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»It wasn't always easy to integrate the necessary modifications resulting from the ongoing product development process within the scheduled time frame. However, the HELLER experts did an excellent job. We knew right from the start that they would not let us down in case of a problem.« Manred Pillhofer, Head of Machine Tool Planning

25% reduction in engine components, 100kg weight reduction – successful product and process development of state-of-the-art 6-cylinder diesel engine

HELLER solutions at MAN Nutzfahrzeuge AG Nürnberg


Task Setting

  • Production of 6-cylinder diesel engine with common-rail technology
  • Product and process development (simultaneous engineering)
  • High flexibility and comprehensive engineering know-how

Project scope and solution

  • Four FST transfer systems with four to six machining stations each plus 18 machining centres model MCH 400
  • With overall responsibility for integrating additional machines from other suppliers
  • Component transfer by means of lift-and-carry system or linear loader
  • In-process gauging for continuous quality assurance


  • 25% reduction in engine parts
  • Weight savings of approx. 100kg per engine
  • Compliance with all existing and future emission standards
  • Extension of maintenance intervals to 120,000km
  • 5% reduction in fuel consumption
  • 18 machining centres model MCH 400 in production at MAN
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