GROUND

The magazine of Hitachi Construction Machinery (Europe) NV

CONTROL
Issue 15 Spring 2013 www.hcme.com

PROTECTING YOUR INVESTMENT

Special HCM issue:
• Factory tour
• Product testing
• Meet the President
 GROUND
CONTROL
The magazine of Hitachi Construction Machinery (Europe) NV
CONTENTS
Issue 15 Spring 2013 www.hcme.com

04 News
Explore Hitachi construction machinery from around the globe as well as all the
latest exhibition and new product news

10 Rising to the challenge

Ground Control meets the new HCM President, Yuichi Tsujimoto, and Chairman
of the Board, Michijiro Kikawa

12 Made in Japan
A tour of HCM’s manufacturing facilities, with an in-depth look at the
production and assembly operations at Tsuchiura Works

18 The quest for quality

Exclusive: HCM’s Quality Assurance Centre and Test Site reveal why Hitachi
products have a reputation for quality

22 New recruits
Two new Zaxis-5 excavators are put to the test in the UK by specialist
demolition company Hughes & Salvidge

26 Bringing down the cost of ownership

Four German companies explain how Hitachi Support Chain helps to protect
their investments in Hitachi machinery

30 A team effort
Ground Control joins the special anniversary celebrations being enjoyed by
Belgian Hitachi dealer Luyckx

34 TRIAS: unique hydraulic technology

Chief engineer, Tsuyoshi Nakamura, explains the cost-saving benefits of the
TRIAS hydraulic system to Zaxis-5 ownersThe tourist trade in Eilat, Israel, is
booming thanks to the support of construction company, S Noufi and Sons

Ground Control is published twice a year and is circulated among 100,000 readers.
Hitachi Construction Machinery (Europe) NV, Siciliëweg 5, 1045 AT Amsterdam, The Netherlands
Telephone: +31 -(0)20 44 76 700
Fax: +31 -(0)20 33 44 045
E-mail: magazine@hcme.com
Website: www.hcme.com
Editor: Hitachi Construction Machinery (Europe) NV: Ghislaine Jonker
Co-ordination: Somacon, www.somacon.nl
Editorial and design: Red International Communication, www.redinternational.co.uk
Photography: Glenn Blackburn, www.glennblackburn.co.uk
Translation: UvA Talen, www.uvatalen.nl
Printing: Roto Smeets GrafiServices, www.rsgrafiservices.nl
Circulation: Vogelaar Verzenders BV, www.vogelaarverzenders.nl

© Hitachi Construction Machinery (Europe) NV (HCME). All rights reserved. Reproduction in whole or in part
is forbidden except with the written permission of HCME. While every effort is made to ensure the accuracy
of information published in Ground Control, HCME is not responsible for inaccuracies or omissions. All views
expressed are not necessarily those of HCME. The manufacturer is not responsible for non-compliance to
industry-standard health and safety measures by third parties, nor for any damage or loss resulting from
anyone’s reliance on editorial and photography in Ground Control.

02 Hitachi Construction Machinery (Europe) NV

 12

10

30

22 18

GROUND CONTROL 03
 NEWS
Hitachi launches largest
dump truck
Hitachi has launched its largest rigid dump truck, the EH5000AC-3.
One of the most technologically advanced products of its kind, it
features the third generation Hitachi Drive Control System.
This new system incorporates such functionalities as slip control
for traction (similar to active traction control) and slide control for
grip (similar to an anti-lock brake system). The new model also
has a pitching prevention feature for a smoother ride and control
of bouncing when stopping, and a Slip Angle Control function for
stable cornering on slippery road conditions.
The EH5000AC-3 has been designed with a Cummins diesel
engine that meets EPA Tier 2 emission requirements. The truck
features the superior braking envelope available from the AC
Drive technology, which provides precise braking and quick
system responses. A new Hitachi system monitor provides display
information and diagnostics of all onboard systems and controls.
HCME’s Dutch dealer employees at their open house event Various layout changes have also greatly improved the overall
visibility around the machine from previous models.

40 years of HCME Greg Smith, HCME Manager for Heavy and Mining Equipment,
says: “Since Hitachi began producing its own drive system four
years ago with the launch of the EH3500ACII, the technology has
Hitachi Construction Machinery (Europe) NV (HCME) developed rapidly. Hitachi is still the only company in the industry
celebrated its 40th anniversary with a series of special events that designs and manufactures its own drive control system.”
for employees, customers and dealers last year. The first was
held at the company’s original headquarters in Oosterhout,
The Netherlands, and was led by HCME President Moriaki
Kadoya. Employees and their families enjoyed the festivities
alongside former HCME President Mitsuhiro Tabei and Shinichi
Mihara, HCM Director.
Over the past 40 years the European subsidiary of HCM has
grown significantly. During his speech, Mr Kadoya delighted in
sharing the company’s achievements, “In 1972, HCME started
with four employees and now we are a company of 600 people
with a turnover of 600 million euros.”
HCME’s second celebration was an open house event held
by the Dutch dealer for its customers. Many visitors were
able to take a close look and even test drive the new Hitachi
Zaxis-5 excavators and ZW-5 wheel loaders. The event also
commemorated the inauguration of the dealer’s new facilities.
The final celebration took place in October at a conference
and anniversary gala to which all international dealers were
invited. Special guests included former HCME presidents from
the past 40 years, including Mr Okajima, who opened the
doors to HCME’s first premises in 1972.
When closing the festivities, Mr Kadoya thanked all of the
dealers, “I recognise that there is much passion, ambition
and drive within our European dealer network to promote and
support Hitachi construction equipment. We are extremely
grateful for your loyalty and commitment, and we will continue
to honour this by supplying the level of technology required to
compete in the construction industry today.”

04 Hitachi Construction Machinery (Europe) NV

Hitachi presents the next generation
An extensive range of new Hitachi Zaxis-5 excavators and ZW-5
wheel loaders will be presented at Bauma this year. Hitachi
Construction Machinery (Europe) NV (HCME) will have a 5,600m2
stand at the world’s largest exhibition for the construction
industry, which takes place from 15 to 21 April in Munich.
Among the Hitachi models to be launched at the event are
four short-tail mini excavators, ranging from the ZX33U-5 to the
ZX55U-5, and three ultra-short swing models, the ZX65USB-5,
ZX85USB-5 and ZX85US-5.
The comfort of the Zaxis-5 mini excavators has been enhanced,
thanks to a larger cab, a wider operator seat and easier access.
A large 3.5” LCD monitor has been installed on some models
and the air conditioning has been improved. An advanced
energy-saving system on the ZX33U-5 to the ZX65USB-5
machines enables them to deliver savings on fuel costs up to
21% (ZX33U-5) compared to the Zaxis-3 equivalents.
Five new medium Zaxis-5 excavators will be on display,
including the ZX210LC-5 and ZX225USLC-5. The new generation
of medium excavators incorporates the efficient TRIAS hydraulic
system (see page 34) and powerful Stage IIIB engine, which
delivers higher productivity with greater fuel efficiency.
Visitors to the 30th Bauma exhibition will also be able to see
four new Hitachi wheeled excavators: the ZX140W-5, ZX170W-5,
ZX190W-5 and ZX220W-5. The advantages of these models
include greater lifting power, added durability with a reinforced
chassis for example, and higher productivity with the new HIOS III
hydraulic system.
Several new ZW-5 wheel loaders are included in the impressive
Hitachi line-up, ranging from the ZW220-5 to the largest model,
the ZW550-5. Designed with operator comfort in mind, they offer
expansive leg room, an improved air conditioning system and
sound insulation. They are intended to deliver a powerful digging
and loading performance, are capable of impressive travel
speeds and offer excellent fuel consumption.
Other attractions from Hitachi will include the latest
special application machines, represented by the
ZX290LC-5 super long front, ZX470LCH-5 with a 27-metre
demolition boom, and the ZX470LC-5 material-handling
model with raised cab. As a further example of the
manufacturer’s advanced technological expertise, the
ZH200 Hybrid excavator is also expected to draw the crowds.
Towering above all of these new machines, however, will
be two examples of the new generation of Hitachi Sumitomo
crawler cranes. The SCX1500A-3 replaces the SCX1500-2
and the SCX1000A-3 is a new addition to the existing series.
Both models have been completely redesigned and offer an
enhanced level of performance, with unprecedented precision
and efficiency.
Hitachi will also display the EX2600-6 ultra-large mining
excavator, which will be among the largest of its kind at the
exhibition. The event is on track for exceeding previous records:
it will be the largest ever, with 570,000m2 of space, more than
3,250 exhibitors, from more than 50 countries taking part.
In 2010, 420,000 visitors attended the show from more than
200 countries, and this year’s figures are expected to exceed
this total.
HCME President Mr Kadoya says, “We are delighted to
present so many new machines at this year’s Bauma exhibition.
These machines are the result of many years of research and
development by our engineering team in Japan and have been
designed to meet the requirements of the latest emission
regulations, and the expectations of our customers. We look
forward to welcoming them, our dealers and all other visitors to
our stand.”
The Hitachi stand is located at F5.515/516. For more information,
please visit www.bauma.de.
GROUND CONTROL 05
 NEWS
Award-winning Zaxis-5 models
Three large Hitachi Zaxis-5 excavators have been named among
the top new construction products in 2012 by a leading American
trade publication.
The ZX470LC-5, ZX670LC-5 and ZX870LC-5 were selected as
award winners for the Contractors’ Top 50 New Products by the
readers of Equipment Today. The magazine serves commercial
construction contractors, and reaches 77,000 equipment owners
and end users.
The editorial teams of Equipment Today and its associated
website, www.forconstructionpros.com, based their
decision-making criteria on various factors. These included the
evaluation of product enquiries, web page views and online voting
from products features in Equipment Today over a 12-month
period between May 2011 and April 2012.
Hitachi Zaxis-5 excavators combine horsepower with
optimised hydraulics for bigger arm- and bucket-digging
forces. The machines deliver superior productivity and durability,
while keeping operating costs low. This allows operators
to be more efficient and get more work done in less time.
“We are thrilled to have these three excavators named
in Equipment Today’s list of Top 50 New Products for
From left, BauRent AG Ost Managing Director Hanspeter Jaiser, HCME’s 2012,” said Ryan Blades, Division Manager, Hitachi Construction
Joep van den Maagdenberg and Dominik Friedrich from Probst Maveg and Mining. “To compete in today’s construction markets,
contractors need highly efficient and powerful products like
these that they can count on.”
A mini milestone
A ZX17U-2 was the 50,000th mini excavator to be shipped
by Hitachi Construction Machinery (Europe) NV (HCME) in
September. The machine was presented to a Swiss rental
customer in a special handover ceremony.
The event was attended by Joep van den Maagdenberg,
HCME Assistant Manager for Mini Excavators Sales & Support,
along with Dominik Friedrich, Product Manager at Probst
Maveg AG, the official Hitachi dealer in Switzerland.
“HCME began assembling mini excavators in Oosterhout
in 1988,” said Joep. “Since then, they have become
renowned around Europe for their versatility, ease of use
and operator comfort. We are extremely proud to see the
50,000th model roll off the production line.”
Probst Maveg supplied the machine to BauRent AG Ost,
which operates throughout the whole of Switzerland. Its
rental fleet consists of 150 Hitachi machines, ranging from the
ZX10U-2 to the ZX225USRLC-3, and the ZX17U-2 is ranked
among one of the most popular models.
“We have been buying Hitachi machines since 2003
and have always been impressed by their versatility,
which makes them ideal for the rental market,” said
BauRent AG Ost Managing Director Hanspeter Jaiser.
“We also receive a high level of service and support from
Probst Maveg.”

06 Hitachi Construction Machinery (Europe) NV

 Maximising mining efficiency
A leading Australian company has invested in a fleet of Hitachi
excavators due to the expansion of its large-scale mining operations
and continued production growth. Watpac has long-term mining
service contracts for commodities such as iron ore, gold, mineral
sands and coal.
Its Hitachi fleet, supplied by Hitachi Construction Machinery
Australia (HCA), comprises several EX1200-6 and EX1900-6
excavators, and an extensive range of medium and large Zaxis
models, including the ZX250H-3, ZX350H-3, ZX670LCH-3 and
ZX870H-3. They are used across a number of Western Australian
sites, including Tutunup South Mineral Sands mine, established
by Iluka Resources, and Ramelius Resources’ Mount Magnet
gold mine.
Brendan Vaughan, Mining Manager for Watpac Civil & Mining,
says: “Watpac’s decision to purchase Hitachi machinery was
based on their reputation for reliability, strong support service
and cost-effective maintenance. Hitachi products have provided
us with excellent operating and maintenance performance. The
strong product support services have enabled us to minimise
downtime and maximise productivity.

A better view “The strategy for our excavator fleet is to aggressively work them
predominantly as production machines before reassigning them
to support roles. Hitachi provides us with excellent back-up and
Hitachi Construction Machinery, Co. Ltd. (HCM) has introduced product support through its reliable parts network, which helps us
a new camera monitoring system called SkyAngle. Developed in limit downtime and reduce warehousing costs.
conjunction with Clarion Co., Ltd, the system has been designed “In addition, Hitachi is an all-round winner with our operators
to enhance the safety features of the machines through facilitating and maintenance personnel. The former have been impressed with
multiple viewing options, one of which is a bird’s eye view of the comfortable cab environment and excellent visibility that have
immediate surroundings. been designed with the rigours of the mining industry in mind.”
The new technology takes synthesised images from several
wide-angle cameras mounted on the machine and displays them
in the cab. The operator can choose from either wide-angle or
close-up views to focus on vehicles. A parallel display option is
also available, showing one of these views next to a traditional rear
monitoring system image.
SkyAngle has been tested for durability, functionality and
performance on Hitachi rigid mining dump trucks. It will initially
be available on these machines, before being applied to other
products, such as ultra-large hydraulic excavators.
This is the latest development by HCM to enhance on-site safety.
In 2001, it was the first to launch a monitoring system featuring a
rear-view camera and display as optional equipment for excavators.
In 2006, HCM was the first manufacturer to introduce this type of
monitoring system as a standard feature on all hydraulic excavators
(6.5 tonnes or larger).
Greg Smith, Heavy and Mining Equipment Manager at Hitachi
Construction Machinery (Europe) NV, says: “The safety benefits
of the SkyAngle system are considerable. It allows operators to
quickly assess what is happening around the machine, such as the
position of other equipment, service vehicles or personnel. This
technology is another example of how Hitachi is able to produce
highly efficient and productive machinery for the mining industry
around the world, and continually improve on and raise the bar
regarding safety features.”

GROUND CONTROL 07
 NEWS
Hitachi strikes gold in Turkey
Several EH4000AC-3 rigid dump trucks and an EX5600-6 ultra-large
excavator will be supplied to the largest Turkish gold mine this year,
following an order by Tüprag Metal Madencilik Sanayi ve Ticaret AS.
The company is a subsidiary of the Eldorado Gold Corporation, a
Canadian mining company, which has developed the Kişladağ Gold
Mine, located in west-central Turkey between Izmir and Ankara.
Kişladağ mine began production in 2006 and is currently operating
as an open pit, heap leach mine with a throughput of 12.5 million
tonnes a year of ore processed. Plans are underway to increase the
mine’s production to approximately 33 million tonnes per year, which
will include a larger mining fleet using bigger loading and hauling
equipment.
The EH4000AC-3 rigid dump trucks will be run on a trolley assist
system and the EX5600-6 is an electric driven model. All the machines
will therefore be powered by an electric power line on site, reducing
fuel costs considerably. Although this kind of technology has already
been adopted by Hitachi customers in southern Africa, this will be the
first installation of its kind in the Middle East and Europe.
The new machines were due to be shipped individually from Hitachi
Construction Machinery Co., Ltd. in Japan from the start of 2013.
The open-pit mine already has two EX3600-6 ultra-large excavators,
which were delivered in 2006 and have developed an impressive
track record for their high levels of productivity.
Hitachi does it again
The first Hitachi ZX290LC-5 to be delivered in Belgium has made
a positive impression on Joris Roebben. His company, based
in Bilzen, took delivery of the Zaxis-5 excavator from the official
Hitachi dealer, Luyckx, in July 2012.
One of its first assignments was on a housing development in the
town of Genk, where it was required to lay 1.5km of sewage and
water pipes. Fitted with a 1.3m3 bucket and a special clamp, it lifted
pipes weighing up to 10 tonnes and manhole inspection chambers
weighing 12,000 kilos.
“We invested in this excavator because of its lifting capacity,”
said Joris. “I’ve been impressed by its smooth operation and swing
motion, thanks to the TRIAS hydraulic system. It is very responsive
and easy to maneouvre, and it’s also a quiet machine, which makes
it ideal for working in residential areas. Another advantage is that it
has excellent fuel consumption for a 30-tonne excavator.”
Joris has worked with several Hitachi models over the years, from
the ZX16-3 to the ZX290LC-5. His father started the company 26
years ago and bought the first Hitachi excavator 20 years ago. “The
advantages of buying Hitachi machines are the service we receive
from our dealer, Luyckx, the reliability and minimal downtime,”
adds Joris.
The latest addition to the J Roebben Hitachi fleet has proved to
be even better than the Zaxis-3 range. “The new Hitachi models are
always faster than the previous generation and the comfort levels
are improved. Every time Hitachi brings out its latest range, we
believe that this is the best machine yet, but then they do it again.”

08 Hitachi Construction Machinery (Europe) NV

 Merchandise

Ballpoint pens
(25 units) €50*

Photograph courtesy of Baublatt Österreich

Keychain €5*
From left, Ehrenreich Lechthaler, Area Representative of Baumaschinen
Handel, at the handover of the new Zaxis-5 to operator Rudolf Pfurtscheller

High expectations
The official Hitachi dealer in Austria, Baumaschinen Handel (BMH),
has delivered its first Zaxis-5 excavator to the country’s largest glacier
ski resort. The ZX250LCN-5 arrived at Stubai Glacier, known as the
‘Kingdom of Snow’, near Innsbruck, in June 2012.
The new model was customised by BMH for working at an altitude
of 3,000 metres and in glacial conditions. Before it could start work, it
had to climb from an altitude of 1,750 to 2,900 metres and completed Hitachi Performance Parts
the journey in five hours.
The ZX250LCN-5 was used for renovation work on the chair
Watch Rubber Strap
lift supports, which is necessary due to the melting of the glacier. Black cap €10*
Working in a glacial area can be hazardous due to rapidly changing
weather conditions, crevasses and moraines. It certainly requires an
experienced operator, such as Rudolf Pfurtscheller, who has worked
at the Stubai Glacier resort since 1973.
“I’m particularly impressed by the new ZX250LCN-5, in terms of
power, performance, durability and reliability,” he says. “The support
and customer service by BMH has also been impressive.”
This is the third Hitachi excavator to work on Austria’s glacier ski
resorts (the Pitztal since 1997 and Kaunertal since 2008). Among other
things, it was the positive operator experiences of these machines that
prompted Walter Müller to swap his previous excavator for the Hitachi
ZX250LCN-5.
“Hitachi excavators have already proven their performance, reliability
and stability at a height of 3,000 metres,” he says. ”The high altitude
did not present a problem for the new Zaxis-5 model with its powerful
Stage IIIB-compliant engine.” Available at www.hcmewebshop.com
*All prices include 21% VAT

GROUND CONTROL 09
 Interview

RISING TO THE
CHALLENGE
In April 2012, Yuichi Tsujimoto succeeded Michijiro Kikawa as President and CEO of
Hitachi Construction Machinery Co., Ltd. (HCM). Two months later, Mr Kikawa was
appointed as Chairman of the Board at HCM. Ground Control speaks to two of the
world’s leading construction industry executives about the challenges that lie ahead
in their new roles
HCM President Yuichi Tsujimoto

M r Kikawa has vast experience in the fields of manufacturing

and technology, having joined HCM in 1970 and been the
Director of Production Technology at Tsuchiura Works and Managing
Director of HCM’s Chinese operation. He also served HCM as Vice
President, Senior Vice President and Executive Vice President,
before being appointed as President in April 2006.
After six years at the helm of the world’s third largest construction
machinery manufacturer, Mr Kikawa has taken responsibility as
Chairman of the Board for a broader remit within HCM. His focus
has switched from the day-to-day issues involved in running a
global business to cementing the company’s relationship with
Hitachi, Ltd., with whom he also now holds a position on the board.
“My new role provides me with the platform to explore good
relations and more collaboration between HCM and Hitachi, Ltd.,”
says Mr Kikawa. “The priority is the development of technology
between the two parties. HCM is gaining invaluable assistance in
matters concerning intellectual property and electrical components,
and we are able to pass on our Global e-Service expertise throughout
the network of Hitachi companies.”
Mr Kikawa has worked closely with Mr Tsujimoto for some
time and so there was no requirement for a formal handover of
responsibilities. However, Mr Kikawa’s views are well known on
such important aspects of HCM’s strategy as localisation and
corporate culture.
“One priority remaining from my time as President is the need to
accelerate localisation,” adds Mr Kikawa. “Eighty per cent of the
company’s business comes from overseas markets. Therefore we
have to promote succession plans that will leverage diversity and
develop local people for specific jobs.
“It is important that all employees (Kenkijin) have the same sense
of values in order to pursue the company’s corporate vision. HCM’s
‘Kenkijin spirit’ highlights these values and the golden rule to be
respected by each Kenkijin in the workplace.
“This is a key factor in the drive for localisation through the three
Cs: the challenge; the customer; and communication. There may
be a difference between corporate culture in Japan and other
countries, but the basic principles are the same. Our aim is to share
these among our colleagues and hope that everyone continues to
enjoy their work.
“HCM is very precious to me, especially with the human
relationship enjoyed by my colleagues and I would like this
atmosphere to continue. I’ve worked with Hitachi for more than 40
years and my love for the company has developed over this time.”
Mr Tsujimoto joined HCM in 1979 and has had a long career

10 Hitachi Construction Machinery (Europe) NV

in production, having successfully held positions within the
Procurement Division. He was also HCM’s top representative in
China from 1999 to 2004, and more recently the General Manager
of the Development Group and Business Strategy Office.
“I have a serious responsibility within my new role, as well
as the opportunity to fulfill and realise myself through my work,”
Mr Tsujimoto says. “As President and CEO, I manage all the
company’s day-to-day business. For example, I am currently
presenting the 2011-13 mid-term business plan to all HCM
companies at home and abroad, including the factories.
“The company’s strategy varies according to each region and
what it needs in terms of product development. Our aim is to
understand these requirements and then manufacture products at
a location close to the customers. In addition to our 37 existing
sites, we will open two new factories in Brazil and Russia within the
next year.”
HCM has seven regions – Africa, the Americas, Asia Pacific, China,
India, Japan and Europe (including Russia, CIS and the Middle
East) – and the intention is to shape a structure for the marketing
of development in each region. There is already a development
engineering team in China, India and Japan, and the next target is
to further strengthen the development team in Europe.
“We rely on a dealer network in Europe and various subsidiaries
in the Asia Pacific region,” continues Mr Tsujimoto. “The dealers
should act like a ‘bridge’ between the manufacturer and the end
users. In addition, we have to enhance our maintenance and after-
sales services by cooperating with the dealers in each region.”
HCM is one of the few companies within the Hitachi group that
develops, manufactures and sells finished products to end users.
With many customers around the world, HCM has become the most
globalised company within the group.
This has led to HCM making a contribution to the Hitachi brand
according to Mr Tsujimoto: “‘Hitachi’ is proudly displayed on all
of our construction machinery. Many people come across these
machines and see the logo in everyday life. This is an example of
our significant contribution to the value of the Hitachi brand. It also
reinforces our vision of being a close and reliable partner all over the
world, complete with a workforce that shares the excitement and
challenge of the ‘Kenkijin spirit’.”
There is an increasing number of stakeholders for HCM to
consider in the development of its CSR policy. “We have to deliver
safe, high-quality products and services for our customers,” adds
Mr Tsujimoto. “Likewise, dealers require highly reliable products
and an appropriate level of support. We would like to continue to
develop a range of construction machinery that contributes to the
creation of affluent and comfortable societies.
“The international community also benefits from HCM’s demining
activities that help to restore rich land areas and people’s livelihoods.
More than 100 demining machines are making a difference to
affected areas in nine different countries and we will continue to
support this initiative.”
Furthermore, the environment is the driving force behind the strict
emissions regulations in Europe. As well as providing machines to
meet these requirements, HCM is also focused on the importance
of saving energy. “Last year we launched a hybrid excavator in
the Japanese market and we are currently testing this product in
Europe,” says Mr Tsujimoto. “Our aim is to further develop these
machines to enhance fuel efficiency and transfer this technology to
other machinery.
“There are electric machines already working in Japan. Hitachi
electric mining excavators and rigid dump trucks operate 24/7
all over the world. Battery powered excavators are also being
developed. This is the electronic and information-orientated era
and therefore we need to develop an electrical control system for
construction machinery. With this in mind, we have a big opportunity
to deliver even better products through our ongoing cooperation
with Hitachi, Ltd. ”
HCM Chairman of the Board Michijiro Kikawa
GROUND CONTROL 11
 Special feature
The ‘mother factory’, Tsuchiura Works

MADE IN JAPAN
Hitachi Construction Machinery Co., Ltd.’s (HCM) product range is manufactured within
a fully integrated and comprehensive production system. The construction machinery
produced at the company’s manufacturing plants in Japan is operated on a global basis
across a wide range of industry solutions. Ground Control goes in search of these
state-of-the-art facilities and takes an in-depth look at the production and assembly
operations at the ‘mother factory’, Tsuchiura Works

Managing production
HCM’s Tsuchiura Works factory – the largest facility of its kind in
the world – faced the biggest challenge of its history in the wake
of the Great East Japan earthquake (and tsunami that followed) on
11 March 2011. All production stopped with immediate effect and
it took a huge effort by the HCM workforce to restart work in April,
before normal operations resumed two months later.
“When the disaster occurred, it caused much trouble to the
supply chain as we obviously weren’t able to fulfill demand,” says
Production Management Centre Manager Takayuki Shiratori.
“Some of our suppliers were also affected and we had difficulty in
receiving the required number of parts for production. In addition,
there was some restriction on electricity usage between July and
September 2011.
“Despite all of this, we still managed to manufacture enough
units with revised shift patterns and extended working hours at
weekends and during holiday periods. Thanks to this massive
team effort, we managed to get back to normal by improving our
processes and adjusting plans accordingly. All of this helped to
overcome the serious issues caused by the earthquake.”
The Medium-sized Products Section of the Production
Management Centre holds responsibility for producing 10-40 tonne
excavators at Tsuchiura Works, planning everything required from
the order to the shipment of machines. “The sales team receives

12 Hitachi Construction Machinery (Europe) NV

HCM Japanese production and test bases

1 Kasumigaura Works
·
·
Operating since 1989
423 employees
·
·
178,000m2 site
Manufactures key components 5
Hitachinaka-Rinko Works
for Zaxis excavators
8
·· Operating since 2008
730 employees
2 Tsuchiura Works ··
181,000m2 site

·· Operating since 1966

3,429 employees
Manufactures large Zaxis and
ultra-large EX excavators, and

··
EH dump trucks
489,000m2 site
Manufactures medium and
large Zaxis excavators
6 Saitama Works
3 Ryugasaki Works ··
Business transferred in 2006

·· Business transferred in 2010

7 ·
40 employees
1,425m2 site
387 employees
··
258,000m2 site
Manufactures compact, medium
· Manufactures small compaction machines

and large ZW wheel loaders

7 Yamagata Works
4 Hitachinaka Works 5 ·· Operating since 1980

·
·
Operating since 2007
1
4
·
340 employees
100,000m2 site

·
275 employees 6
·
·
218,000m2 site
Manufactures large Zaxis and ultra-large 3
2 Manufactures ride-on compaction
equipment, recycling machines,
rubber crawler carriers and parts
EX excavators, and key components for
for Zaxis excavators
dump trucks, wheel loaders, crawler
cranes etc. 10

9 8 Urahoro Test Site

(see pages 18-21)
11
·· Operating since 1992
Six full-time employees,
plus other support staff
··
427 hectares
Tests mini, medium, large and wheeled
Zaxis excavators, medium and large
wheel loaders, and large AC-drive rigid
dump trucks

9 Shiga Production Centre

··
Business transferred in 1990
393 employees
·· 170,340m2 site
Manufactures mini Zaxis excavators

10 Nagoya Works

11 Osaka Production Centre

·· Operating since 2004
250 employees,

·· · 110,000m2 site
Business transferred in 1990
56 employees, ·
Manufactures crawler cranes,

··
foundation machines and truck cranes
12,620m2 site
Manufactures parts for Zaxis
and mini excavators

GROUND CONTROL 13
 Special feature
Production Management Centre Manager Takayuki Shiratori
orders from the various regions around the world,” explains Mr
Shiratori, who had previously worked for the after-sales team in
the Japanese domestic market after joining HCM in 1982.
“We then finalise the annual production plan to ensure that the
correct quantities of each model are manufactured. There are
some fluctuations to the sales figures after the plan has been
set and therefore it has to be adjusted on a monthly basis to
accommodate any changes in demand. Logistically speaking, the
production plan is then integrated into the schedule for the factory
as a whole.”
The role of the Medium-sized Products Section is to meet global
demand for Hitachi Zaxis medium excavators, the most popular of
which is the ZX200 (ZX210 in Europe). To achieve this, it sets the
target and liaises with the Assembly Section regarding the number
of each model required on a monthly and even daily basis.
The assembly process
There is an average of 53 Zaxis 10-40 tonne medium excavators
rolling off the mixed-model assembly line each day. HCM has the
capacity to produce 62 units by the team of 160 Assembly Section
workers across two shifts: 06.15 to 14.45; and 14.45 to 23.15.
There are 120 different model variations that can be produced
from the 32 base models in a cycle time (the amount of time that
must elapse between two consecutive unit completions in order
to meet demand) of 12-14 minutes. If the assembly line is on
14 Hitachi Construction Machinery (Europe) NV
Part of the truckframe team in the medium assembly group
schedule and the cycle time is being adhered to, then the base
machines can also be customised for specific orders at this stage.
HCM still produces its Zaxis-3 and Zaxis-5 models side by side,
although the former range is slowly being superseded. There are
three types of Zaxis-5 models, with different specifications in place
for the markets in China, other parts of Asia, America, Europe and
Japan to comply with the emissions regulations for each region.
The carefully planned assembly process starts with the upper
structure (mainframe) and undercarriage (truckframe) assembly
teams working in parallel. The two lines meet at the midpoint to
join the mainframe and truckframe sections, before the finished
product emerges from the base machine line.
Safety first
Ryo Nakajima has been the Manager of the Assembly Section
for medium and large excavators at Tsuchiura Works since 2011,
having moved from another factory within the HCM group two
years before. “We have a meeting every morning to ensure that
the assembly line runs smoothly that day,” says Mr Nakajima.
“If there are no issues to resolve, such as parts not arriving on
time, then I will continue my routine by inspecting the assembly
line. I’ve had a good day if there are no problematic issues arising
during the shifts.
“One of my main priorities is to plan for the method of production
by looking at how operations will run in the future and if we have
 Assembly Section Manager Ryo Nakajima

the capability to meet these. If the answer is negative, then we

make the suggestion to invest in new machinery.”
Mr Nakajima’s job is also to manage the factory in such a way
as to avoid risk. If something happens within his section and he
knows there is potential for this to escalate, then he will research
the surrounding issues with the aim of finding a solution.
“Safety in the workplace is of the highest priority,” he adds.
“This is reflected by the emphasis placed on this subject during
training courses, particularly for new employees.”
HCM’s production recruits spend their first few months of
employment at the Kasumigaura Training Centre. From April
to July, they attend lectures to improve their basic knowledge,
and from August to September, they take practical lessons at
Tsuchiura Works.
After the training has been completed, they join the Assembly
Section. There are four teams – mainframe, truckframe, inspection
and customisation – in the medium assembly group and three
teams – same as medium, except for truckframe – for the large
assembly group.

Teamwork counts
The Assistant Manager for the medium Zaxis mainframe and
truckframe teams is Kazuhiko Mori. There are 80 people in each
of these teams (40 per shift) and Mr Mori’s number one priority is
Safety is of the highest priority
also the safety of his colleagues.

GROUND CONTROL 15
 Special feature
Assistant Manager Kazuhiko Mori
“I ensure that the workforce follows the correct procedures and
take care of any potential risks on the assembly line,” he says.
“If there is a mishap, I deal with the outcome and then find out a
solution to prevent it from happening again.”
He is also keen to emphasise the importance of teamwork
instilled throughout the organisation: “The highlight of my job
is if we reach the targeted number of units for each day. This
is because it happens as a result of the combined effort of the
whole team to reach this goal. If one line stops for any reason,
perhaps due to a lack of parts or a faulty component, then we
can’t achieve it.”
Mr Mori joined HCM from another company in 1985. This is unusual
among large Japanese companies, which don’t typically reward
workers recruited later in their careers compared to those who
join straight from school or university. However, Hitachi evaluates
each worker’s ability on an individual basis and Mr Mori was made
Team Leader in 2003, before being promoted to his current role
in 2008.
HCM also presented Mr Mori with a Ko-sho (craftsmanship and
engineering) award in 2005. He wears the Ko-sho patch proudly
on his uniform, which depicts a chrysanthemum. This beautiful
flower has a special place in the hearts of many Japanese people
as a symbol of autumn (when it blooms most brightly).
It is clear from talking to Mr Mori that he has much respect
for his employer and Hitachi products. “I worked in the Design
16 Hitachi Construction Machinery (Europe) NV
120 different model variations can be produced from 32 base models
Centre for two years, when I took the opportunity to compare
our machines against those of our competitors. In my
experience, Hitachi machines are easier to handle and offer the
smoothest operation – this gives me a really positive feeling
about my work.
“I am also proud to work for a truly global company and
of the opportunities that I have had to travel with my work. I have
been to Indonesia, India, China, America and The Netherlands
to assist my colleagues in other Hitachi factories. The overall
aims were to pass on some of our experience of expanding
production and assist with the introduction of new products
on to the assembly line.”
The power of motivation
Mr Mori is ably assisted by Foreman Junichi Nakamura, who has
worked with HCM for the past 25 years since leaving high school.
He is also proud of his work with HCM: “Not only is HCM one
of the leading companies in the Hitachi group, but it is also famous
all over Japan. I am very loyal to the company and proud to say
that I work for Hitachi.”
After Mr Nakamura checks for absenteeism each morning,
he attends the daily team meeting. He reports on important
information relating to the production target, for example the
type of products that they will be assembling and if overtime
is required that day. He also provides feedback on the

previous day’s performance, especially if any issues arose and
what solutions were found to combat these.
Within each team, the workers are split into three units and they
are able to rotate their jobs within each unit. This helps the staff to
learn some of the 22 jobs on the assembly line and provide cover
in case of absenteeism.
To achieve the desired results, Mr Nakamura focuses on the
motivation of his team, which comprises of regular, temporary
and contract workers. “I prefer to handover responsibility to the
regular full-time employed workforce and I find that this helps to
motivate them. However, the temporary and contract workers are
targeted more with financial incentives.
“These groups have different purposes: the regular workers
wish to be promoted; whereas the temporary workers are
more motivated by money. Regular workers are also given the
opportunity to learn new skills on external training courses, which
helps them to improve their overall performance.
“Training also helps their decision-making capabilities. I’m really
happy when someone within my team is able to solve a problem
without my input. It is good to see them develop in this way.”
Mr Nakamura also reveals that there is a special chart that helps
to minimise the numbers of mistakes made on the assembly line.
“The chart is updated and assessed on a daily basis by three
inspectors, who look for potential problems. Mistakes can also be
found and reported back during testing procedures.
Foreman Junichi Nakamura
“If an employee makes a mistake, he must complete an
assessment form. If he makes ten mistakes over a three-month
period, then he must attend a meeting with his manager.
“The chart system is a huge motivation for every worker and
illustrates the huge emphasis that is placed on quality within the
Assembly Section. If a mistake is made, then we believe that it is
a positive thing, because it leads to the next success. Everyone
learns from their mistakes.”
The importance of the ‘mother factory’ to HCM’s overall
operation is undoubted. With a strong workforce in place, Mr
Nakajima and his team are confident that Tsuchiura Works cannot
only help HCM to overcome the most challenging economic and
climatic conditions, but also to continue capitalising on HCM’s
competitive advantage.
“Hitachi is currently number three in the industry,” concludes
Mr Nakajima. “However, if we continue to adapt to the new
technology that is available from other Hitachi companies, then
we can hopefully go on to become the global market leader.”
To receive a digital version of Ground Control with new movies,
please register online at www.igroundcontrol.com/subscribe/en
GROUND CONTROL 17
 Quality control

THE QUEST
FOR QUALITY
Quality is often used to describe many brands, products and services. The
construction industry is no exception and Hitachi Construction Machinery Co., Ltd.
(HCM) places great emphasis on the saying that “the race for quality has no finish
line”. Ground Control is given access to all areas at the Tsuchiura Works Quality
Assurance Centre and Urahoro Test Site to reveal the secrets behind the success
of Hitachi quality assurance

18 Hitachi Construction Machinery (Europe) NV

S ince its inception more than 40 years ago, HCM has maintained
a customer-focused quality assurance system based on
the ‘quality gleaning’ concept (named after an 1857 painting,
The Gleaners, by Jean-François Millet). This is a process in which
product defects are re-examined by revealing the underlying cause
and implementing further measures to prevent any reoccurrence.
In September 1995, HCM obtained ISO 9001 certification, which
verified and clarified its commitment to quality assurance policies.
It also established the Corporate Quality Assurance Division as an
umbrella organisation to ensure the quality of Hitachi construction
machinery. The Division formulates policies and sets targets for
product quality, develops strategies and specific measures for
implementing these, and oversees the actual execution.
In addition, the Quality Assurance Centre at the Tsuchiura Works
leads the actual guidance, awareness building and training activities
for the quality assurance divisions of each company within the
HCM group. In April 2012, the 405 staff at the Centre were placed
directly under the control of the Corporate Quality Assurance
Division to further enhance this systematic approach.
This Division now oversees the quality assurance programmes
at all of HCM’s global production bases. It is working to raise the
quality of all product lines, with the aim of implementing a uniform
‘Made by Hitachi’ global quality standard.
To do this, it collects comments and requests from customers
and Hitachi sales and service personnel. These are reported at a
monthly product improvement meeting – attended by the HCM
President – along with any relevant information from each quality
assurance department. After an investigation into the cause of a
problem, countermeasures are taken to prevent any reoccurrences
– not only for the product in question, but for all other similar
products too.
Masashi Takano is a Senior Engineer at the Centre, where he
works for the New Model Evaluation Section within the Corporate
Quality Assurance Division. He joined HCM after graduating in
engineering in 1991 and his current role is to test the Zaxis medium
excavator prototypes before the final models go into production.
“Firstly, we go to customers and research the conditions in which
they use the machines,” explains Mr Takano. “We also gather
information on any issues within the construction industry at large.
“Based on this feedback, we discuss the proposed specification
with the Design Centre, who then brief the Manufacturing
Department to produce the prototypes. Our team inspects and
tests these special machines under top security and secrecy at
Tsuchiura Works using a detailed checklist of ‘Hitachi standards’.”
There are up to 100 points on the Centre’s checklist, which fall into
three main categories: performance, which covers such important
points as fuel efficiency, productivity and front attachment speed;
reliability, which includes stress and endurance tests; and safety,
which is in line with ISO standards.
The Zaxis-3 and Zaxis-5 prototypes have been fitted with a
combination of orange and yellow panels, so that they don’t
resemble the finished product. An array of electronic equipment
has been installed within the cabs to extract the required data
from the machines, such as speed, hydraulic pressure, and oil and
water temperatures.
“Our overall aim is to ensure that customers don’t have any issues
with the machines when they are released on sale through the
dealer network,” says Mr Takano. “To achieve this, HCM’s priorities
are, in order of importance: safety, quality, delivery and cost.”

GROUND CONTROL 19
 Quality control
Mr Takano’s colleagues in the Quality Management Section ask
HCM’s suppliers for the supply of “perfect” parts and a quality
check is carried out upon delivery. After the parts have been fitted
to the assembled machines, a final check is made at the end of the
line to ensure that they are in pristine condition and perfect working
order. The finished and approved machine is then forwarded to the
stockyard for dispatch to the market.
When asked to consider what he enjoys most about his job,
Mr Takano says after due consideration, “I’m at my happiest when
I am thinking about a new challenge. A good example of this would
be the creation of a part for a new model that will enhance its
overall quality.
“The department’s main job is to detect any potential risks from
prototype machines, so that we can prevent any such issues
occurring in the market. So, our proudest moment is when we are
able to do this in the first instance and our customers avoid any
related inconvenience as a result!
“We check the machines on behalf of Hitachi customers. We
know that we have done a good job for them if the machines are
durable, reliable, easy to manoeuvre and allow operators to go
about their work effortlessly.”
The testing procedures at Tsuchiura Works have been a huge
success, so much so that these activities were expanded into
another facility. The restriction in terms of space at the factory led
Senior Engineer Masashi Takano
20 Hitachi Construction Machinery (Europe) NV
to the purchase of some land on Hokkaido – the second largest and
most northerly of the four main Japanese islands – in June 1990.
“We used to look after everything at the factory,” says Mr Takano.
“However, the Urahoro Test Site allows the capability of conducting
24-hour tests and large-scale activities in actual job site and
variable weather conditions.”
The remote Test Site is situated 50km east of the city of Obihiro
(see map on page 13). This rural region is subjected to temperatures
as low as -25°C and as high as 35°C.
Urahoro was opened in April 1992, with the first excavation tests
being carried out in September of the same year. A license has been
issued for excavation work on 153 hectares – the size of 30 Tokyo
Domes (a 55,000-seat baseball stadium in the country’s capital).
Up to 20 professional operators are hired from local construction
companies for the purpose of earthmoving from the hills and filling
in an adjacent valley.
There are six full-time Hitachi employees on the 427-hectare site,
which is up to 3.3km long and 1.8km wide at its furthest points.
Other support staff are employed to help manage the engine-test,
maintenance, office, catering and accommodation facilities.
Koji Otani has worked at Urahoro for the past eight years of his
20-year HCM career, having joined the company directly from high
school. Perfectly suited to his Assistant Manager role at the site,
he was previously employed in product development and testing
Assistant Manager Koji Otani

under the Quality Assurance Division, and product support for the
Japanese domestic market.
“Most Hitachi product lines are tested here,” says Mr Otani.
“These include Zaxis mini, medium, large and wheeled excavators,
medium and larger wheel loaders, and the large AC-drive rigid
dump trucks, all of which are available in Europe. However, the
large EX mining excavator range is still tested at the Rinko Works,
where all of these models are assembled.
“The dump trucks were first installed here in 2006 and the
landscape is currently being prepared to complete a 1km straight
as part of the test track with 10- and 8-20-degree slopes to
simulate mining conditions. This also helps the operators to carry
out durability tests 24/7.
“Our biggest achievement in recent times was the complete
development of the EH3500ACII. This was first dump truck to be
launched after all of the tests had been carried out here, rather than
in Canada where they had been completed previously.”
Stringent testing procedures are carried out, so that each model
can be launched with the same level of quality. The main tests are
for: durability, which includes an excavating and operating test from
1,000 to more than 10,000 hours, and a non-stop 24-hour swinging
test with a remote-controlled machine; stress, which incorporates
machines travelling along a bumpy test track, and being subjected
to a strength test by hooking the bucket to a fixed object; and
HCM’s 427-hectare Urahoro Test Site
performance, with measurements taken for such variables as
productivity and fuel consumption.
“We test a new machine against one with 1,000 hours during
the troubleshooting test,” continues Mr Otani. “The operator
records his ‘feeling’ about each machine and these comments are
evaluated against the number of working hours.
“If a problem occurs, then we will keep testing the machine to
assimilate the feeling from an operator’s point of view. This is the
best part of our job, because if we detect a fault here, then we can
help to ensure that it won’t happen in the market.”
Other uses for this impressive and versatile facility include:
Zaxis-5 end-user tests; supporting the development of advanced
technology, such as fleet management for dump trucks;
demonstration opportunities for Hitachi customers in Japan;
and other promotional events for the domestic market and local
community.
Perhaps the race for quality has no finish line for HCM, with
the continuous development of new and existing products for the
construction, mining and other related industries. However, with
hundreds of dedicated personnel carrying out tried-and-tested
techniques and procedures, the pedigree of high quality associated
with the Hitachi brand and product range will remain intact for this
and the next generation of construction machinery.
Dump trucks are subjected to durability tests 24/7
GROUND CONTROL 21
 Customer

NEW RECRUITS
Among the first Zaxis-5 models to be delivered in the UK are the ZX250LC-5 and
ZX470LCH-5 now owned by one of the country’s leading demolition companies, Hughes
& Salvidge Ltd. The Hampshire-based firm put the two machines to the test on a
challenging £600,000 project in its home county

W orking on up to 30 projects at any time, Hughes & Salvidge

carries out demolition and decommissioning for a variety
of blue-chip companies, major contractors and local councils
all around the UK. One of its most notable recent customers is
pharmaceutical giant Pfizer Group. It won the work to demolish
several buildings (including a warehouse, office block, boiler
house, workshops and outer buildings) at its manufacturing and
distribution site in Havant, Hampshire. The work was due to be
completed in December 2012.
Managing Director Martyn Burnett explained the challenges of
the project, which began in April. “This is a global pharmaceutical
company, so it is a high-profile job,” he says. “It’s a live site, where
290 Pfizer employees are still working. There is also a water
treatment plant that must not get damaged during the project,
because it allows the company to operate on a daily basis.
“It is also situated in a residential area, so we have to consider
the local community and only work between 8am and 6pm. Health
and safety is vital, and nothing can go wrong. The Site Manager
was handpicked to be here, the attitude of our workers has to be
100% right, and all the machines need to look good to create the
best impression.”
Hughes & Salvidge has a total of 20 Hitachi Zaxis excavators,
from five to 50 tonnes. Two of the most recent additions to its fleet
were working on this site during Ground Control’s visit in October.
The first ZX470LCH-5 in the country was equipped with a pulveriser
attachment, and the ZX250LC-5 had been fitted with a grapple
attachment. Both machines were supplied by the UK Hitachi Group
company, HM Plant Ltd.
“The larger model was used to crush reinforced concrete, which
had been pulled down by a ZX470LCH-3 high-reach excavator
with a multiprocessor attachment,” says Site Manager Wayne
Jeves. “The ZX250LC-5 was required to handle and process
materials from the demolition process, sorting them into piles
and loading skips. Up to 95% of materials will be recycled after
being transported 30 miles (48 kilometres) to Southampton docks,
and shipped to countries such as China and India.”

22 Hitachi Construction Machinery (Europe) NV

The ZX470LCH-5* uses significantly less fuel than the previous Zaxis-3 model

Martyn Burnett, Managing Director of Hughes & Salvidge

GROUND CONTROL 23
 Customer

The ZX250LC-5* is versatile and easy to use

As an indication of the amounts of material involved, between

September and October 2012, 143 tonnes of steel were removed
from the site and 100% of this was recycled; and 99 tonnes of
general rubbish were removed and 72% of this was recycled,
with the remainder going to landfill. “All hardcore materials will
be recycled,” adds Wayne, “and 1,500m3 has been removed
to date.”
Both Wayne and the operators on site have been impressed by
the performance of the Hitachi Zaxis-5 excavators on this project.
With 30 years of experience in the industry, Wayne began operating
machines at the age of 18 and has worked with Hitachi excavators
up to 80 tonnes.
“I think the ZX470 model has evolved over 30 years,” he says,
“I think it’s one of the best Hitachi machines available for this kind
Operators Gary Longyear and Philip Marsh have been impressed by
of work. It’s reliable, represents excellent value for money and the
the performance of the Hitachi fleet
support from HM Plant is very good.”
Operator Nick Winter agrees: “I’ve worked with Hitachi excavators
on and off for 30 years. I started with the old UH models in the early With such satisfied employees, Martyn can feel confident that
1980s and they have come a long way since then. Every model is he has made the right decision to continue investing in Hitachi
better than the last. excavators. He is equally passionate about machines and has been
“I’ve operated the ZX460LCH, then Hughes & Salvidge’s first operating them since the age of ten.
ZX470LCH-3 and now the ZX470LCH-5. The technology has been “I bought my first Hitachi excavator in 2002 for my previous
enhanced on the latest model, it’s also comfortable, and the fuel company, K&B Crushers,” he says. “It was an EX220, I had it up to
efficient Stage IIIB engine is another improvement. 18,000 hours and it was extremely reliable. It was maintained and
“Demolition is a hard life for machines, working 12-hour days,” he serviced properly, which I believe is the key to the performance of
adds, “but Hitachi excavators just keep going. I’d choose Hitachi any machine.”
over other brands because they are smooth and responsive, and Since then, Martyn has been convinced of the reliability of Hitachi
easy to operate. I think Hitachi has got it right.” construction machinery. “That’s the number one reason why I
Another Hitachi enthusiast is operator Philip Marsh, who has buy Hitachi,” he says. “The product itself is fantastic, the people
worked for Hughes & Salvidge for 20 years. He prefers working employed by Hitachi and HM Plant are easy to get along with,
with the smaller ZX250LC-5 to the ZX470LCH-5. “It’s versatile, I and the support they provide if something goes wrong is second
can work on smaller jobs for houses and bungalows, as well as to none.”
larger projects like this one,” he explains. “It’s a good, all-round Martyn joined Hughes & Salvidge in 2008 and K&B Crushers
machine and easier to use than other brands. The new three-pump became part of the Hughes & Salvidge group. In 2009, he became
TRIAS hydraulic system is really good. I like the fact that Hitachi Managing Director of the group, which now has 153 employees and
excavators are easy to control and comfortable, and I think they are encompasses Hughes & Salvidge, K&B Crushers, Aasvogel Waste
the best machines for operator training.” Management and recycling company H&S Metals.

24 Hitachi Construction Machinery (Europe) NV


The following year, the company opened a regional office in
Huddersfield in the north of the country, to add to the head office
in Portsmouth, and additional locations in Swindon (west) and at
Heathrow Airport (London). “The northern office has helped us to
double our annual turnover to £25 million,” says Martyn.
He is keen to continue developing the business over the next
five years and has plans to invest in a further four ZX470LCH-5
models in 2013. “The Stage llIB engine of the ZX470LCH-5 uses
less fuel than the previous model and results in a saving of tens of
thousands of pounds in terms of fuel costs,” he explains. “This is
the most important advantage of the new models for me.”
The new Stage IIIB low-emission engine of the Zaxis-5 range was
also an important consideration when tendering for work. “This will
allow us to work on projects in central London and to comply with
emission regulations that come into effect in the near future. By
investing now, we will be ahead of the competition.”
The growing Hitachi fleet of Hughes & Salvidge looks like
it will be a part of its continued success story, and not just in
the UK. “I’d like to achieve steady growth in the UK and overseas,
in markets such as Europe, Canada or Australia,” adds Martyn.
Up to 95% of materials from the site will be recycled
“I want to push the company into areas we haven’t even
dreamed about.”
Although it sounds like an ambitious plan, the fact that he’s
currently training for a climb up Mount Kilimanjaro in a few months
hints at Martyn’s determination to aim high and make things
happen. It seems that Hughes & Salvidge is on the right path
to reaching its international goals, with the support of an
experienced management team, expert operators and a reliable
fleet of modern machinery.
*Some modifications, such as the cab guard, were added by dealer HM Plant to
comply with UK safety regulations.
To see a movie of Hughes & Salvidge’s Zaxis-5
machines, please visit www.youtube.com/user/
HitachiConstruction. To receive a digital version of
Ground Control with new movies, please register
online at www.igroundcontrol.com/subscribe/en
GROUND CONTROL 25
 Customer

BRINGING
DOWN THE
COST OF
OWNERSHIP
The Hitachi Support Chain encompasses all of the manufacturer’s
after-sales services: Global e-Service, technical support, Hitachi Extended
Life Program (HELP) and Hitachi Parts. It has been developed to protect
customers’ investments in Hitachi construction machinery. Ground Control
visited four of German dealer Kiesel’s customers to measure the success
of this package and find out if it has helped to reduce their running costs

Hartmut Pieper, Managing Director, H Ehlert & Söhne (GmbH & Co.) KG
Hitachi fleet: two ZX16s, a ZX16-3, four ZX210LC-3s, two ZX210LCN-3s, a ZX250LCN-5, ZX280LCN-3 and ZX350LCN-3

E hlert & Söhne was founded in 1907 by Managing Director

Hartmut Pieper’s wife’s great grandfather, Heinrich Ehlert.
The Hamburg-based demolition and recycling company’s team
of 70 employees is currently being managed by the fourth
generation of the family, namely Hartmut and his brothers-in-law,
Christian and Matthias Strauch.
“Our fleet of Zaxis excavators receive a routine maintenance
inspection every 1,000 hours as part of the Hitachi Support Chain
service provided by Kiesel. We also have our own workshop in
Hamburg with a team of eight technicians. They carry out quick
repairs to the machines if they are damaged due to the nature of
our work on demolition sites.
“We buy Hitachi Genuine Parts from Kiesel. There is
excellent availability of these items and we can have everything
delivered directly as and when required. We know that these
parts have been designed to work with Hitachi construction
machinery for optimum levels of performance. Less expensive
imitation parts don’t provide the same peace of mind.
“The information received from Global e-Service helps us to
minimise any downtime or idle time. It’s useful to keep a track
of these statistics, so that we can work with the operators to
improve on-site productivity. It is also ideal for advising when
routine maintenance is required.
“For example, we are alerted by email if there is an issue with
the machine. We then check with the operator if he has seen this
on the multi-function monitor within the cab and then we agree
on the appropriate course of action. We can call Kiesel at any
time to ask for their assistance.
“In today’s market, we know that Hitachi is technically better
and more reliable than many of its competitors – it just works with
Hitachi! In our experience, there are fewer technical problems
with Zaxis excavators, due to their overall quality and how well
they have been engineered in Japan.”

26 Hitachi Construction Machinery (Europe) NV

 “The complete service
package from Hitachi
means that the total
cost of ownership is
of maximum benefit
to our company”

Peter Kögel, Member of the Management Board, Kögel Bau GmbH & Co. KG
Hitachi fleet: a ZX170W, ZX145W-3, ZX210W-3, three ZX280LCN-3s and two ZW95s

K ögel Bau was established in 1968 by Jürgen Kögel at its

current site in Bad Oeynhausen. The company’s general
construction projects are carried out by the current team of 180
employees (including 17 apprentices) under the management of
his son Frank Kögel. The emphasis placed on youth and
development – among other criteria – has resulted in Kögel Bau
being awarded the coveted ‘Grand Prix of Small and Medium
Businesses’ for 2012 by the Oskar Patzelt Foundation.
“We have a fixed cost for routine maintenance and servicing up
to 6,000 hours for our Hitachi compact wheel loaders, and crawler
and wheeled excavators. There is also an extended three-year
warranty in place for these models.
“The warranty package means that our machines are fitted with
Hitachi Genuine Parts. We believe and trust in the quality and
reliability of these components.
“Global e-Service is another strong element of the Hitachi
Support Chain programme provided by Kiesel. It is important
to know the location and fuel consumption of each machine. In
addition, it is useful to monitor any downtime, so that we can
calculate the degree of utilisation.
“Our aim is to work five days a week with no breakdowns, but
if there is an issue, then we know that there is a reliable solution
close to hand. Our partners, Kiesel and Hitachi, have never left us
high and dry.
“Having tested Zaxis excavators and ZW wheel loaders against
competitors’ machines, we decided on the Hitachi models due
to their power and performance, value for money and cost
effectiveness, as well as the after-sales service.
“We run the machines for up to five to six years, so the cost of
the machine over this life cycle is important. Fortunately, we know
that the complete service package from Hitachi means that the total
cost of ownership is of maximum benefit to our company.”

GROUND CONTROL 27
 Customer
Werner Ohlrogge, Managing Director, Heidemann Abbruch GmbH
Hitachi fleet: a ZX17U-2, ZX60USB-3, ZX210W-3, two ZX280LCN-3s and four ZX350LCN-3s
S iegfried Heidemann established Heidemann in 1982 as a
recycling company. A group of 12 companies is now run by his
son Alf and this incorporates everything from demolition to waste
disposal. After five years of demolition activities, Heidemann
Abbruch GmbH was launched as a separate company in 2007.
It is currently based in Himmelpforten with 17 employees (there
are 140 in the group) under the management of Werner Ohlrogge.
“Our Hitachi excavator fleet is covered by an extended
5,000-hour warranty. Everything connected with our after-sales
package is coordinated through Kiesel, as it’s easier for us to
call them and we always receive an instant response. We’re very
happy with the level of service all over Germany.
“The technicians always have a high level of knowledge that
is required to maintain Hitachi excavators. We know that the
manufacturer is behind the service provided by Kiesel and we
trust that we receive the full benefit of the advanced technology
in this way.
28 Hitachi Construction Machinery (Europe) NV
“Global e-Service
is an invaluable
tool to check each
machine’s exact
location and fuel
consumption”
“Kiesel uses Hitachi Genuine Parts for our Zaxis excavators
as part of the warranty package. We trust in the quality of these
parts and prefer that they are used for the added reliability and
peace of mind that they bring to our operation.
“Global e-Service is an invaluable tool to check each machine’s
exact location and fuel consumption from our head office. We
also like to monitor the number of hours that the machines have
worked each day and if they are working effectively.
“Overall, it is important that every aspect of Support Chain
works in unison. After 5,000 hours, we usually sell our equipment
and therefore want to know the total cost of each machine over
this period of time. We only operate Hitachi excavators and
are very happy with them. The machines offer a high level of
performance and are very durable, which is so important on
demolition sites.”
“The total cost
of ownership
is favourable
and we enjoy a
reliable service”
Hitachi fleet: two ZX8s, a ZX17U-2, ZX52U-3, two ZX85US-3s, a ZX135US-3, ZX170W-3, two ZX250LCN-3s,
a ZX280, ZX280LCN-3, two ZX350LCN-3s, a ZX470LCH-3 and a long-reach ZX870LCH-3 on order
M oß was founded as a transport company by Bernhard Moß
in 1963. The company diversified into earthmoving in the
late Sixties and demolition in the early Seventies. Markus Moß
took over from his father as Managing Director in 1995 and the
company currently employs 103 personnel. It moved to new
premises – incorporating a recycling centre – near Lingen in 2009.
“Moß has a full range of mini, medium and large Hitachi
excavators. We have arranged an extended warranty package
to cover three years/5,000 hours and a fixed price for routine
maintenance and service. This means that we know the fixed cost
of each excavator over the following three years.
“It is important for us to talk to one person at Kiesel, who
coordinates all of our after-sales support to cover every eventuality.
If an operator has a problem, he knows that he only has to make
one call and everything will be sorted out to our satisfaction.
“Hitachi Genuine Parts are also supplied as part of our extended
warranty agreement. This is important, as we know that we can
Klaus Nieweler, Operations Manager, Moß GmbH & Co. KG
rely on Kiesel to supply us with a full package to complement our
line-up of Zaxis excavators.
“The technical support, parts and warranty are elements of
Hitachi Support Chain that you would expect to be supplied with
any new machine. However, Global e-Service is a useful additional
tool. It is the best solution in the market compared to what is
offered by the competition.
“I’m impressed with the technology incorporated into Global
e-Service and the level of information that we have at our disposal.
This type of communication with the machine is very useful to our
business. It’s good to know which type of attachment is being
used and to assess the fuel consumption on a regular basis.
“Hitachi Zaxis excavators are excellent value for money and
offer an all-round care-free package. This means that the total
cost of ownership is favourable and we enjoy a reliable service –
no matter where we are working in Germany.”
GROUND CONTROL 29
 Dealer

A TEAM EFFORT
Belgium’s Hitachi dealer had great cause for celebration in 2012 with two special
anniversaries. Ground Control visited Luyckx to find out what has helped to make the
company so successful over the years, and discovered that teamwork played a huge part

30 Hitachi Construction Machinery (Europe) NV

 D uring our interview with Managing Director Jos Luyckx, the official
photographs from Luyckx’s 60th anniversary celebrations arrive
at the company’s headquarters in Brecht. As he quickly flicks through
them and describes the many highlights of the event, his pride in the
company’s achievement of such a milestone, and being able to share it
with 15,000 visitors, is evident.
The company’s largest ever open house in September 2012 also
marked its 30th year as Belgium’s official Hitachi dealer. One hundred
machines were on display during the two-day event, including several
new Zaxis-5 models for visitors to test drive, as well as the ZH200
Hybrid and EX1900-6 excavators.
“Our focus was on the operators, engineers and their families –
everyone was welcome,” says Jos. “The theme was ‘See the difference,
feel the experience’, and it was a great opportunity for our customers
to try new machines and feel the difference, particularly between the
Zaxis-3 and Zaxis-5 models.”
Among the visitors were senior representatives of Hitachi Construction
Machinery Co., Ltd (HCM) and Hitachi Construction Machinery (Europe)
NV (HCME), along with representatives from other national Hitachi
dealers, including the UK, Finland and The Netherlands. This gives
some indication of the high regard in which Luyckx is held within the
Hitachi family and industry at large.
A brief glance over the past six decades shows there is every reason
for Jos, his family and the 144 Luyckx employees to celebrate. The
company has come a long way since its humble beginnings in 1953,
when Jos’s father, Louis, established a firm specialising in forestry and
agricultural machinery. It entered the construction market some years
later and struck up a partnership with Hitachi in 1982.
By 1985, Firma Luyckx NV had established Hitachi as the market
leader in Belgium where it has remained ever since. Sales figures for
2011 show that its overall market share was 30% – 32% for crawler
excavators and 30% for wheeled excavators.
“We are proud to be market leaders,” says Jos, “but it’s difficult
to stay at the top. You always have to be aware of the competition.
Our competitors can be extremely aggressive in their strategy to take
market share from Hitachi.”

From left, Product Support Manager Patrick Claeys, Commercial

Director Pascal Vangramberen, Product Support Manager
The Luyckx family with the company’s 144 employees and the Hitachi EX1900-6 René Van Ginneken and Managing Director Jos Luyckx

GROUND CONTROL 31
 Dealer
So how has Luyckx managed to sustain such success and stay
one step ahead over the years? The answer has everything to do with
teamwork. This ethos extends throughout the Luyckx family, from Jos
and his two sisters, Paula and Chantal, who work in the financial and
parts departments respectively, to the whole company, from senior
management to the workshop. “Our company works as a team,” says
Jos, “and teamwork is crucial to its success.”
A strong team spirit is undoubtedly important for an expanding
national and international enterprise such as Luyckx. As well as locations
in Antwerp and Izegem covering the north and west of the country,
and two mobile product support units based centrally in Dinant, the
company also has a branch in Abu Dhabi to support its growing number
of customers operating in the oil and gas industry in the Middle East.
“We opened this location in early 2012 with four employees for the
office and parts depot,” says Jos. “We mainly supply cranes, excavators
such as the ZX870 and EX1200, and super long front attachments to
this market. The machines are prepared here at our 17,000m2 workshop
in Brecht, then shipped to the Middle East.”
The impressive facilities at Brecht have received a significant
amount of investment in recent years. Commercial Director Pascal
Vangramberen explains: “We have created a new training facility, with
a dedicated instructor who attended courses at HCME, to train our
engineers. There have also been considerable improvements to the
parts warehouse and office. We have invested €1.5million in machinery
over the past six years and are also constantly investing in smaller
welding machines.”
The state-of-the-art workshop allows Luyckx to make custom-made
modifications to machines if required. “This accounts for 15% of our
machine sales,” says Pascal.
“It’s very important for us to be able to give added value to our
customers. It usually applies to the larger machines, starting with the
The Luyckx offices and workshop are based in Brecht, close to the Dutch border
32 Hitachi Construction Machinery (Europe) NV
boom for instance, but we can offer a full range of modifications. The
larger the machine, the more complex it is to modify, but making the
impossible possible is the strength of the company.”
Throughout the course of its 30-year partnership with Hitachi, Luyckx
has appreciated the support it has received from HCME for supplying
special application and modified machines to its customers. “There is a
transparency of data from HCME and, during our long relationship, we
have appreciated the complete product support from the organisation,”
says Jos.
The relationship between the two companies is based on loyalty,
mutual respect and honesty. “Hitachi is loyal to its dealer network,” says
Jos, “even in financially difficult times. And we give them honest, open
feedback, and Hitachi appreciates that. Then our customers see that
Hitachi machines are the result of teamwork, that Hitachi listens to our
feedback – which is based on their comments – and acts upon it.”
The most popular Hitachi machines in the Belgian market include
those in the 20-tonne class and the ZX140W wheeled excavator. “The
market for short-tail machines is also growing rapidly, so the ZX135 is
another popular model,” says Pascal.
“The wheel loader market is extremely competitive, however, and
a difficult one to break. Still, the initial response to the new ZW250-5
from our customers has been extremely positive, particularly with the
feedback on its smooth operation.”
The reaction of Luyckx’s customers to the new Zaxis-5 excavators
has been equally positive. “Our focus has been on reliability, the
Global e-Service system, smooth operation and fuel consumption,”
says Pascal. The company is also focusing increasingly on after-sales
support due to a growing demand for service, repair and maintenance
contracts.
Product Support managers Patrick Claeys and René Van Ginneken
have worked for their department at Luyckx for 20 and 17 years
 Photographs courtesy of Luyckx
The demonstration area was popular among visitors to the open house event

respectively. “Customers are asking for service contracts more and

more, and their machines need to be maintained for several years,”
says René.
“We have delivered an EX1900-6 to the south of Belgium, for
example, with an eight-year contract. All our customers need to be sure
of long-term reliability, support, parts and service. We stand behind our
products, and our customers know that.”
“The success of Luyckx is due to the fact that it doesn’t take long to
make decisions,” says Patrick. “We work with the customer, we never
say ‘no’. We look at all the possibilities to find a solution for them – not
selling just what we have, but what the customer wants.”
Looking ahead to the future, the strategy for Luyckx is simple – just
to keep on going. “Our aims are to continue giving the best possible
service to our customers, investing in product support, and retaining
our talented technical people,” says Jos.
He also wants the company to continue expanding and its partnership
with Hitachi has its part to play in that: “We are proud to work with
strong, global and innovative manufacturers like Hitachi. It gives us,
as a dealer, the opportunity of a strong future, helping to stabilise our
turnover, maintain our market share and continue growing.”

To see a movie of the first ZX290LC-5 delivered

by Luyckx, please visit www.youtube.com/user/
HitachiConstruction. To receive a digital version of
Ground Control with new movies, please register
Luyckx has invested heavily in its workshop
online at www.igroundcontrol.com/subscribe/en
and training facilities in recent years

GROUND CONTROL 33
 Technical focus

TRIAS: UNIQUE
HYDRAULIC
TECHNOLOGY
The TRIAS hydraulic system has been heralded as one of the most technologically
advanced features incorporated into the design of the Zaxis-5 medium excavator
range. Ground Control meets Hitachi Construction Machinery Co., Ltd.’s Tsuyoshi
Nakamura, the man with the knowledge and expertise to develop this unique
concept into a reality

When did you join HCM?
I studied engineering at university and joined HCM after graduating in
1992. I started working in the Construction Equipment Development
Centre and am now the Manager of this facility at Tsuchiura Works.
I am a Senior Engineer, responsible for the 12-35-tonne medium
excavator class.
What is your specific role?
My specialty is hydraulics, such as the latest TRIAS system for the
new Zaxis-5 models. This has been my area of expertise for the past
18 years.
How is your team structured?
There are approximately 150 personnel involved in the overall
development of Zaxis-5 medium excavators. The Centre is divided
into several departments according to the device that they are
responsible for, such as the hydraulics, electronics, cab, software and
front attachment.
Why was the TRIAS system developed?
The main reason was to lower fuel consumption. We weren’t satisfied
by a 10% reduction and so our target for the 20-tonne Zaxis-5 model
was 20%. The only way to achieve this goal – while maintaining the
speed of the machine – was to reduce the loss of pressure in the
hydraulic system.
In addition, our target was to make the Zaxis-5 range even more
user friendly. We did this by making the new models easier to control
and more precise, especially for use in Europe, where so many
different attachments are used with each machine.
How did you achieve these goals?
To be more exact, the TRIAS system was designed with three pumps
– rather than the previous two – and a control valve. The pumps are
used for adjusting the amount of hydraulic oil and the control valve
is a hydraulic circuit for efficiently dividing the oil into each actuator.
We spent much time experimenting with these components to
find the best tuning point. Therefore, we are confident that the loss
of pressure has become less and the controllability has also been
improved with this new hydraulic system.
What are the benefits to the end user?
The owner of a Zaxis-5 machine will benefit from the reduced
running costs generated by the lower fuel consumption. This was
the driving force behind the development of TRIAS, even for Zaxis

34 Hitachi Construction Machinery (Europe) NV

 Figure 1
ZAXIS-3 HIOS III SYSTEM
Arm Swing Boom Bucket
Less restriction
Less energy loss
Pumps
Zaxis-5 medium excavators benefit from enhanced fuel efficiency,
while maintaining a high level of productivity. This has been
achieved by the introduction of TRIAS, which has increased the
efficiency of the hydraulics by reducing the loss of pressure in
the system.
Hybrid excavators to ensure that they were more efficient than our
competitors’ hybrid models.
In Europe, the operators will be happy with the enhanced level
of versatility if they use more than one attachment. The new range
also delivers increased productivity, as well as less stress and
fatigue on the operator, because it is easier to operate – this is vital
when working on long shifts.
What is the key to the new system?
The combination of the three-pump system and control valve is the
key to the new TRIAS system. If they were parts of the human body,
the pump would be the heart and the control valve would be the brain.
Without the control valve, there would be no advantage over the
old system.
Why is the control valve so important?
The control valve has been improved to cater for three pumps
and is therefore the most important part of the circuit. The tuning
system is a vital component in the TRIAS system, because without
it, there would be no efficiency in the control valve. This technology
is unique to the construction industry, and in my opinion, it is the
number one sales feature of the new Zaxis-5 medium excavators.
Why is this a good example of Hitachi advanced technology?
Hitachi places great emphasis on controllability, which is a vital
feature in today’s construction equipment. Other companies
produce control valves and pumps, but we are the only one to have
this level of expertise in tuning and none of our competitors can
easily copy this level of technology.
Why does TRIAS not feature in large Zaxis-5 models?
Installing the TRIAS system is a significant change for base
machines. It means that we need much more time and engineers to
Figure 2
ZAXIS-5 NEW TRIAS SYSTEM
Arm Swing Boom Bucket
Pumps
The conventional HIOS III hydraulic system (see figure 1) performs
combined operations by supplying pressurised oil through two
pumps with some restrictions in the system. However, with three
pumps, TRIAS (figure 2) is equipped to supply an adequate amount
of pressurised oil to each actuator.
complete products as the perfect machine. That is why we decided
to implement TRIAS into Zaxis-5 medium excavators, as they are
used across a wider range of applications.
How do you feel after developing the new hydraulic system?
At the moment, I take some pride in this achievement, however
I would like to receive more feedback from customers and
dealers around the world as the Zaxis-5 range has just
been launched.
I know that it’s not possible to achieve 100% positive feedback,
especially as there will be a learning curve for operators moving
from Zaxis-3 to Zaxis-5 models. It’s difficult for us to decide
on the extent of the success of TRIAS without the support of
the operators.
What is the next step in the development of hydraulic systems?
We’re looking at further reducing pressure loss in the hydraulic
system for even greater controllability and to improve the efficiency
of the components.
What do you consider to be your biggest achievement?
My biggest achievement is when I hear that the end users believe
the latest Zaxis model is an excellent machine. My proudest
moment has changed during the course of my career. For
example, when I was younger, I operated the machines and
replaced parts on a daily basis as part of the process to learn how
they work.
Now that I have developed the circuit for the hydraulic system,
I am really proud of bringing this concept to reality! Development
work is full of challenges and even some torment, but when I hear
of some positive feedback from owners and operators, it makes it
all worthwhile.
GROUND CONTROL 35
 Now available at
www.hcmewebshop.com
EW
N

ZX250LCN-5 Excavator
Scale 1:50