An internationally operating OEM in the premium automotive sector intends to build its first assembly plant in accordance with the latest Industry 4.0 standards. As a global pilot project, the plant will also be realized on an empty site under the aspects of existing best practices and the Greenfield approach.
A new way of thinking
An integral part of the project – a blueprint for a 360° connectivity of supply chains as well as the digitalization of modern production processes – is to be developed. The blueprint should also be applicable to future car assembly plants.
Up to this point, there have been isolated technology trials in individual plants – but no extensive networking of several technologies in the production environment.
This is how the challenge was addressed
- Building IoT capability
- Applying flexible AGVs
- Networking assembly lines and conveyor technology
- Installing an intelligent and automated picking system that loads baskets of goods
- 100% paperless
- Big Data Analytics for continuous process refinement
The following benefits were achieved for the OEM
- 360° networking throughout the entire value chain: real-time exchange with suppliers
- Real-time availability of production-KPIs for all management levels
- Fast and transparent communication between R&D and Production
Flexible, digital, efficient, and sustainable:
The Factory of the Future embodies the future of automotive production. Production volume, material flow, and the number of models produced – from conventional to plug-in hybrid and electric drive systems – can be integrated into series production in just a few days.
With a 25 percent increase in efficiency compared to previous assembly, it sets new standards in the car industry.
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Dr. Gunther M. Wagner