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FAStplant® in India – Production at BMW with innovative assembly system from Dürr FAS

04/12/2007

Stuttgart, April 12, 2007 – BMW has opted for FAStplant^® the modular final assembly concept from Dürr Factory Assembly Systems (FAS) for its new production facility at Chennai. Assembly of BMW 3 Series models began there in February of this year, 5 Series models are to follow in May. 

BMW chose flexible FAStplant^® Assembly Kit for the company’s CKD assembly line at its new location in the growth market of India. The system’s standardized modules provide assured flexibility in adapting to changing process and capacity requirements.

The fact that installation time would be cut by a third and process risks minimized was decisive for BMW. Pre-assembled and pre-tested FAStplant^® modules enable commissioning to be carried out quickly. For BMW this meant, in real terms, an installation and commissioning period at Chennai of only eight weeks.  

FAStplant^® Assembly Kit is a fully-expandable total solution that can supply everything - even down to pneumatic screwdrivers. The modular system is independent of the building, in which it is installed, each module being a self-contained unit. The basic module is made up of a self-supporting steel structure and all mechanical and electrical overhead conveyor elements – in the case of BMW this is an electrical monorail system (EMS). Utilities, such as compressed air, lighting and power, are fully integrated in each module. In addition it is possible throughout to incorporate suspension systems for the handling tools required for the various operational cycles.

In total Dürr FAS has supplied 14 FAStplant^® modules, each measuring 6 x 5.4 x 7.5 meters. Vehicles weighing up to 2.5 tons can be conveyed even through the basic module version. The 14 assembly modules are arranged in an oval-shaped loop and vehicles are transported from operational cycle to operational cycle by 4 EMS hangers, each equipped with a scissor lift so that the vehicles can be raised or lowered to the optimum height for each different task. 

This order underscores for Dürr FAS the successful development of its business in India. Dürr has had its own team of experts there since 1997, working to Dürr’s global standards. Dürr India Pvt. Ltd. carries responsibility, under an internationally experienced project management team, for utilities equipment, installation and electrical installation for this project. 

FAStplant^® provides sustainable support in meeting increasing calls for flexible and rapidly adaptable final assembly equipment. As early as 2004 DaimlerChrysler purchased FAStplant^®  for its Sindelfingen facility. In November 2005 Toyota started up operation of a FAStplant^® line at its factory in Valenciennes in northern France.  Since October 2006 Audi has also been assembling its new R8 luxury sports car at Neckarsulm in Germany with FAStplant^®. At present three other OEMs also have final assembly facilities under construction using this modular system.  

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.