* First place for tool manufacturing in Wackersdorf

Gerresheimer Werkzeug- und Automatisierungstechnik GmbH ranks among the best tool manufacturers in the German speaking area. This is evidenced by top placings in the prestigious competition “Excellence in Production”. The Wackersdorf-based specialist in Gerresheimer’s Medical Plastic Systems Division successfully stood out from the field and was pleased to win first place in the category “Internal Tool Manufacture with up to 100 Employees”.

With the top placing in the category “Internal Tool Manufacture with up to 100 Employees” Gerresheimer Werkzeug- und Automatisierungstechnik GmbH ranks among the industry best in the German-speaking area. In a strongly fought competitive environment the Wackersdorf-based specialist successfully stood out from the field. The coveted honor is the reward for outstanding achievements at all levels of the specialist facility in Wackersdorf. The competition also contributes to heighten the awareness and regard enjoyed by tool manufacturing among members of the public.

For the sixth time now in 2009 the “Excellence in Production” competition was organized by the Tool Machine Laboratory of the Rhenish-Westphalian Technical College in Aachen and the local Fraunhof Institute of Production Technology. Particularly qualified companies were invited to compete for the “Tool Manufacture of the Year” title. All tool and mold manufacturing operators in Germany, Switzerland and Austria are entitled to enter. Both independent companies (“external tool manufacture”) and departments within a company (“internal tool manufacture”) can register. The award is given to one company with up to 100 employees and one with more than 100 employees.

This year a total of 311 companies took part in the competition, of which 71 passed an initial selection hurdle and went into the second round, during which they underwent a thorough examination by the organizers. In the end, nine companies qualified for the final – among them Gerresheimer Werkzeug- und Automatisierungstechnik.  The high-caliber jury was composed of representatives of industry and engineering associations (VDI, VDMA, VDA, VDEh) and Finalists and prizewinners in the competition “Excellence in Production 2009” and the worlds of science, business and politics. To determine the winners the jurors not only assessed technological performance over the entire process chain but in their decision also took particular account of economic, organizational and strategic aspects. Assessments were based on the criteria in the Aachen Tool and Mold Manufacture guidelines developed particularly for tool manufacture from the familiar EFQM model. In detail: financial results (weighting 20%), employee-related results (5%), customer-related results (10%), product-related results (5%), processes (20%), resources (20%), organization (15%) and management (5%). Against the background of this assessment system, a team of experts visited the nominated plants on the ground and carried out an “Excellence in Production” audit. In the course of this, employees and managers were interviewed and questioned about selected subjects. Not only the financial results of the participating tool manufacturers were evaluated but also the efficiency and effectiveness of their processes and their technical and organizational capabilities.

In their interviews with the employees of Gerresheimer Werkzeugund Automatisierungstechnik GmbH and their analyses of the data and facts the jury identified a number of particular strengths.

With its concentration on mold and special machine manufacture, Gerresheimer Werkzeug- und Automatisierungstechnik GmbH has developed a clear strategy. The company’s employees are distinguished by a high level of autonomous responsibility. The Technical Competence Center provides a comprehensive service to the company’s customers. Analyses of customer benefit and assessments by customers evidence a high level of delivery reliability and customer satisfaction, which earned praise from the jury on the customer criterion. The fact that the company ensures a high level of employee satisfaction through individual training plans, knowledge build-up through projects with research institutions and early integration of apprentices in the day-to-day business earned praise on the criterion of employee/knowledge management.

On the criterion of company resources the jury particularly highlighted the exceptionally high performance in cavity sinking by EDM. In the product range the wide service spectrum attracted positive comment. The above-average investment rate earned praise in the assessment with regard to the area of finances. A positive strategic aspect is the integration of tool manufacture into the Group’s value-added chain. In order handling the short throughput times as the result of segmentation stood out. On development and design the experts praised the advantageous makeup of tools using standard components, and in production they assessed the internal
department for modification orders and the multiple-machine utilization concepts as particularly valuable.

Tool manufacture in Wackersdorf at a glance

For Gerresheimer’s Medical Plastic Systems Division, Gerresheimer Werkzeug- und Automatisierungstechnik GmbH at the Wackersdorf plant produces sophisticated injection molds for medical plastics which are suitable for clean-room production, and special plant and machinery in the field of automation technology. Tool manufacture at the Wackersdorf plant is linked to the internationally staffed Technical Competence Center (TCC), in which Gerresheimer Medical Plastic Systems concentrates technical knowhow and through simultaneous engineering covers the entire product creation process up to series readiness. The TCC uses stateof- the-art 3D CAD technology to design precision tools and special machines, develops products and production processes and comprises the areas of Project Management, Quality Planning, Laboratories and Technology.

The internal tool manufacturing facility produces high-cavity injection molds and hot runner molds as well as tiered, round-table and multi-component tools.
Gerresheimer employs around 10,000 people in more than 40 locations in Europe, America and Asia. In the financial year 2008, worldwide sales totalled €1.06bn. The product portfolio ranges from pharmaceutical vials made of glass and plastic through to complex drug-delivery systems for the pharma & healthcare industry. These include sterile syringes, inhalers and other system-based approaches for safe dosage and application of medications. The Group enjoys a leading position in markets which are characterised by high technical and regulatory barriers.