Final assembly system on tour
07/05/2007
Stuttgart, July 5 2007 – They were first installed in the spring of 2004 – in a building used for R&D trials situated close to the DaimlerChrysler factory at Sindelfingen. “They” were FAStplant® assembly modules supplied by Dürr Factory Assembly Systems (FAS). These modules, like all FAStplant® modular plants, can be dismantled and re-assembled in a matter of days and in this particular case the plant will shortly be relocated for a second time – something that would be unthinkable for a final assembly line of conventional design.
DaimlerChrysler was the first customer to greet the idea of modular assembly systems with enthusiasm and that enthusiasm is certainly paying off. FAStplant® modules are pre-assembled and pre-tested so commissioning is fast, they are independent of the building in which they are installed and each module is a self-contained unit. A module is basically made up of a steel support structure mechanically and electronically equipped with a Dürr TTS (Twin Trolley System®) conveyor. Each module is fitted with lighting and includes connections for compressed air and power supply lines. FASmotion, Dürr’s non-contact system, is utilized for energy and data transfer.
Modular FAStplant® units were ordered by DaimlerChrysler to be set up as a pilot line at the test facility near the company’s Sindelfingen factory. The line was installed in March 2004 within a period of three weeks. The fact that installation was optimized through the pre-assembled modules and that the planning process was also simplified were significant advantages contributing to minimizing the time line.
DaimlerChrysler used the pilot line to standardize vehicle assembly stages and to define smooth and efficient processes. Once the “Standard Assembly” project was completed in December 2005 the test facility had to be cleared for other purposes. This was no problem with a FAStplant® line! Within three weeks it was relocated to the assembly section for C series models in Building 30 at the Sindelfingen factory. The relocation exercise highlighted even more of the advantages offered by FAStplant®. Plant planning engineers and plant users saw the benefits of having a uniform conveyor system throughout. It eliminated not only interfaces with structural steelwork for the building but also the need for pits and conveyor transfer points – and it was also very flexible in its utilization. With these modular plants no difficulties arise when changes have to be made to suit different cycle times or in the integration of model variants.
Because of FAStplant® ‘s flexibility, DaimlerChrysler has now decided to relocate the line for a second time. On this occasion the journey will even involve a “stop-over” – and again, as a result of the line’s modular design, this will pose no problem. The plant will be dismantled at the beginning of July and moved to Building 42 where it will be stored until February 2008. In March 2008 the FAStplant® modules will then be installed for a third time. On the basis of past experience, this is likely to be yet another smooth exercise as, even should adjustments in levels of automation be required or individual modules need to be added or removed to facilitate changes in production capacity, these can be carried out quickly and cost-effectively.
FAStplant® fulfils an increasing demand for final assembly systems offering sustainable flexibility and ease of modification. Six other vehicle manufacturers, in addition to DaimlerChrysler, are already working with this innovative system. They include Toyota at Valenciennes in Northern France, BMW at Chennai, India and SeverStal Auto at Elabuga, Russia. Since October 2006 Audi has been using FAStplant® for the production of its new R8 luxury sports car at Neckarsulm. FAStplant® is moving into high volume production too – Dürr is currently working on the construction of a 30 job per hour line that will be extendable to handle a capacity of 60 jobs per hour.
The Dürr Group is one of the world's leading suppliers of products, systems, and services for automobile manufacturing. Its range of products and services covers important stages of vehicle production. As a systems supplier, Dürr plans and builds complete paint shops and final assembly facilities. Dürr also delivers cleaning and filtration systems for the manufacture of engine and transmission components as well as diagnostic and balancing systems for vehicle components. Around 90% of Group sales relate to business with automobile manufacturers and their suppliers. The machinery, chemical, pharmaceutical, coating and aviation industries are also major customers of Dürr.
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Dürr Systems GmbH
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