the reconstructed premises in close vicinity of the production itself so that the requirements of 100% assembly could be materialized forthwith after finishing the rings and rolling elements. Anyhow we shall not bid farewell to the old production, simply we have to find more suitable premises for it, which would not obstruct the working setting by their unfavorable influence. All of us will face quite an ordeal, as all what has been said will be carried out under full course of production. It represents relocation of more than 100 machines, great number of hours for maintenance and special companies. After all alter-natives become more precise the preparatory jobs should start in March and April and construction works should probably start at full stretch by the beginning of May already. Principal reconstruction should finish by end of year and last adjustments by March 2015. The entire project is planned to take place in 3 stages.

ZKL Brno, a. s.Vladimír Vansa, Eng.

Process Technologist

By the end of November 2013 Mr. Michal Za-firelis Eng., Executive Director of ZKL Bearings CZ, a.s. and Mr. Martin Zbožínek Eng., Head of Design Dept. of ZKL Výzkum a vývoj, a.s. set out for business trip to Thailand. The objectives of the trip were the attendance at METALEX Fair (International Machine Tools and Metalworking Technologies) as well as the training seminars for dealers’ network and end users.

METALEX is an established engineering fair held in Bangkok and our authorized distributor Dhana Sirm takes part in it regularly. The com-pany exerts sizeable efforts in ZKL trademark presentation on Thai market. Its stand on the fair was furnished with a number of posters

in Thai language, in Fair news ZKL was ad-vertized as reliable and certified supplier of standard and large-size bearings. Dhana Sirm also published new catalogue of ZKL bearings in Thai language.

In course of the trip there were also organ-ized two seminars. The first one was oriented to dealers, the attendance comprised 25 per-sons. In course of it ZKL trademark and a brief company history was presented, further the participants were acquainted with the product portfolio and individual ZKL manufacturing com-panies. In the other seminar oriented to end us-ers 36 persons attended. The participants were presented with the company and ZKL trademark

first, followed by presentation of research and development and finally the application of ZKL bearings in individual industrial sectors. These presentations were primarily oriented to sugar factories, steel industry, cement plants, paper and pulp industry and engineering industry. In course of the presentation the participants were also explained the division of spherical roller bearings to individual design groups. The tech-nical discussion with the participants was held at the end of the seminar. Both venues were completed by a display of products covering all individual types of bearings.

In course of the visit there were held also commercial discussions with Mr. Jitti Rachjai-bun, the owner of Dhana Sirm company and with representatives of distributing company Summit Goal from Myanmar (Burma).

ZKL Výzkum a vývoj, a.s.Martin Zbožínek, Eng.

Head of Design Department

Forthcoming Reconstruction of Hall No. 4 in ZKL Brno

Business Trip to Thailand


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Construction of central store of bearings (CSB) is nearing the fina-le. Construction jobs are scheduled to finish by end of March 2014. Outside work will proceed further, depending on weather conditions. In parallel the installation of shelves system and assembly of Kardex storage technology has started already. These jobs will terminate on turn of February/March 2014. Then the phase of testing the logistics

processes in SAP informa-tion system using bar code of hall operation will follow. The anticipated timing to move the goods into the store should take place by end of March 2014.

In course of construc-tion we were facing un-favorable conditions of bedrock and foundations

resulting in postponement of finishing time limit date but we are confident now to bring the project to successful end.

ZKL Bearings CZ, a.s.Andrej Klim, Bc.

Head of Logistics

As can be documented historically, the pro-duction of bearings in ZKL Klášterec was always mainly oriented to ball bearings. Owing to this fact the decision to start production of spherical roller bearings is worth to mention.

People not being in the picture may feel at fleeting glance on Klášterec products and spher-ical roller bearíngs in comparable dimensions that there is just a slight difference, introduction their production should not last long and all can be done in a short time.

In retrospect we must say today that it was quite different, as the time consumed for pro-duction mastering of first 6 types of group 222 including applications, counting from assign-ment to finishing in external examination, took three years.

In course of these 3 years we solved both relatively viable tasks, such as the production of outer rings similar to our assortment of double row self-aligning ball bearings, and tasks less ordinary, such as grinding of inner rings race-ways. There were also entirely new matters, such as production of pressed steel sheet cages for these bearings.

Greatest problem to be handled was with cages of small dimensional types of bearings in

which the design solution requires very precision made pressings with fine details decisive for en-tire bearing function. This compels to use rather very intricate pressing tools with considerable failure incidence in the process. This matter is not yet solved to full satisfaction so that unnec-essary production complications and material losses do not occur.

Another field for solving was securing suitable rolling elements – spherical rollers – of small sizes. Production experience exists in ZKL Brno but it concerns greater sizes of rollers than those designed for initial assortment of ZKL Klášter-ec. Therefore we have chosen the solution of purchasing the rolling elements from well-es-tablished manufacturers and related merchants. Having clarified the specification and samplings the spherical rollers started to be purchased, nevertheless the attention could not weaken – in course of shipments several inspections of rollers’ dimensions and precision discovered inconsistencies namely in respect of non-ad-herence to main radius of rolling area. This had to be solved with the supplier, now it seems satisfactory solution has been found.

I would like to come back to production prob-lems and gauging the inner rings of double row self-aligning spherical roller bearings. As men-tioned already, grinding the raceways brought considerable difficulties. Firstly, we could not use the technology of double wheel stoning by diamond point dresser which is used in ZKL Klášterec for most raceways grindings of double row ball bearings, and secondly, the metrology had to be tuned up for incomparably larger radi-uses than those measured so far in double row bearings. The technology was therefore solved for machine enabling to work with diamond-point dressing shape burr. As for the metrology, after initial phase of minor repetitiousness of results it was managed finally, though by using laboratory profilograph only.

To the whole issue of production start the tests of selected items at the testing laboratory of ZKL Výzkum a vývoj, a.s. also relate. The initial tests proved rather considerable production problems of prototypes, where considerable heating-up oc-curred, both in load and limiting speed frequency tests. After tuning up the technology the situation in subsequent tests improved. At the end of this review I would like to mention the present activities about double row self-aligning spherical roller bearings in ZKL Klášterec. Last year it was decided to further extend the production by 223 series and at present we have mastered already 3 types including applications. Here we are able to draw from technology experiences of our own as well as of ZKL Brno, where production existed earlier. Therefore the time consumed was much shorter.

It is apparent that production start of new bearing series by an entity which did not pro-duce them before cannot be performed without complications. Simply saying the experiences cannot be acquired promptly and a professional for specific type of bearings does not become from day to day.

ZKL Klášterec nad Ohří, a.s.Josef Hraběta, Eng.

Head of Development and Design

Launching Production of Double Row Self-AligningSpherical Roller Bearings in ZKL Klášterec nad Ohří, a. s.

Central Store of ZKL Bearings


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Statistics of complaints incidence raised by prominent clients of ZKL Klášterec nad Ohří, a.s. (SKF and Schaeffler in particular) in thrust ball bearings product series show that there occur repeatedly identical errors of mistaken shaft rings and housing rings respectively of missing ball in bearing cage. These faults repeat in spite of the fact that accurate instructions and methods of as-sembly including visualization are issued, there is also performed 100% inspection of completeness before packing the bearing into inner package – plastic foil.

The principal causes of higher incidence of the above faults are the following:> Specific assembly method, where individ-

ual components are put together without any fixation ( except of full complement special thrust ball bearings without cage);

> Hand-made assembly – because of wide dimensional range of assembled bearings the automation in this area is very problem-atic and eventual investments would be ex-tremely high and inefficient in proportion to incidence frequency (very low returnability);

> Qualification and experience of assembly staff – there is a shortage of experienced workers in the assembly shop, particular-ly by the calendar month end, when it is necessary to complete the staff by less practised workers from other sections.

For the above reasons it is apparent that these are faults of human factor. To rectify the situation the remedial measures shown in 8D Reports are in form of repeated trainings

of the staff, multiple audits, faults visualiza-tion and similar, i.e. those aimed at human factor. Evidently they are not of enough ef-ficiency and the client is insisting on more radical measures of POKA YOKE method type, the outcome of which will be faultlessly assembled bearing without admittance of human factor fault. In spite of the fact that the incidence of these faults is not great comparing with the total production of thrust ball bearings, it is essential to minimize their occurrence, particularly with regard to mate-rialization of ZD4S (Zero Defects for Suppli-ers) project proclaimed by SKF, in which our company participates and in frame of which we shall be evaluated by SKF in conformity with the rules of this project. Adverse rating might then influence our position as a key supplier of SKF. Proposal of solution:

In view of unfavorable impact of hand-made assembly on completeness quality of thrust ball bearings primarily a technical solution at the assembly outlet after pack-ing the bearing into inner package has been searched, namely such which would reliably discover defects of completeness and pre-vent the transfer of inconsistent bearing for shipping. Thus a proposal was made to carry out 100% weighing the thrust ball bearings, namely those of lower dimensions (up to 120 mm of outer dia.) on precision industrial scales of the following technical parameters: > Precision of industrial scale must be 0.01 g;> The scale will have optical resp. sound

signaling when limiting weight values are exceeded;

> The scale will have an outlet for connec-tion to peripheral mechanism which would reject an inconsistent product from further process;

> The scale will allow to program limiting val-ues for approx. 150 dimensional types (the range of bearing types was fixed for weigh-ing according D dimension up to 150 mm).

Based on these requirements and accord-ing to tendering process the company Mettler was selected. They presented 2 offers – for a continuous and stationary weighing system. Ín view of the required precision the stationary weighing system was chosen. It was phys-ically tested in ZKL Klášterec in November 2013. The systems are shown on Picture 1.

The next step to materialize the said meas-ure was necessarily to start and carry our weighing of selected bearings, simulate faulty assembly and establish limiting values to pin-point an inconsistent product. This process started in October 2013 already and its fin-ishing is fixed for February 2014. An example of weighing process and fixing limiting values is shown on Picture 2.

Further indispensable step is securing pre-cise cutting the inner plastic foil. The rule with specification of inner package for individual dimensional types of bearings is stipulated in in-house regulation LKT.

This technical solution was presented to our key clients and its materialization be-came part of action plans for elimination of inconsistencies and at the same time a part of permanent improvement plan. The imple-mentation of weighing system will take place by July 2014 and after subsequent trial op-eration when verification of limiting weight values is made for release, regular operation of the installation will start. Its application will certainly contribute to reduction of thrust ball bearings product series rejects.

ZKL Klášterec nad Ohří, a.s.František Šimek Eng.

Director of Quality

Clients’ Complaints on MistakenThrust Ball Bearings in Klášterec

Nearly 50 percent of bearing failures or breakdowns use to be caused by wrong mounting or by penetration of unwanted particles and impurities into bearing, 40 percent of failures are fault of insufficient lubrication and roughly 10 percent fall upon fatigue damages of functional bearing surfaces as a result of long-term operation.

ZKL company is going to publish in March 2014 a new complex mounting manual. The handbook is first of all designated for operation technicians, fitters and servicemen being in contact with rolling bearings.

The publication contains instructions for mounting, dismounting, maintenance and storing the rolling bearings. Each type of bearing suits to a specific kind of usage and at the same time requires specific method of mounting, dismounting, maintenance etc. Applying correct mounting

procedures, suitable tools and performing proper maintenance are basis for prevention of bearing damage in course of its mounting already and for reaching failure-free bearing operation and its maximum service life as well.

The handbook contains also well arranged manual of defects remedies. Incorrectly functioning bearing commonly shows very clearly identifiable symptoms. In reliance on stage of bearing damage there may appear a whole number of other misleading signs which usually are the result of subsequent breakdown. For damage remedy it is always necessary to carry out an analysis of symptoms which became evident as first ones.

ZKL Výzkum a vývoj, a. s.Jaroslav Kalábek

Application Engineer - Assembly

New ZKL Complex Mounting Manual

Continuous weighing system Mettler

Stationary weighing system Mettler


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Quality and Clients’ Requirements

Rationalization Activities in ZKL Hanušovice in Year 2013

In view of continuously rising requirements and specifics in automotive industry we have, being a direct supplier of VW Group, to adapt ourselves to such trends. The evaluation system of suppliers’ qualification for VW Group is based on quality standards for automotive industry elaborated by technical group of VDA (Verband der Automobilindustrie). Quality Management System according to Technical Specification ISO/TS 16949 and VDA 6.1 is a base for sup-pliers and as a supplement of QMS are manuals VDA 6.3 – Process Audit and VDA 6.5 – Product Audit. In frame of the process of continuous amelioration each supplier is obliged to carry out a self-appraisal at least once a year by a self-audit of all processes. The aim is to carry out process and product audits and to reach the level “A” – quality capable supplier. VW Group can subsequently carry out the process and product audits by themselves to re-examine the “A” classification. In addition to general stipula-

tions for QMS the supplier must keep particular documentation of product quality and compul-sory documentation (D/TLD). It is a technical documentation markings “D” or “TLD” protecting the supplier and vehicle manufacturer in defiance of product liability against consequent damag-es. Another important instrument of quality is Technical Examination of Suppliers by means of which the following goals are inspected:> Securing conformity of parts and components

with specific requirements;> Checking of parts production and all activities

to its provision on spot;> Inspection of remedial measures efficiency

and verification of agreed quality management standards

VW has the right to carry out the examination whenever, with notification the company manage-ment in writing one day prior to its performance.

We are obliged to engage all our sub-con-tractors in this suppliers’ evaluation, since as

the supplier of VW Group we are responsible for meeting all their requirements in entire supplier’s and processes chain. In frame of the evaluation of us as direct supplier VW Group may take this fact in consideration in case of negative appraisal of any of our sub-contractors. The management of sub-contractors is one of principal processes and any process change must be approved by specialized departments of VW Group prior to its execution.

By the end of 2013 year the Central Pur-chasing Dept. of ZKL Group ended its activity in concluding contractual relations with sup-pliers for Automotive Purchasing as it did not manage to engage all sub-contractors in these commitments. Therefore in year 2014 this far from easy task has been transferred to ZKL Hanušovice, a.s.

ZKL Hanušovice, a.s.LubomírLáhola

In charge of Quality

Meeting the financial plan of ZKL Hanušovice in year 2013 demanded among others enhanced activities in the field of production processes rationalization with the goal to reduce laboriousness share on total costs.

Our efforts in this sphere were concentrated first of all on products of large and medium series.

In view of rather demanding character of these tasks we concluded an agree-ment with consulting company ROI International having great experiences in these issues. After performing the initial analysis the following spheres of rationalization activities were jointly specified, namely in the field of production management and planning, in-house logistics and organization of production workplaces.

Subsequently the management methods leading to production streamlining were partially materialized in cooperation with this company, such as:a. Creation of Kanban store for pressed components;b. Sorting out the production portfolio by ABC method;c. Production system One-Piece Flow;d. Monitoring the workplaces by OEE method.

Besides of these rationalization activities we oriented ourselves also to productivity increase of individual operations. Here we would like to emphasize first of all the process of assembly on 03L series parts, setting the layout of pre-ssurization workplace and of part 1K0 121 070 BR shape inspection workplace to multi-machine attendance.

At the end we would like to say that the year 2013 was successful, the total laboriousness savings reached 43 000 standard hours.

In year 2014 we shall proceed in rationalization measures with alike intensity, the goal is to obtain the results at least as in year 2013. A whole number of topics is ready and elaborated, such as multiple spot welding of holders on 04L series parts. ZKL Hanušovice, a.s.

Jiří Záluský, Eng.Production DirectorJosef Pospíšil, Eng.

Head of Technical Section - Automotive

Indian bearing market prevails to be the market of buyers, because a wild price war between bearing suppliers is under way.

In year 2014 ZKL comes with a new mar-keting policy for India. Instead of one single distributor ZKL company will now cooperate with 2 authorized distributors with desig-nated authorized dealers’ network. Besides of that ZKL Group is going to focus also on direct shipments to OEM and to large end users and projects. For this purpose the Group established its office in Mumbai – Mulund. This office can be contacted by clients to its e-mail address bipin.kulkarni@

zkl.cz or to mobile phone +91 98339 88313. The contact person is Mr. Bipin Kulkarni, Director (Marketing). ZKL is already sup-plying its products to companies such as Neyveli Lignit, Vishakhapatnam Steel Plant, Elecon Engineering and other private clients on direct shipments basis. This step was greatly appreciated by Indian clients who are constantly afraid of spurious, false brand bearings.

As a consequence of permanent strug-gle with severe competition by domestic bearings ZKL Group is also considering to start production directly in India in frame of

a joint venture there. ZKL took part in 5th International Mining, Exploration, Mineral Processing Technology, Metals and Machin-ery Exhibition held in Kolkata in the days of February 13 to 16, 2014.

The goal of ZKL is to secure deliveries of original ZKL brand bearings at correct price and to minimize the activities of suppliers of spurious bearings as much as possible. Another consistent goal is naturally a close cooperation with the clients.

ZKL Bearings CZ, a.s.Jan Rott, Eng.,

Sales Director Division 32

ZKL in India


9

ZKL Engaged in Mixer Truck Transmission Optimization

Collaboration with Hungarian Company Bombardier MÁV

ZKL is developing two-speed epicyclic trans-mission designed for direct drive of drum of con-crete ad-mixer. The drum of ad-mixer superstruc-ture will be in the application fi tted to driving fl ange of the transmission, transferring the torque from hydraulic motor to ad-mixer drum. The transmission serves also for mounting the front part of the drum. The target of this transmission is:> Reliable operation> Longer transmission service life thanks to special

design of the most loaded bearing> Unifi ed design> High performance yields> Low noise level> Simple maintenance

After fi rst analysis of the transmission it is ap-parent that the most loaded bearing is spherical roller bearing 23122EW33MH New Force. Owing to drum inclination the bearing is subjected to

great axial force. As a result the majority of load will be accommodated by one row of the spherical roller bearing only.

Our aim is to enhance the mounting service life where the spherical roller bearing 23122EW33MH New Force is installed at present.

ZKL Výzkum a vývoj, a.s.Martin Špaček, Eng.

Application Specialist - Analyst

Bombarier Transportation belongs to network of manufacturing com-panies in over 60 world countries. Wide production portfolio of this entity covers a range of railway coaches as well as entire transport systems for airports, city transport and long-distance railway operation.

Being the world No. 1 on railway rolling stock market Bombardier Trans-portation has available a very wide offer solutions and brings innovative products and services of new standards in the fi eld of sustainable mobility.

In Hungary this multinational company is represented by Bombardier MÁV Kft. History of this company reaches the year 1926 when the central workshop for Hungarian State Railways (MÁV) was founded in the town Dunakeszi. Since the year 2001 Bombardier company has majority share in it. Bombardier MÁV Kft. is active in the fi eld of production, modernization, repairs, maintenance, testing and designing railway coaches and their parts both for Hungarian market and foreign clients as well.

ZKL Bearings CZ, a.s. started collaboration with Hungarian branch of Bombardier in autumn 2012 by direct shipments of bearings. After several negotiations on expansion of further collaboration the Consignment Stock Agreement was signed in July 2013 and since that time we are supplying the consignment stock, based on forecasted needs. This consignment stock is situated directly in the premises of Bombardier MÁV in Dunakeszi. Commeercial collaboration with this important client is supported by

trainings of the company’s technicians in ZKL Brno, a.s. The joint session at the end of 2013 year evaluated positively the

existing collaboration and both sides expressed interest in its broadening in the coming period on a larger scale than hitherto.

ZKL Bearings CZ, a.s.Kubešová Marie, Eng.

Sales Director, Division 36

News from Germany We would like to report further news from

German market. More than half year ago we opened our

branch in Germany in order to establish and expand our dealers network.

Today among our new authorized dealers were added MS Bearing GmbH residing in the South of Germany and Christian Feddersen GmbH & Co. KG, member of Knust Gruppe in the north. At present we have a wide dis-tributors network thanks to which we are able to provide an improved service to the clients.

Simultaneously we invited large OEM cli-ents to visit / audit our company, which will take place in the coming weeks. Responses to

opening our branch were very positive and we managed to fi nd thus new clients. Our refer-ences speak for themselves, because among our clients belong signifi cant German compa-nies such as Arcelor, Auma, GFC, Eickhoff, Getriebebau Nord, Zollern, RAG, DB, Audi VW, Vattenfall, SMS Group and Andritz Sundwig. In the coming months there will follow audits by companies Siemens, K+S, Bosch Rexroth, based on which we may be able to rank among our clients further important enterprises.

Valuable asset of ZKL is the production of bearings in Czech Republic, as in Germa-ny a great emphasis is given to European production. Here we can demonstrate the

quality and advantages of ZKL products, as a vast number of traditional trademarks were bought up by Asian investors, though further presented as traditional brand. ZKL proceeds in the course entered upon, which is grounded in tradition and quality production of bearings in Czech Republic.

We would like to avail of this opportunity to express here our thanks for confi dence given to us by founding the German branch and look forward to further positive cooperation with our clients and buyers.

ZKL Bearings CZ, a.s.Heiko Rothe

Head of ZKL Branch, Germany


10

The rolling element of spherical roller bear-ing does not roll in the raceway in its full length but in two points only. Apart from these points the roller is sliding in the raceways. This prop-erty is given by inner geometry of the bearing and therefore we are speaking about slippage which can be quantifi ed by so called skewing moment. It is the moment of friction forces in rolling contact creating skewing of the rolling element. High value of skewing moment is causing great friction and temperature growth

in the bearing, which is unde-sirable.

The Sales T e c h n i c a l Support De-p a r t m e n t has created a mathematic model inter-c o n n e c t e d

with Creo design program. After inputting the entering parameters defi ning the bearing inner geometry the model determines the moment value and based on it is easily pos-sible to adjust the current inner geometry until the acceptable result is reached. The model further gives information of contact ellipses dimensions, of contact pressure value on both rings and force action on rolling elements. The object of the mathematic model is to describe by analytic relations the entire bearing and thus to contribute to bearings design process.

ZKL Výzkum a vývoj, a.s.Erik Gergel’, Bc.

Application Specialist - Analyst

Kinematics Optimization of Spherical Roller Bearings

The continued development of sealed double row angularcontact ball bearings with plastic cage in NEW FORCE design

ZKL Klášterec this year continues to introduce double row angular contact ball bearings with angular series 32 and 33 It is an application without the fi lling opening with plastic cages. The quality and design of bearings is comparable to that of the world's leading manufactu-

rers. This fact is supported by the implementation of a number of comparative tests and trials. By increas ing the in te-rest of our customers, this step is shown to be correct with regard to this fact ZKL Klášterec will continue to introduce a progressive addition to our assortment in the range of cu-rrently manufactured products with steel cage and fi lled bore. Technical development plan ZKL Klášterec range for 2014 counts with introduction of an additional 8 dimensional type:> 3202 A 2RS TNG NEW FORCE > 3203 A 2RS TNG NEW FORCE> 3211 A 2RS TNG NEW FORCE > 3212 A 2RS TNG NEW FORCE> 3217 A 2RS TNG NEW FORCE > 3308 A 2RS TNG NEW FORCE > 3309 A 2RS TNG NEW FORCE > 3310 A 2RS TNG NEW FORCE

ZKL Klášterec nad Ohří, a.s.Martin Helebrandt, Eng.

Commercial Director


11

History Repeats Itself –Kometa Brno in ZKL Jerseys Shone Again!

Under the ZKL Group logo the ice hockey team Kometa Brno had played in the past several successful seasons. On November 29, 2013 at the occasion of the sport club 60th anniversary both Brno perennial stars joined again. Brno hockey players appeared in the 2nd third of 25th round of Tipsport ex-tra-league in historical jerseys with logos of ZKL, the largest Central European manufac-turer of large size spherical roller bearings, special bearings and split bearings, against Rytíři (Knights) Kladno. Although they did not repeat the historical shocking victory as in the warm-up match held on November 18, 1953 when Kladno team had been defeated 18:0, they left the ice ring as winners, applauded by 7 200 chanting fans. The 4:0 result was digni-fied culmination of celebrations. Three quick shots at the start of the game brought the opponents to their knees and helped Kometa to get back on the winning rails. The team

dug out 3 important points to the festivities and goalkeeper Ciliak maintained his fourth “Clean Account” in the season.

The winners changed in the match three series of jerseys – each set for one third. First period was played in jerseys of Rudá Hvězda (Red Star) Brno, the second with ZKL logo and the third one with the present emblem on breasts. “Changing jerseys was very in-teresting, quite refreshing. We really enjoyed it”, said the Comet goalkeeper Marek Cili-ak. Neither the forward Pavel Bendl, recent team backup had no problems with jerseys changes. “It belongs to such events. You just undress one jersey and take on another one but the game goes on.” Asked which of those three he liked best, he answered: “All three

are nice but if I may make a choice, I would select the second one,” meaning the jersey with ZKL logo.

60 years history is not the single attribute which ZKL and HC Kometa Brno have in com-mon. Both Brno legends engage in long-term philanthropic projects and therefore at the opportunity of the rounded jubilee celebrated by Comets they decided to renew cooperation. “HC Kometa came with an estimable idea to sell ZKl logo jerseys at auction and donate the yield for support of sickbed ward of St. Anna College Hospital in Brno. Such an initiative cannot be considered for long. In next year we would like to agree with Kometa on a similar charitable project,” says the Executive Director of ZKL Bearing CZ, a.s. Mr. Michal Zafirilis, Eng., who not only watched the “Birthday” match in sold-out Kajot Arena but also handed over a prize to the best player of the match.

“Naturally I would wish Kometa to win the title and for another 60 years at least the equal-ly successful period as those in the years 1953 – 1973,” added Mr. M. Zafirelis who also re-minded his own boyish years spent in his free winter time mostly at the skate ring with other boys from the housing estate. “Everybody at that time dreamed to become second Karel Lang, for sure there was no shortage of goal-keepers there,” smiled the Executive Director of ZKL Bearings CZ, a.s. who often answers questions on our national sport in course of informal discussions with the clients. “Czech ice hockey is being perceived very positively in the world and the long-time clients of ZKL remember the famous era of Brno Kometa and its connection with our company.”

Original Communications, s.r.o.Eva AlbrechtováZKL PR Official


12

ZKL attended the 2014 Mining INDABA Fair in Cape Town held between February 3 to 6, 2014in CTICC (Cape Town International Convention Centre). At this Fair there were present over 6000 professionals from more than 80 mostly African countries, from Australia and Canada, engaged in mining industry. The Fair is being held regularly since year 1995 and is considered as efficient form how to obtain latest information on investment mining opportunities in African countries. It is the place where key investors and decisive government representatives of individual African countries in the field of mining, analysts and last but not least, the manufacturers of mining machines and installations including multinational servicing companies as well, meet. By its participation on this Fair ZKL wanted to better understand the present situation in this market segment in Africa and its further possible development. At the same time ZKL intended to get introduced to the servicing organizations operating in most of African countries and to mining technology manufacturers as a poten-tial supplier of high-quality standard, split-type, large size and special bearings, having good experiences in this sector.

The fact that the image of ZKL trademark, which is not known much in most of African countries except of the north, is in these coun-

tries influenced negatively by its past and its non-implementation. Therefore ZKL decided to gradually rectify this situation by its surveying, by participation in important trade fairs, by organiz-ing technical conferences and seminars and by establishing an efficient distributorship network on this continent. This progressive creation of new and correct African image of ZKL trademark as an alternative and first-rate brand with rea-sonable prices also for mining industry, which is one of most important and prospective industrial sectors in many African countries, or is at the stage of being created, will be ZKL contribution to these developing countries. The fact that ZKL is successful supplier to this industrial segment in Europe, Asia, Latin America and elsewhere, will undoubtedly contribute to this idea.

ZKL cooperates in South Africa with the distributing company Bearing Vision founded on January 1, 1993 by Mr. Patrick Starkey. Its history stands for servicing the bearing mar-ket of South Africa for more than 20 years. In course of time the company worked its way up, to become the largest supplier of spherical plain bearings to mining industry and is endowed with a modern and purpose-built store in addition to commercial facilities in Modderfontein and Johannesburg. In order to get closer to the client there it has a branch in Randfontein in West

Rand District. The activities of the company include also a centre for supply of lubricants and production of hydraulic hoses. The cooperation with ZKL started in year 2009 when Bearing Vision became its authorized distributor. From the beginning it struggles for advancement of ZKL image, to secure its proper position on the market and to promote it as an appropriate al-ternative of renowned and established brands. It also took active part in ZKL presence at the above mentioned Fair.

ZKL Bearings CZ, a.s.Jana Pařízková, Eng.

Sales Director, Division 33

ZKL Also Introduced in South Africa

Dovolujeme si Vás pozvat do naší expozice ZKL, stánek B6

na 15. Mezinárodní veletrh drážní a manipulační techniky Czech Raildays,

Areál Cargo ČD Ostrava hl. n., který proběhne 17.– 19.06.2014.

We Would Like to Invite You to the Exposition of ZKL at 15th International trade fair

of the railway and manipulation technology Czech Raildays, Cargo Railway

Area Ostrava, stand B06, from June 17th to 19th Ostrava Exhibition.

ZKL, a. s. | ZKL Bearings CZ, a. s. | ZKL – Výzkum a vývoj, a. s.ZKL Brno, a. s. | ZKL Hanušovice, a. s. | ZKL Klášterec nad Ohří, a. s. | ZKL Nářadí, a. s.

POZVÁNKAINVITATION CARD

www.zkl.euwww.zkl.cz

ZKL Group QuarterlyThis Issue: March 2014

Run by Editorial BoardFor needs of ZKL Group published by ZKL, a.s., Jedovnická 8, 628 00 BrnoPhone: +420 544 135 139 Fax: +420 544 210 360

Editor in Chief: Eng. František Piálek

Registered at Ministry of Culture of Czech Republic under Ref. No. E 11989.

Type Setting and Print: Studio Ideal Brnowww.ideal-studio.cz

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