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Exhibitor Profile: Hilti High quality Hilti Alan Guthrie visits the manufacturer’s world headquarters and learns about its emphasis on research and development, new products and ambitious expansion plans. The principality of Liechtenstein, where the Hilti Corporation has its headquarters, is a tiny landlocked country with a population of only 30,000. Tucked away between Switzerland and Austria, it is surrounded by mountain slopes rising above the Rhine valley. It would be wrong, however, to think that such geographical remoteness bred a sense of corporate isolation. Rather, the company was eager for EHN to visit facilities and talk to technical specialists at its head office in the town of Schaan, and also in Germany. The company includes product innovation and quality amongst its main priorities and says that, while this may be reflected in the price tag, this is outweighed by performance and longer product life. Indeed, confidence in the quality of its equipment led Hilti to introduce its Lifetime Service initiative, designed to create a flexible and cost-effective management system for the entire life of its power tools. It consists of an initial two-year no-cost period, a lifetime repair cost limit and a lifetime manufacturer’s warranty, designed to reduce whole-life running costs for hirers. Assessing new ideas Hilti’s approach is exemplified by its extensive facility at Kaufering, approximately 50 miles west of Munich. The headquarters of Hilti Germany, it also accommodates production facilities and a rigorous testing complex. No fewer than 350 of the 1,200 employees work in research and development, assessing new equipment ideas. Christian Rehekampff, Heavy Duty Systems Tester, explains that “tests are undertaken on both prototypes and tools already in production, simulating years of usage under extreme conditions. We can set a combi hammer, for example to drill upwards into 40Nm concrete, so that the dust falls directly onto it, really testing the seals of the machine,” he states. Another rig simulates the effects of a chisel suddenly breaking through hard material. In this situation, full impact power is briefly transferred to the interior mechanism, placing strain on the components. Other test bays replicate the long-term performance of slip clutches, anti-vibration mechanisms and other key components. Motors for certain Hilti products are assembled at Kaufering, as well as premium quality SDS Plus and SDS Max drill bits. Martin Emery, National Tool Hire Manager of Hilti (Gt. Britain) Ltd, contends “there is renewed interest in our drill bits from hirers and end users aware of HAV. We can guarantee that the independently tested tri-axial readings of our tools will be achieved if Hilti inserts and accessories are used, and many major contractors are now specifying that only Hilti bits are used on their sites.” Georg Schmid, Unit Leader Tool Manufacturing at Kaufering, explains that sophisticated production techniques are used. “Larger drill bits, of 18-40mm diameter, are formed by heating the steel rods to 750°C, quickly flattening them and twisting them to form the helix. This method, patented by Hilti, does not affect the granular strength of the steel and avoids machining, which would create waste. The tungsten tips are welded on and then the drill is induction hardened, whereby a high electric current is applied quickly to give strength without brittleness.” Wear indicators are incorporated on the helix to show when replacement is necessary. Special technology is used to make the TE-C3X hammer drill bits, launched in the UK only last October, and which Hilti will promote at the Executive Hire Show this month, along with other new launches. The bits’ solid carbide heads have four cutting edges in an ‘X’ configuration for speed and dust removal. “Two-component tungsten carbide is used, one element of which is softer for impact absorption and reduced HAV, the other being harder for a strong tip,” states Georg Schmid. “To optimise the welding of the two materials, the drills are cold-formed by being rolled between two profiled grinding wheels, which again creates the helix without wastage.” Research into HAV As EHN readers know, Hilti has been particularly pro-active in addressing HAV. Axel Fischer, Project Manager - Advance Development/Heavy Duty Systems, states that “much research work goes into understanding the nature and control of vibration itself, and this knowledge can then be applied to specific tools and accessories. Product development takes account of clear criteria such as typical usage times, applications, extremes caused by factors like operator error, target vibration values, tool size, weight, efficiency, ease of service and, of course, cost. Methods such as isolating masses, the use of counter masses and other ideas are explored thoroughly, with the aim of developing highly productive tools that get work done quickly.” Axel Fischer states that Hilti’s sophisticated computer modelling can accurately simulate vibration generated along the three principal axes, and the effects of possible reductive measures can then actually be monitored on screen. “Test samples can be made and refined according to criteria such as typical operator handling and other subjective criteria.” Manfred Burtscher, Senior Product Manager - Breakers in Hilti’s Power Tools Business Unit, contends that the company has particular knowledge of machines in this category, having developed what Hilti claims to have been the world’s first reliable electro-pneumatic hammering mechanism, featuring a roller locking system for the drill bit connection end, sealed assembly with permanent lubrication, hammering cut-out and a slip clutch. “Having such thorough technical understanding has enabled the development of Hilti’s Active Vibration Reduction on tools like the TE706-AVR, whereby the hammering mechanism, gear and motor are suspended on special hinges. Other developments have included Active Torque Control on larger combi hammers like the TE 56-ATC and the TE 76-ATC.” Sensors like those used in automotive air bags monitor the movement of the tool round its own axis. If the drill bit should stick and the tool turns to a certain angle, the controller triggers the electromagnetic clutch and disconnects the motor axle, reducing risk of serious injury. Wave of new product launches During 2007, Hilti is commemorating the 40th anniversary of the electro-pneumatic hammering mechanism’s development. The company has also scheduled a wave of new product launches over the next 12 months, some of which EHN was shown during our visit to Kauferin and to another plant at Mauren, close to Schaan. It is obvious that the manufacturer’s next generation of drilling and demolition tools are currently in development, and are being designed for performance and reliability. Hilti was reluctant to release technical specifications prior to their launch later this year, but says that visitors to its Executive Hire Show stand may catch a glimpse of future SDS drilling and breaking developments. Overall, Hilti has ambitious plans. “We currently employ 17,000 people worldwide, and turnover for 2006 is forecast at 4 billion Swiss francs (£1.57 billion). In 2000, turnover had been 2 billion Swiss francs (£0.79 billion),” states Jan Pacas, Marketing Manager for Hilti’s Business Unit - Power Tools in Schaan. “By 2015, we intend to be employing 30,000 and to have doubled turnover again, by continuing to focus on quality and innovation. And because we deal directly with our customers, we learn from them and can react quickly to their needs. Approximately 5% of turnover is reinvested in R & D. A culture of stability and, perhaps, conservatism prevails throughout Hilti, but we intend to make bold strides forward in all our markets worldwide.” Among the undoubted benefits of working in Schaan are the magnificent views of the Alps that employees see from the Hilti offices. With so much confidence, and a host of new products nearing their final stages of development, the commercial outlook would appear to be equally impressive. • T
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100 Executive Hire News › Archives › Jan/Feb 2007 › Exhibitor Profile: Hilti › High quality Hilti
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