Internship report (1/3)

From 01.09.2013 to 28.02.2014

Bruno Henrique Graa Pinheiro

Hochschule Reutlingen
(Home University: Universidade Federal da Bahia)
Course: Mechanical Engineering
Number of Identification: 209200167

Location
ThyssenKrupp Aufzugswerke GmbH
Bernhuser Strae 45
73765 Neuhausen a.d. Fildern

ThyssenKrupp Aufzugswerke GmbH

ThyssenKrupp AG, which ThyssenKrupp Aufzugswerke GmbH
belongs, was founded by a merge between Thyssen AG and Krupp AG
in 1997, both companies before that time were had basically flat steel
activities. In 1999, after the complete fusion between the two
companies a new company was founded: The ThyssenKrupp
Aufzugswerke GmbH. Nowadays the company is a huge multinational
conglomerate corporate, which consists of 670 companies worldwide,
based in Duisburg and Essen. ThyssenKrupp is actually one of the
worlds largest steel producers and also provides components for the
automotive industries, elevators, escalators, material trading and
industrial services.
The company is divided in two major divisions: Materials division
that is focused on carbon steel, stainless steel and material services;
and Technologies division that is focused on elevators, plant and
components
technology,
and
marine
systems.
Nowadays
ThyssenKrupp is one of the majors companies regarding the elevator
branch worldwide.
The Neuhausen plant was initially constructed by Rheinstahl in
1973 to be used as a base to the Rheinstahl Aufzg GmbH. In 1976,
Rheinstahl was acquired by Thyssen AG and arising the ThyssenKrupp
Aufzge GmbH. But a great fire destroyed the new created plant. The
activities of the elevator branch came back with the fusion in 1999.
Nowadays ThyssenKrupp generates 33% of its consolidated sales
in Germany, the other key regions are: rest of EU (28%) and NAFTA
region (21%). ThyssenKrupp companies hold leading positions with
their products in numerous international markets and are the worlds
leading producer of tailored blank steel. The company is also installed
in more than 60 countries with more the 800 plants built. With more
than 46000 workers the company acquired a turnover of 4,1 billion
Euro in 2011/2012.

Location
The Neuhausen plant was founded in 1973 as a plant from
Rheinstahl Aufzge. But today the plant is part of ThyssenKrupp
conglomerate as ThyssenKrupp Aufzugswerke. The plant consists of
approximately 1200 workers and is one of most important productions
plants and business unit from ThyssenKrupp Elevator.

In the plant are produced many types of elevators systems:

rotors, cabins, doors, electrical parts and all the parts that compose
these systems with a wide variety. The plant also has all the
necessary machinery and systems to produce almost every part
there. Most part of the production is destined to exportation.
The plant is also focused on developing researches on new
pieces, components and assemblies that provides better products all
the time. An example of this development is the recently released
elevator called synergy BLUE that possibilities a headroom that's up
to 30% lower and a pit reduced by up to 70% and also was the first
elevator with the A-class efficiency rating to VDI standard 4707 in
various countries.

Products
The plant is divided in five great halls each of them keeps
different processes and productions. The main products of the plant
are separated components for elevator, as electrical motors, cabins,
panels, supports, installation frames, safety devices, doors, tracks,
cabins interiors and parts that compose the previous components.
But even the plant produces all these, the plant dont produce fully
assembled elevators. The pieces are produced and those are sent to
other plants. This happens because most of the plant production is
destined to exportation. So most of the pieces are sent to other plants
around the world where they will be assembled and compose a
complete and functional elevator.
All over the five halls there are different processes that are
related to the production, assembly, storage, and dispatch of the
pieces. There are different locations, for example a place reserved for
welding and another for the machines that will work on the sheet
metal folding, cutting or drilling, one destined for the assembly of the
electrical motors, one destined for the safety components. And also
inside these halls there are some treatments that are applied to the
produced parts, for example powder coating.
The production on the plant covers a wide variety of components,
and while accomplishing this, the plant yet meets all the safety and
environmental requirements an effective way. That makes the plant a
healthy workplace for all the employees.
The major material input at the plant are the flat steel sheets
that are used in almost every component, the most used are the
Stainless steel and Carbon steel in different thicknesses. The major

material reject is linked to the major input that is the scraps from the
produced during the conformation of the flat steel sheets. All the
rejects are separated within its own kind and sent to a recycling unit
when its possible.

Internship overview
During the internship I will be allocated inside the industrial
engineering division which is responsible for the evaluation of new
types of systems and parts. I will be under the supervision of Mr.

Andreas Frank as the leading engineer of the division of Industrial

Engineering. Here is an organogram of the division:
During the first month I was able to participate in an assembly of
a new kind of door and witness a test to prove its functionality. After
that I was given the opportunity to continue the improvements of the
door and I was also given a few drawings to handle over the system
and update them. My actual activity involves the adjustment of a door
assembly to fit a new component that will replace an older type of it.

Timetable and Activities

The internship period is from 1st of September to 28th of February.
The working days are from Monday to Friday, with a 35-hour-per-week
working hours. The activities predicted activities for the internship

period were: Involvement in development projects; Design-to-cost

Projects; Test planning and execution; Finite element methods; Typical
engineering tasks such as creating specifications and designs; Design
and computational evidence of mechanical parts and elevator
components; Works with CAD (CATIA V5): parameterized 3D modeling
of structures, creation of 2D production drawings; Support of
manufacturing segments.

Training
In the first week, trainings about safety, the working places, the
company and emergencies situations were given a specific system
from the company on a computer. These trainings are really important
to prepare you for everyday situations because of the great number
of risks you are under during your stay at a production plant like this,
giving instructions on how you should behave and what you should
wear to ensure your safety. At the second week an intensive course
about the functionality, main parts of elevators and elevator
structures was given. During the first month there were also two tours
over the plant with an instructor to explain the functionality of the
machines and some of it processes.

Challenges faced
As mechanical engineer students, we are often put face-to-face
to some problems regarding calculus, and mechanical analysis, but
we are not prepared as good as we should about the day-by-day work
of an engineer in a company. The real work of an engineer is far more
complex than only what is taught during the university. It involves
many other areas such as working with people, different departments,
different interests, different suppliers and, above all, limited budget
and projects requirements, standards and guidelines.
During the internship many opportunities to learn these different
aspects will be faced in the daily life of a company. And in such a big
company as ThyssenKrupp, these new challenges are often and solve
them requires both the use of theoretical knowledge acquired during
the semesters of study and also practical knowledge that will start to
be developed and improved.
Thats the motivation of the internship: face real problems and
activities from a real company that develops engineering the way it is
developed on the whole world. And in such time learn new
techniques, new knowledge and, most important, learn how to

behave and work as an engineer does in the real life outside the
classrooms.

FEDERAL UNIVERSITY OF BAHIA

POLYTECHNIC SCHOOL
MECHANICAL ENGINEERING DEPARTMENT

ENG-374 INDUSTRIAL INTERNSHIP

COMPANY ASSESSMENT
(Report 1/ 3)
NAME OF THE COMPANY: ThyssenKrupp Aufzugswerke GmbH
ADDRESS:
_____________________________________________________________________
TELEFON: ___________________________
E-MAIL: ______________________________________
ENGINEER IN CHARGE: Andreas Frank
CREA: _________________________
NAME OF THE INTERN: Bruno Henrique Graa Pinheiro
TELEFON: +55 71 8883 8607
E-MAIL: bhgpos@gmail.com
INTERNSHIP HOUR: Monday to Friday, 7-15h
Professor in Charge: PROF. GERALDO QUEIROZ (eng374@gmail.com)
ITEM

WEIGHT

Behaviour

1
1
1
1
1
5

Assiduity
Interest
Initiative
Practical Sense
Overall
Performance
*************

Signature from Engineer

Signature from Professor

Date

******

ASSESSMENT(0 10)

TOTAL

TOTAL

Date

Company Stamp