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ANNUAL REPORT 2013
ANNUAL REPORT
2013
ANNUAL REPORT OF THE YEAR 2013CTI Systems S.A. Z.I. Eselborn-Lentzweiler | 12, op der SangL-9779 LENTZWEILER | G.D. [email protected] R.C.S. Luxembourg N° B94647
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CONTENTS
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COMPANY INFORMATION
FOREWORD
BOARD OF DIRECTORS - EXECUTIVE MANAGEMENT
CAPABILITIES
VALUES
FINANCIAL INFORMATION
INTRALOGISTICS
SOFTWARE
EMERGING MARKETS
SURFACE TREATMENT
AVIATION
AUTOMATED GUIDED VEHICLES
CTI-MOVE
SERVICE SUPPORT
EVENTS
GO LIVE FOR NEW WEBSITE
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08 - 09
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14 - 17
18 - 22
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Evolution from patent track cranes to INTEGRATED SYSTEM PROVIDER
CTI Systems S.A. is an industry leader in the supply and installation of integrated automated manu-facturing solutions in the area of heavy loads. Our portfolio contains automated material handling solutions, storage systems, surface treatment installations, assembly lines, process software (MES) and integration of machines and installations from other suppliers.
We design, develop and supply complete, tailor-made solutions based on the latest technologies particularly with regard to energy efficiency and productivity. Our turnkey systems also consider optimal cost effectiveness and economics.
With over 50 years of experience CTI Systems serves the following industries:
• Aviation industry• Commercial vehicle industry• Agricultural equipment • Railway industry• Print and paper industry• Steel and aluminium industry• Foundry industry
With more than 1000 installations worldwide and a highly-qualified team of over 210 employees CTI Systems is recognized for quality, experience, flexibility and reliability.
CTI Systems develops concepts and designs for production sites of the future. With automated solutions we create high performance manufacturing systems which guarantee strong competitiveness.
COMPANY INFORMATION
1962Incorporation of CTI in
Luxembourg as subsidiary ofthe Cleveland Crane &
Engineering Co., Ohio, USA
1997Cleveland Tramrail
International becameCTI Systems S.A.
Supplier of standard patent track cranes and
monorail systems
Supplier of automated
material flowand storage
systems
1993Majority shareholderLuxembourg invest-
ment Bank
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KEY FIGURES (000 €)2013 2012 2011 2010 2009
New orders 28.810 69.420 46.350 49.860 40.730
Order book 49.310 75.110 63.180 47.400 40.470
Turnover 54.609 57.489 30.570 42.929 40.033
Result before tax 1.533 2.076 1.120 2.682 1.577
Net result 1.063 1.767 1.000 2.675 1.540
Stockholder Equity 10.034 9.147 7.677 9.350 6.675
Supplier of integratedturnkeysystems
2003New
engineeringcenter in
Lentzweiler
2005New manufacturing
facilities in Lentzweiler
TODAY100% member of
3 BRANCHESINTRALOGISTICS
SURFACE TREATMENT AVIATION
2009Paul Wurth takes a
majority stake inCTI Systems S.A.
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With the acquisition of the remaining shares of CTI Systems S.A. by Paul Wurth S.A. in 2013, the takeover process started in 2009 has been completed and CTI Systems is now a full member of the Paul Wurth Group of companies.
In 2013, CTI Systems once more proved its competence as a supplier of turnkey systems for surface treatment and intralogistics with two successful commissionings for AGCO, a worldwide manufacturer of agricultural equipment. CTI Systems acted as general contractor for the engineering and implementation of these installations, which are equipped with the latest technology material handling devices and surface coating system providing a thorough, consistent, and durable finish.
In handling systems, CTI Systems received an order for the delivery of a fully-automated overhead conveyor system for a trailer assembly line from the German trailer manufacturer CIMC Silvergreen in 2013. Another noteworthy order for the company was for an automated transport system for train bogies in China. In co-operation with the local Paul Wurth engineers, CTI Systems provided the engineering, manufacture, delivery and assembly supervision of a maintenance line for high-speed trains. The railway industry represents in fact an emerging business area for CTI Systems.
CTI Systems has been in demand in the aviation industry for many years. Leading global aircraft manufacturers, airlines and maintenance companies rely on CTI teleplatform and crane systems, along with its aircraft docking and engine handling systems. The list of CTI System’s references also increased significantly in 2013. A number of systems were commissioned in Europe, Asia and in the USA. Contracts concluded in the aviation industry worldwide again accounted for a major share of the new order volume in 2013.
Another important business branch where CTI Systems has become more active is air cargo handling. In 2013, CTI Systems undertook the modernization of the cargo center at Luxembourg
FOREWORD
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Airport for LuxairCargo, in particular by integrating new, air-conditioned and temperature-controlled storage facilities for the new healthcare & pharmaceuticals center.
In the past 10 years, CTI Systems developed into a qualified supplier of solutions for the aviation industry, including the Chinese market. In view of the potential of this market, CTI Systems established in 2013 its own set-up in Shanghai by incorporating a 100% subsidiary (CTI Systems China LLC). In the framework of the trade mission lead by Their Royal Highnesses the Crown Prince and the Crown Princess of Luxembourg together with His Excellency the Deputy Prime Minister and Minister of the Economy of Luxembourg, CTI Systems officially inaugurated on 17 December 2013 this new branch.
CTI Systems S.A. is steadily looking forward to improve and expand its activities. With more than 50 years of experience and approximately 210 highly-qualified employees, CTI Systems has become one of the most prestigious suppliers of aircraft maintenance, painting and manufacturing systems, automated material flow technology, storage systems for heavy loads and surface treatment installations.
At this point, we expressly thank our employees worldwide for their commitment and loyalty.
Special thanks also to our customers and partners for the faith they have again shown in us during the past financial year. Our gratitude and appreciation also go out to our shareholders for their committed and constructive co-operation and for their dedication to the best interests of the company.
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René Jost
Chief Executive Officer
Marc Solvi
Chairman Board of directors
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Mr. Marc SOLVI ............................................................................ CHAIRMAN
Mr. Georges RASSEL ............................................................. VICE-CHAIRMAN
Mr. René JOST ................................................................................ MEMBER
Mr. Patrick LEYSER .......................................................................... MEMBER
Mr. Frank WAGENER ........................................................................ MEMBER
Mr. René JOST ..........................................................CHIEF EXECUTIVE OFFICER
Mr. Alexander BORN ................................................. CHIEF FINANCIAL OFFICER
Mr. Laurent BISSEN .................................................. CHIEF TECHNICAL OFFICER
BOARD OF DIRECTORS
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CAPA
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uTURNKEY PROJECT MANAGEMENT Concept and design of innovative and cost-effective solutions
uENGINEERING Core competencies in - Mechnical and Electrical Engineering - Process Automation - Programmable Logic Controller
uMANUFACTURING Production and assembly area of 12 000 m2, equipped with modern production tools
uIMPLEMENTATION & SITE SUPERVISION Highly-qualified technicians for successful implementation of turnkey systems
uQUALITY - Certifications - Quality control - Audits by customers
uSERVICE - Consulting - Maintenance - Hotline - Spare parts - Training
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VALUESHEALTH & SAFETYMore than a priority, it’s a mind set
The innovative approach of CTI’s engineers is linked to a strong quality control. It goes without saying that safety to personnel is our prime consideration.
Striving to improve the health and safety performance constantly, CTI renewed in 2013 its action plans and set objectives in terms of accident prevention, risk management and workplace safety. An external safety audit was elaborated qualifying safety in the workplace. Consequent measures were taken accompanied by awareness workshops. Also particular attention was paid to raising safety matters to sub-contractors’ personnel entering CTI’s premises.
For several years now CTI organizes its yearly Health & Safety day, mobilizing all employees to take part in a whole host of informational sessions and activities on health and safety issues in the workplace and in everyday life.
In the health and safety framework the entire staff was invited to participate at a road safety training organized with the support of specialized driving academy with the aim to improve the driving behaviour not only on the way to work but also in private life.
Calling on everyone to take part in the safety process, our employees and partners are encouraged to behave responsibly and proactively. Even if the rate of accidents is steadily decreasing year by year, the record of accidents highlights the permanent necessity to create awareness amongst CTI’s staff, customers and sub-contractors on safety risks.
DEVELOPMENT OF COMPETENCESThe skills and commitment of all CTI employees are crucial to meet the technical and commercial challenges every day. Considering the high level of automation and technology of CTI products, the company recruits highly-skilled personnel from a broad range of disciplines. Our core competencies in Mechanical and Electrical Engineering, Programmable Logic Controller, Process Automation, Estimating and Application Engineering as well as Sales Project Management contribute considerably to the success of our company. However, it remains a priority to invest considerable efforts and resources into developing our employees. A holistic training program is set up and any training needs, whether identified
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VALU
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by the employee or called for by technological developments, are taken into account.
In 2013 the coaching program for new employees was expanded in order to optimize integration of the employee into the company. This coaching program enables the new employee to achieve quickly the level of skills and performance needed for the job.
The training program in 2013 was not only based on technicalexpertise, but also on human qualities and managerial skills needed to develop.
Creativity, flexibility, mobility, team orientation, motivation and commitment – these are the qualities that foster a mutually profitable relationship based on trust between CTI and its employees, thereby ensuring the company’s long-term survival and prosperity.
QUALITYQuality plays an important role at CTI Systems. Quality assurance is carried out systematically and this is emphasized not only by our ISO 9001 certification, but also by customer satisfaction.
While targeting excellence, the quality of CTI’s products and services is the key issue and our customer can always rely on our equipment performance.
To come up to the clients’ expectations in an even more efficient way, CTI Systems continuously strives to optimise its working procedures and as a consequence steadily improves its 1995 achieved operational Quality System according to the prescriptions of the international Standard ISO 9001. In 2013 the ISO 9001 certification was successfully renewed.Moreover, mainly customers in the aviation industry carry out their own control audits. During test assembly of the Beluga project at CTI’s facility in the second quarter of 2013, Airbus carried out its conformity inspection on the installation with positive results.
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FINANCIAL INFORMATION
uORDER INTAKE uBACKLOG
uTURNOVER - TREND
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The financial information in the following pages has been derived from CTI Systems’ audited statutory annual accounts as at 31 December 2013, established in accordance with the accounting principles laid down by applicable Luxembourg law and regulations (LUXGAAP).
uTURNOVER - BREAKDOWN BY GEOGRAPHIES
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ASSETS 2013 2012
FIXED ASSETS
Tangible assets
Land and buildings 7.214.947 7.651.585
Plant and machinery 1.143.790 1.337.405
Other fixtures and fittings, tools and equipment 378.909 540.152
Financial assets 120.564 10.672
TOTAL FIXED ASSETS 8.858.210 9.539.813
CURRENT ASSETS
Stocks
Raw materials and consumables 1.073.978 1.412.578
Work and contracts in progress 12.399.803 10.490.917
Debtors
Trade debtors 9.723.435 11.807.426
Amounts owed by affiliated undertakings 462.622 0
Other debtors 279.707 760.232
Cash at bank and in hand 11.232.077 15.268.999
TOTAL CURRENT ASSETS 35.171.621 39.740.152
PREPAYMENTS 91.435 70.710
TOTAL ASSETS 44.121.266 49.350.676
BALANCE SHEET DECEMBER 31, 2013 (EURO)
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LIABILITIES 2013 2012
CAPITAL AND RESERVES
Subscribed capital 4.400.000 4.400.000
Legal reserve 440.000 440.000
Profit brought forward 4.131.752 2.539.553
Profit for the financial year 1.062.655 1.767.449
TOTAL CAPITAL AND RESERVES 10.034.407 9.147.002
PROVISIONS
Provisions for taxation 778.702 396.648
Other provisions 4.729.973 5.299.242
TOTAL PROVISIONS 5.508.675 5.695.890
NON SUBORDINATED DEBTS
Amounts owed to credit institutionsBecoming due and payable after less than one year 155.585 118.071Becoming due and payable after more than one year 112.370 267.507Payments received on account of orders 15.369.890 21.248.992Trade creditors 5.318.832 5.422.393Amounts owed to affiliated undertakingsBecoming due and payable after less than one year 811 415.304Becoming due and payable after more than one year 0 22.075Tax and social securityTax 284.542 347.466
Social security 667.250 647.722
Other creditors 2.471.593 2.473.340
TOTAL NON SUBORDINATED DEBTS 24.380.873 30.962.870
DEFERRED INCOME 4.197.311 3.544.913
TOTAL LIABILITIES 44.121.266 49.350.676
BALANCE SHEET DECEMBER 31, 2013 (EURO)
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CHARGES 2013 2012
Raw materials and consumables 34.317.909 32.748.722
Other external charges 7.226.361 9.253.017
Staff costs
Wages and salaries 11.190.831 10.497.700
Social security costs 1.540.642 1.406.044
Value adjustments
On tangible and intangible fixed assets 1.030.466 1.019.923
On elements of current assets 200.500 165.590
Other operating charges 70.071 69.802
Interest payable and similar charges
Concerning affiliated undertakings 0 6.209
Other interest payable and similar charges 67.171 114.580
Tax on profit or loss 494.289 288.055
Other taxes not included in the previous caption -23.998 20.737
Profit for the financial year 1.062.655 1.767.449
TOTAL CHARGES 57.176.896 57.357.828
INCOME
Net turnover 54.608.892 57.489.495
Change in inventories of finished goods and of work and contractsin progress 1.908.886 -1.047.331
Fixed assets under development 0 236
Other operating income 569.269 753.961
Other interests and other financial income
Other interest receivable and similar income 69.818 156.286
Extraordinary income 20.030 5.181
TOTAL INCOME 57.176.896 57.357.828
PROFIT AND LOSS ACCOUNT DECEMBER 31, 2013 (EURO)
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INTRALOGISTICS
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CTI Systems realizes automated intralogistics systems for industries where heavy and bulky loads need to be moved and stored.
The turnkey intralogistic installations comprise:• Automated storage & retrieval systems (ASRS )• Manipulators & handling devices • Floor conveyance systems• Monorail systems• AGV systems & omnidirectional carriers• Special / custom crane systems• Control by WMS and MES with connection to ERP systems
Solutions for:• High bay warehouses and ComStore warehouses for heavy loads• Surface treatment lines• Production and assembly lines• Maintenance lines• Complete installations for manufacturing processes
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3D animation
Test assembly at CTI Systems’ facilities in Lentzweiler
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Airbus Beluga line station loading equipment
Under the so-called “Fly 10,000” project, aircraft manufacturer Airbus will increase the use of its Beluga transport planes. This requires improvement of the infrastructure where the transport connects up with production facilities.
In the framework of a long-term relationship with many installa-tions successfully set up, Airbus awarded CTI Systems with the development, manufacturing and installation of the new Beluga line station loading equipment.
To perform ground loading operations into the Beluga plane and to speed up the transfer of parts, Airbus intend to construct ad-ditional facilities at its main stations in Bremen and Hamburg Germany, Saint Nazaire France, Broughton Wales, and Getafe Spain.
For CTI Systems S.A., it was all more pleasing to have prevailed thanks to its knowhow in mechanical and electrical engineering, as well as production of key components in our facilities were decisive for the award.
Loading equipment is a set of different equipment which will al-low Transport Cargo Unit unloading / loading operations from Beluga to Storage Racks and vice versa in each main Line Stations.
The contract included the design, manufacture, delivery, assembly and commissioning of the following:
• 6 Beluga Interface Racks (BIR) for the Airbus manufacturing sites of Bremen (1), Broughton (1), Saint Nazaire (1), Getafe (1) and Hamburg (2)
• 8 Mobile Racks for the Airbus manufacturing sites of Bremen (2), Getafe (2) and Hamburg (4)
• 6 Cargo Boarders for the Airbus manufacturing sites of Broughton (2), Saint Nazaire (2), and Hamburg (2)
A control and monitoring system manages permanently the loading equipment between all units and ensures and provides permanent status configuration.
The first line station loading equipment has recently been finished in test assembly at the CTI Systems production site in Luxembourg. Assembly at Airbus Hamburg will start in 1st quarter 2014.
CTI Systems is proud to highlight to Airbus its capabilities to optimize safety, reliability, availability, steadiness, performance and operating/maintenance costs of the proposed equipment.
By participating in this important project, it once again confirmed that CTI Systems belongs to the leading providers in the field of intralogistics in the aviation industry.
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Entry Into Service of first Integrated Loading Facility at Airbus Hamburg
CTI Systems to support “Fly 10,000” project
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CIMC Silvergreen - Günzburg, GermanyFull automatic overhead conveyor system for trailer assembly line
For the new plant of CIMC (former Burg) Silvergreen in Günzburg, Germany, CTI Systems delivers the complete conveyor installation for the final assembly of curtainsiders.
This installation will assist CIMC Silvergreen to fulfil its commit-ment to realize highly efficient as well as environmentally compatible production. CTI’s scope of supply comprises: • 4 bi-rail load carriers • 2 sets of transversal transfer bridges • 1 automatic crane with vaccuum
including: • design & engineering • manufacturing & supply • installation & commissioning • project management
This new plant and headquarters of CIMC Silvergreen will be noticeable not just due to its location directly adjacent to the motorway, but also thanks to special architectural accents. CIMC Silvergreen equipped the plant with a climate-friendly energy concept, thereby underscoring the ecological approach of the company that recently presented the first climate-neutral trailer in the world.
HTMC - Shenyang, P.R. ChinaAutomatic transport system for train bogies
For the new high speed train maintenance center at South Station of Shenyang Railway Bureau, a subsidiary of China Railway Corporation, which will be erected in Shenyang, CTI Systems delivers the automatic transport system for the maintenance of the high speed train bogies.
The scope of supply comprises the design, manufacturing, delivery and installation of: • 2 transfer bridges (TB) • 4 overhead carriers (OC) • runways for two disassembly lines (approx. 18 m) • runways for two assembly lines (approx. 18 m) • runways for one maintenance line (approx. 6 m) • bus bars along runways • electric & control system for TB and OC
Also included in the scope is the engineering of: • supporting structure for runways • one runway for the main line, approx. 94.5 m
The acquisition of this order demonstrates the importance that CTI Systems provides the railway industry which represents a significant potential for CTI.
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uTOTALLY INTEGRATED AUTOMATION
uPROGRAMMABLE LOGIC CONTROLLER
uMANUFACTURING EXECUTION SYSTEM
uWAREHOUSE MANAGEMENT SYSTEM
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uTOTALLY INTEGRATED AUTOMATION - COMPLIANCE WITH ANSI/ISA 95
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EMERGING MARKETSSolutions for the railway industry
Production and assembly lines CTI Systems plans, produces and installs full automatic manufacturing lines for the production of railway vehicles.
The automatic production line manages automatic material flow of different components and sub-assemblies like bogies during the assembly stages.
The flow is assisted by automated guided vehicles (AGV), and contains the following equipment:
• automatic control work platforms (ACP) which are equipped with a support and lifting unit for payload of 7 tons
• automatic overhead carriers (OC) which are equipped with a special lifting frame for the assembled parts (payload of 10 tons)
• automated guided vehicles (AGV) which are responsible for the material flow of all smaller parts for payloads of 5 tons
Besides AGVs, CTI Systems offers a comprehensive scope of products and ser-vices for internal logistics, e.g:
• overhead crane & monorail handling systems• semi-/automated transfer systems with integrated workstations• automated warehouse systems
The production line is under control of a CTI management system.
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Maintenance linesCTI Systems engineers solutions for MRO of trains and railway vehicles.
Today’s workshops are confronted with maintaining different types of trains and railway vehicles or maintaining one single type of train. Both requests need highly sophisticated and specialized infrastructure which is, once installed, not flexible and will not allow reducing maintenance costs on a high level.
Even more, it is not practical to adapt the infrastructure afterwards when it comes for example to integration of a different type of vehicles then that foreseen.
CTI provides equipment to help clients stay flexible in the long term and help the short term reduction of maintenance costs by permitting the introduction of continuous maintenance improvements.
Teleplatforms• CTI teleplatforms grant quick and safe access to all
railway vehicles, especially to the roofs but also to the sides and nose
• clear floor areas• ergonomic and safe working conditions• shortest possible train repair times
CTI-MoveThe special omnidirectional working platform, regarding the application, grants movements in all directions and rotation around a center point, i.e. can be manoeuvred with a minimum of space and time required.
Every train or railway vehicle can be approached quickly and safely with the most flexible access possibilities especially to the sides and nose but also to the roofs.
As there is no need to implement guiding rails in the floor, the floor stays hazard free.
Special equipment like e.g. lift tables are equipped with the CTI-Move omnidirectional drive technology. These height adjustable multi-mobile platforms are free running on wheels and provide the well-known CTI stable and safe working conditions.
They are available in 3 sizes. When in work position, smoothest final movements can be made in raised work position and mobile platform extensions give access to cantilevered maintenance locations.
The omnidirectional CTI-Move provides great flexibility for any maintenance task.
Automated guided vehicles (AGV)The use of AGVs permits the reduction of travel paths for the operators and helps reduce maintenance time. Thanks to the omnidirectional drive technology of the AGVs, access to every location in the maintenance hall is granted. The supply of spare and wear parts to the maintenance operator is ensured in a quick and orderly manner. Maintenance tasks are not interrupted.
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SURFACE TREATMENT
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Customized turnkey surface treatment installations comprise the material handling systems, storage and buffer and all various surface treatment processes. Acting as general contractor CTI Systems takes care of customized concept, detailed engineering, manufacturing and installation of the entire system.
Turnkey surface treatment installations:• Material handling systems for heavy & bulky materials• Tools & loadbars for product transportation• Various processes • Control by WMS and MES with connection to ERP systems
Supported processes:• Pretreatment
• Shot blasting• Degreasing (dip and spray)• Pickling• Iron or zinc phosphatizing • Nano surface treatment • Conversion layer deposition • Waste water treatment
• Paint systems • Cataphoretic coating (E-coat / KTL)• Autophoretic coating (ACC)• Powder coating• Wet paint coating
• Curing & drying • Chamber ovens• Continuous ovens• Infrared dryers
• Air cleaning systems
• Chemical milling / galvanic coating
• Conveyors & transport systems
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Laverda - Breganze, ItalyCustomized coating and handling system for bulky agricultural machine assemblies
The Vicenza-based company Laverda belonging to the American AGCO Corporation is specialized in the production of combine harvesters. In the framework of its specific values which are the reliability of the machine and its ability to produce, in turn contributing to profitability, Laverda, with 140 years of history, declared the Breganze facility as its strategic center for combine production and operations in Europe, meaning the complete integration of Laverda and AGCO harvesting products. The plant had to become the innovative center with the latest equipment and advanced production lines. In order to comply with highest corrosion quality standards Laverda decided in 2011 to invest in a new paint shop. In 2012 CTI Systems was awarded with the project to equip the new facility with the most advanced coating and handling technology.
CTI Systems assisted the customer during design and construction phase of the building which is designed around the process equipment and especially constructed to support the cranes weight. The plant is equipped with the latest systems to meet the customer’s quality requirements and those of their clients to deliver first-class products.
CTI provided the engineering for operating a paint shop at 14 combines per day (3 shifts) and the delivery and implementation of equipment for an installation at a capacity to produce a maximum rate of 10 combines per day.The coating line is equipped with 14 tanks for pre-treatment and E-coat, 2 counter tanks and 3 waste water tanks as
well as all necessary pumps, filters, heat exchangers, chiller, RO-Water installation and oil separator. 6 E-coat ovens and 4 powder ovens were also included in the scope of supply. CTI Systems integrated the automated powder booth provided by a third party.
The transfer through the coating processes and to the intermediate buffer zones is ensured by CTI provided automatic handling and transport equipment: • 3 loading and unloading stations for narrow load • 2 loading and unloading stations for wide load • 2 lifts • 7 distribution transfer bridges (with and without conveyor system) • 4 tank line distribution bridges • 1 main load frame return bridge • 4 transfer buffer systems • conveying system through the powder booth • significant central buffer
This is the third installation for AGCO where CTI could showcase its excellent capabilities as turnkey system provider in the surface treatment and intralogistics branch. With core competencies in project management and engineering, CTI Systems provides the best and most innovative solutions yielding the maximum benefit in terms of cost and productivity, but also taking individual circumstances into account.
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AGCO - Hesston, USAState-of-the-art paint and handling equip-ment for agricultural machinery production
AGCO, Your Agriculture Company, a worldwide manufac-turer and distributor of agricultural equipment, completed its modernization project equipping its Hesston, Kansas, 18 500 m² (200 000 ft²) manufacturing facility with the latest finishing and paint technologies, together with auto-mated handling equipment. This is the second time CTI Sys-tems was awarded by AGCO to act as general contractor for design and implementation of the entire installation. The first one was completed in 2013 at the Santa Rosa plant in Brazil.
The entire paint shop is equipped with automated floor-based and overhead material handling devices from CTI Systems for connection of the different steps of the pro-cesses, including: • tank line transfer bridges • tank line bridges • distribution transfer bridges • elevators • loading/unloading stations.
The system for the tank line can handle part sizes up to 8.5 x 3 x 3 m (28 x 10 x 10 ft) and up to a weight of 2 950 kg (6 500 lbs). For the wet paint line, the system can handle part sizes up to 15.9 x 3 x 3 m (52 x 10 x 10 ft) and up to a weight of 2 270 kg (5 000 lbs).
The entire material flow process is automated and under control of software developed by CTI Systems, to ensure process visualization and data acquisition, with connection to the customers ERP/MES system.
In the spacious load and unload center, components are placed on load bars and transported to the paint line by 18 unmanned automated guided vehicles (AGVs) with full omni- directional capabilities which are programmed to follow a series of magnets in the floor as they move parts into the paint facility. This high level of automation reduces employee exposure to the paint process, increases productivity and improves parts flow through the paint center and back to the assembly lines.
This successfully accomplished project again emphasises CTI’s excellent capabilities as turnkey system provider in the surface treatment and intralogistics branch. With core competencies in project management and engineering, CTI Systems provides the best and most innovative solutions yielding the maximum benefit in terms of cost and productivity, but also taking individual circumstances into account. With CTI’s knowhow in implementing turnkey systems, new installations operate with their full potential within the required schedule.
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AVIATION
Worldwide leading aircraft manufacturers, airlines and MRO service companies benefit from successful installations of teleplatforms, crane systems, docking and engine handling systems.
CTI Systems offers different systems and solutions for the aviation industry:
• teleplatforms• overhead crane systems• docking systems• carrier systems for engine handling• CTI-MOVE - omnidirectional working platforms
Solutions for:• aircraft maintenance and painting• engine handling in maintenance & test centers• aircraft manufacturing• air cargo handling systems
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Complex air cargo handling systems allow right in time and right in place provisioning
Adapted from CTI Systems’ successfully realized projects in industrial automation, advanced in-stallations for air cargo handling between air- and landside at airport cargo centers are being offered:
Modular system componentsDesigned in various dimensions and in accordance with individual requirements, the modular handling systems comprise
• truck docks for loading/unloading trucks and cargo loaders
• TVs, ETVs and AGVs• shuttles and lifts• pallet movers• roller decks, right-angle decks• turntables• pass-over decks• automated storage & retrieval systems (ASRS)• integrated climatized cells• customized control and warehouse
management software (WMS)
Besides the AGVs, CTI Systems offers a comprehensive scope of products and services for the internal logistics, e.g:
• overhead crane & monorail handling systems• semi-/automated transfer systems with inte-
grated workstations• automated warehouse systems
The production line is under control of a CTI manage-ment system.
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Spirit AeroSystems - Wichita, USAModule Segment Loader for production of Boeing 787 Dreamliner airplanes
This special product is based on the CTI-Move technology with full omnidirectional capabilities.
The objective was to provide a means of transporting and installing aircraft floor board assemblies in an aircraft fuselage in the safest, most efficient and most reliable manner. With a movement capability of 6 degrees of freedom and a positioning accuracy of 2 thousands of an inch, aircraft floor boards are installed in the cockpit section of Boeing 787.
The Module Segment Loader provides cell to cell trans-port and positioning of the load into the fuselage and several staging locations in the building. The control system provides all required motion and accessory control, operator inputs, system interfaces, and safe-guards and protections.
The system was designed to meet all performance requirements under continuous usage, 24 hours per day; 7 days per week.
Technical features: • The maximum travelling speed is 60 fpm ~ 18 meters / min. • The weight capacity is 15 000 lbs ~ 6 800 kg
In the fuselage approach phases, longitudinal, lateral and yaw movements are achieved thanks to the omnidirec-tional capability of the four wheel drives. The vertical hoist movement is actuated hydraulically and has a lifting stroke of 165 inches ~ 4 200 mm.
Longitudinal, lateral, vertical, pitch, and yaw fine positioning movements are ensured via high precision electrical cylinders. The roll fine axis is actuated hydraulically.
Video cameras and laser pointer systems are also included as guidance supports to the operator.
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MDS Aero - Ottawa, CanadaEngine Handling System Rolls Royce
In close collaboration with Rolls Royce’s Prime Contractor, Canadian company MDS Aero Support Corporation, CTI Systems developed a safe engine handling system for RR’s new 14m x 14m Indoor Engine Test Facility in Dahlewitz/Berlin (Germany).
MDS Aero Support Corporation is a recognized supplier of turnkey test facilities and test systems for aviation, industrial and marine gas turbine engine industries. CTI Systems developed the overhead aircraft engine handling installation for maintenance and test functions that will minimize engine handling time and offer many advantages in terms of safety and efficiency.
The complete facility is designed to dress engines in the preparation area prior to test and allow production and development testing of current Trent series engines and capability of future growth engines.
The equipment is based on a monorail and carrier system completed with transfer bridges and height adjustable powered workstations in order to improve engine handling efficiency and the operators’ access conditions to the engine.
The scope of supply includes:• 1 CTI patent monorail gantry system with
- 6 monorail spurs for transport to and from fixed and variable height workstations in the preparation area - 2 transfer bridges, one with a 270 degree turntable, for transport to and from the test cell with a pivot monorail section allowing complete isolation of the test cell by acoustic doors - a second monorail spur for extension towards a future test cell
• 2 twin hoist engine carriers travelling on the monorail system to transport the engine within the preparation area and the test cell
• 1 auxiliary hoist carrier equipped with a hoist to lift up accessories
• 4 height adjustable workstations, all offering access to engine interfaces, and hoists for engine dress kit assembly / disassembly.
• 1 Test cell lift platform measuring 14m x 8m for lifting personnel to the engine for final connections prior to test.
The design of the transfer bridges allows highest flexible workflows and simplified transfers.
The transfer bridge concept will allow free engine carrier transfer to any required further service location, no matter in which location of the system the carrier is currently parked.
The overhead configuration concept allows unhindered personnel access around and even below the engines. Floor surfaces will be kept clear from any carriers and will grant a free working environment. Lifting and lowering the engine with the carrier integrated hoists provides optimal individual ergonomic work levels.
The installation is currently in process with commissioning planned for end of 2014.
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Advantages:• reduced risk of damage• reduced turnaround time• reduced operating time• increased safety for work personnel• improved working/access conditions• increased work quality
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AUTOMATED GUIDED VEHICLES
FLATBED OMNIDIRECTIONAL AUTOMATED GUIDED VEHICLE FOR HEAVY LOADS
• In the aviation industry: safest transfer of fuselage segments.
• In the print and paper industry for the automated transport of paper coils.
• In the commercial vehicle manufacturing for the transport of voluminous chassis components from one work place to another.
• In the railway industry for the manufacturing and maintenance of trains.
Benefits of an AGV System:
• Low building costs• Flexibility, usage in multiple buildings• High availability• Extendable according to increase of production
capacity
Integrated flexible floor transport solutions
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• Load positioning: accuracy ± 1 mm
aCup & Cone centering system
• Floor base to mobile stand• AGV to mobile stand• Centering & floating lift table
• Dynamic safety: relevant redundant load identification
• Floor based guidance
• Flexibility for path changing• Relatively low cost for implementation &
changing• Very reliable in comparison to other systems
• Payload up to 60 tons• Flat bed height 400 mm• Travel speed up to 60 m/min. • Full omnidirectional capabilities• Full AGV capability (magnetic, wire, optical
guidance)• Low wear/abrasion of wheels or floor• Modular design (hoist or part adapters)• Battery or inductive power rail• Available in Ex-proof: ATEX, IEC-EX & NFPA• Many special features
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CTI-MOVE technology allows movement in all directions and 360° rotations around the vehicle center point.
• Rotation around the own axle• 100% flexibility• Even possible on closest narrows
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OMNIDIRECTIONAL WORKING PLATFORMS• Micro version• Mini version• Maxi version• Mega version
LIFT TABLESThe mobile lift table can pick up and move materials to the worksite, where the lift table can be lowered or raised to achieve an ergonomic work position for the operator.
• Mobile lift table C1 (load capacity: 700 kg)• Mobile lift table C2 (load capacity: 2.000 kg)• Mobile lift table C3 (load capacity: 3.000 kg)
CTI-MOVE ATEX94/9/EG and Norm EN 1755.Available to Zone 1 / Zone 22 (not conductive dust)Category 2G & 3D, explosion group IIB, temperature class T4 (135° C).
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Beyond commissioning of our systems, we continue the support of our customers. CTI offers a full range of service support in after sales activities to guarantee a trouble-free and reliable system operation.
The customer received the right service for the entire life cycle of the installation. Our service package minimizes downtimes, increases productivity, product quality and maintains the value long-term.
At CTI Systems the partnership does not end with the purchase and installation, it becomes more intensive. CTI Systems provides a comprehensive service package for all installations:
• Consulting - Active support in dealing with modifications - Advice for planned equipment expansions
• Inspection, load tests• Spare and wear parts• Preventive maintenance• Training by CTI’s well trained employees• Hotline service
- Fast/speedy service by call - Trouble shooting
E-mail: [email protected]
CONSULTING
Concept designsTechnical & process
ConsultingFeasibility studies
Equipment checkMaintenance service
Remote service
Fast serviceRepairs & trouble
shooting
Fast delivery Start-up supportOn-site training
MAINTENANCE HOTLINE SPARE PARTS TRAINING
SERVICE SUPPORT
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11. - 16.02.2014Singapore AirshowSingapore 25. - 26.02.2014Aircraft Maintenance Russia and CIS RU - Moscow
25. - 27.02.2014LogiMatDE - Stuttgart
12. - 13.03.2014KranfachtagungDE - Madgeburg08. - 11.04.2014 PaintExpo 2014 DE - Karlsruhe
11. - 13.05.2014Airportshow 2014UAE - Dubai
08. - 10.07.2014India Material Handling & Logistics ShowIN - New Delhi
11. - 13.09.2014Ankiros 2014TR - Istanbul23. - 26.09.2014InnoTransDE - Berlin
07. - 09.10.2014Aluminium 2014DE - Düsseldorf07. - 09.10.2014 International Air Cargo Forum and ExhibitionKR - Seoul
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EXHIBITIONS 2014
EVENTS
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21. - 23.01.2013MRO Middle East conferenceUAE - Dubai The region’s leading MRO exhibition and conference addressing your top issues and concerns
19.–21.02.2013LogiMat DE - StuttgartThe International Trade Fair for Distribution, Materials Handling and Information Flow, sets new standards as the biggest annual intralogistics exhibition in Europe
20.-21.02.2013Aircraft Maintenance Russia and CIS Conference and ExhibitionRU - Moscow
13.03.2013KranfachtagungDE - Bochum
06. - 08.05.2013Airportshow 2013UAE - DubaiBenchmarked as one of the world’s leading events and a vital link to the airport industry in the MENA and Indian Subcon-tinent region
15. - 17.05.2013Airport Development Russia & CISRU - Moscow
30.-31.05.2013Aluminium Alloys Profiles and Rolled 5th International ConferenceRU - Ekaterinburg
27.08. - 01.09.2013MAKSInternational Aviation & Space SalonRU - Zhukovsky/Moscow
07. - 11.09.2013Euro-China Business MeetingCN - Changchun/Beijing
12. - 14.09.2013PaintExpo EurasiaTR - IstanbulPaintExpo Eurasia is the trade fair for industrial coating technology in Turkey and the region
08. - 10.10.2013Nordic Rail ElmiaSE - Jönköping
08. - 11.10.2013Interairport EuropeDE - MunichThe world’s leading exhibition for the airport industry to find out about the latest technical trends and invest in new air-port equipment
15. - 16.10.2013DFO - Erste Deutsche Land- und Baumaschinen ForumDE - Münster
28. - 31.10.2013CeMAT Asia 2013CN - Shanghai
08. - 09.12.2013Kuwait Airport development Forum 2013KU - Safat
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In the framework of the trade mission lead by Their Royal Highnesses the Crown Prince and the Crown Princess of Luxembourg together with His Excellency the Deputy Prime Minister and Minister of the Economy of Luxembourg, CTI Systems officially inaugurated on 17 December 2013 its new subsidiary CTI Systems China LLC in Shanghai.
Since 2002 CTI Systems has been active in China, mainly in the aviation branch, and in the last decade CTI could strengthen and enlarge its position on the Chinese market. CTI’s first project in China started in September 2003 with the installation of a teleplatform and crane system at Guangzhou New Baiyun Airport.
With now more than 12 projects realized in the People’s Republic of China, it appeared obvious that CTI needed to be present in the Chinese market.
OPENING OF CTI SYSTEMS CHINA
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GO LIVE FOR THE NEW WEBSITE
Our website design has been improved making the homepage more user-friendly. The content is more detailed giving the website visitor more informative ideas of CTI Systems’ products and activities.
Please visit and discover our latest technologies !
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CTI Systems Inc.MRA Building
N19 W24400 Riverwood DriveWaukesha WI 53188
USA
P.: +1 262 696 38 13F.: +1 262 696 38 15
CTI Systems is a full member of the Paul Wurth Group, headquartered in Luxembourg and with international set-ups in Brazil, Chile, Czech Republic, Germany, India, Italy, Japan, Korea, Mexico, P.R. China, Russia, South Africa, Taiwan, Ukraine, U.S.A., Vietnam. (www.paulwurth.com)
CTI Systems R.O.Level 3, WISMA RKT
N° 2, Jalan Raja AbdullahOff Jalan Sultan Ismail50300 Kuala Lumpur
MALAYSIA
P.: +60 3 2695 31 92F.: +60 3 2694 11 33
CTI SYSTEMS S.A.Z.I. Eselborn-Lentzweiler
12, op der SangL-9779 LENTZWEILER
G.D. LUXEMBOURG
P.: +352 2685 - 2000F.: +352 2685 - 3000
CTI Systems China LLCRoom 405, Building 24 Sanlin World Expo BlockNo. 62 Heng Da Road (access via No.295 South Lingyan Road)Pudong new areaShanghai 200126 P.R. CHINA
P.: +86 21 68416335F.: +86 21 68416309
CTI Systems S.A.Z.I. Eselborn-Lentzweiler | 12, op der SangL-9779 LENTZWEILER | G.D. Luxembourg
W W W. C T I S Y S T E M S . C O M
2013
