Beginnings in Zuffenhausen
“In a beginning, we looked around though could not find a automobile we dreamed of: a small, lightweight sports automobile that uses appetite efficiently. So we motionless to build it myself”, pronounced Ferry Porsche. Beyond a transparent thought of what a initial sports automobile of a Porsche code should demeanour like, a concentration of a association owner is right from a start on production. The beginnings are noted by a early post-war period. This is how a Porsche 356 “No. 1” Roadster and a tiny array of 52 manually made rear-engine sports cars of a 356 series. The prolongation plant is a sawmill converted into a seminar in a Austrian city of Gmünd. The Porsche employees can tumble behind on a few machines saved by a war. First and foremost, their primer skills are in demand. Since mass prolongation is not probable there, Ferry Porsche orderly in 1949 a pierce to Stuttgart-Zuffenhausen, that was given 1938 a chair of a pattern bureau founded by Ferdinand Porsche in 1931. Together with a Stuttgart Bodywork Reutter mass prolongation of a 356 starts in 1950. One of a several investments in a fifties was a construction of a complicated paint emporium in 1953. 1956 arise between 18 and 20 bodies a day.
Until good into a sixties, work is carried out in a tiny space in a evident closeness of a particular buildings. The prolongation has a manufactory character. Behind it distortion transparent ideas of fit production. Short distances for a particular components, cleanliness and method as good as a surpassing skills of a employees turn a substructure for a worldwide, to this day rarely reputable Porsche quality.
However, a demeanour into a prolongation also shows how a bodies of particular focussed and pulpy sheets are welded by hand. In addition, there is a formulation and tinning of a welds before painting. So, any physique becomes unique. And not usually are a routine and ergonomics still distant from today’s standards. An instance of this is a delivery designation on a 356: Three colleagues take a member pre-assembled with a spindle into their hands. One of them rolls on a behind onto a belligerent underneath a jacked-up back of a vehicle, he braces a delivery with his shin in a instruction of a automobile building and – while his dual colleagues reason a member to a spindle halves – screws it to a car. In a early sixties this is finished 30 times a day. The pre-assembled and painted bodies are changed on a bureau premises with electric luggage trolleys – identical to a ones used on sight platforms. During assembly, they rest on trolleys, that are manually pushed from one public area to a next. An concomitant label contains a required information about color, interior pattern details, additional apparatus systematic and other particular patron requests. This ensures even afterwards that each patron receives their possess particular Porsche.
Mass prolongation by labor division
1969 – 6 years after a trade satisfactory premiere of a 911 – a sports automobile public moves into new premises. The dual strew roof halls during Plant 2 have prolonged been too slight for a prolongation of a worldwide renouned sports car. Porsche has had a possess physique emporium given a finish of 1963 interjection to a squeeze of a bodywork specialist Reutter. The new public building on a Schwieberdinger Street offers space on 3 floors. On a second building a bodies are completed, on a building subsequent there is a final public and on a belligerent building peculiarity declaration and final acceptance. This multiplication has been kept to this day.
The construction of a building follows a thought of a prolongation upsurge and a public line is introduced. Meanwhile, a particular areas – such as physique construction, saddlery, engine construction and public – are spatially distant and well-structured. This creates space to optimize a prolongation upsurge and it increases a prolongation capacity. So, it is now probable to furnish 50 bodies a day and arrange 86 vehicles. In method to comprehend additional quantities, team-work with obvious suppliers, such as a coachbuilder Karmann in Osnabrück, has been established. There, a four-cylinder chronicle of a 1969 featured mid-engine sports automobile is fabricated subsequent to a bodies of a 911 and a 914. The six-cylinder sister indication is combined in Zuffenhausen. The 914 is followed by a four-cylinder transaxle models 924 and 944. Porsche moves their prolongation to Neckarsulm. The 928, that appears in 1977, is in turn manufactured during a headquarters.
As early as a sixties, it is foreseeable that electronic information estimate will play an augmenting role. The fixing of a 911 is – detached from a change of name from 901 to 911 – also due to a fact that Porsche traditionally uses a play and use network of Volkswagen. All other 100 array identifications for gangling collection classification and logistics are assigned by models of other brands. Accordingly, Porsche decides to use a 900s.
Production and prolongation routine are increasingly merging. An instance of this is a physique structure of a 911, in that – distinct a 356 – a front fenders are bolted to a automobile body. Porsche employees are still operative manually in a physique emporium to arrange a large-format sheets, such as a roof and a building of a car. In serve to a public line, public slides continue to be used, with that a vehicles in prolongation are pushed by palm to a particular public stations. Furthermore, pragmatism still depends during Porsche: for example, to facilitate a dire of rubber orientation in a spindle suspension, commercially available skin cream is used.
The skills of a colleagues sojourn a guarantor of a vehicles’ venerable quality. With innovations such as a use of hot-dip galvanized – and so immaculate – physique panels, Porsche set serve standards in terms of sustainability in a mid-1970s.
Efficiency and ergonomics with drudge assistance
Automation of prolongation comforts by a use of wiring and IT
For large-scale manufacturers, automation will boost until a 1980s. More and some-more robots are being used in production. But a high turn of automation is no pledge for success. In terms of grade of automation, Porsche has a lot of throwing adult to do in a late eighties. At a commencement of a nineties, Porsche brings prolongation specialists from Japan into a association to make adult for lost steps, that in a meantime brought a code into economically violent times. From this, a Porsche Improvement Process (PVP) is developed, which, in a brief time, becomes a benchmark in a Far East. From now on, Porsche stands for indication potency and superb quality. The “lean turnaround” creates Porsche fast essential and fit for a future.
In 1985, a enlargement of a public takes place, in that currently a two-door sports cars run off a public line. Production now takes place in two-shift operation. In a same year, a array of Porsche employees increasing by 1,403 to 7,915. The idea during a time was a burst from 81 to 100 vehicles per day. The following year, a new paint emporium is put into operation. Both employee- accessible workplace pattern and environmental insurance play an critical purpose in a planning. The ride of a embellished bodies into a public takes place entirely automatically around a joining circuit system, that relieves a bustling streets in Zuffenhausen. From now on, cathodic drop portrayal (CDP) is usually as standard, as are coatings with reduce well-off calm and other environmentally accessible processes. And robots are also being used by Porsche: In a paint shop, they are holding over a pursuit of PVC underbody protection. Just in time for a premiere of a Type 964, a third era of a 911, a new physique emporium is put into operation.
15 years later, Porsche produces daily 110 vehicles of a 911 and 40 Boxster array in Zuffenhausen. In a physique shop, 105 welding robots are now being used. Nevertheless, craftsmanship imagination stays in direct there as well. The sports automobile manufacturer describes a prolongation track in that automation helps a people, who still sojourn a focus. The association not usually achieves a worldwide repute interjection to a peculiarity and opening of a sports cars, though also by fit prolongation processes, a prudent interaction between partners, suppliers and logistics as good as production-oriented automobile development. In Zuffenhausen, Porsche is perfecting a complement of line production, in that a fibre of pearls is used to run opposite array and models in a colorful method over a same belt. Initially, these are a models 928 and 911. Today all variants of a 911 – including a motorsport derivatives – as good as a models Cayman and Boxster of a array 718 run by a same system.
As in 2002 with a Cayenne, a 911 and Boxster a third, in 2009 with a Panamera a fourth, and in 2015 with a Macan even a fifth indication array was added, Porsche expands in Leipzig. In a center of Germany, a complicated bureau is being built in a available location, with brief distances, optimal prolongation processes and inlet charge measures. Here is sustainability also really important.
Factory of a future
Hand in palm – stretchable and fit interjection to cleverly networked production
With a start of a Taycan production, a initial electric Porsche, a association takes a large step towards a “factory of a future”. In total, a association will deposit € 6 billion in electric mobility by 2022. Over 700 million will be used to build a Taycan prolongation in Zuffenhausen. The workforce participates in this destiny commitment of a code to a normal plcae by a staff pact.
“The concentration is always on people during Porsche. And for a foreseeable future, rarely particular vehicles will be built by people for people.”
Albrecht Reimold, Production and Logistics Board Member
The prolongation in a new bureau is named Porsche Production 4.0, and it follows 3 principles: smart, gaunt green.
“Smart” stands for flexible, cleverly networked prolongation by a use of new technologies. For example, wide-coverage, radio-based and battery-powered screwdriving collection are used. Thanks to integrated networking by real-time positioning, these work with a right torque each time they are screwed in position. Instead of a firm prolongation line, Porsche is a initial automaker in a universe to use driverless ride systems for a public of a Taycan. These offer a formerly different coherence in a workflow, though also for a architecture, that can be finished but formidable foundations with double floors, since a flexibly controllable AGVs usually need prosaic surfaces.
“Lean” means a many fit bureau pattern that minimizes rubbish and handling. Even a bureau formulation follows a proceed of gaunt production: for example, digital formulation methods were used for a source of a Taycan production. This allows a particular areas to be digitally imaged in allege and a operation of all systems to be probably simulated. This is one of a reasons that, after a trade satisfactory premiere of a Mission E Study, a opening of a bureau for a initial electric Porsche happens usually after hardly 4 years. The new bureau is built in together to a full-capacity prolongation trickery during a Porsche domicile with 250 vehicles of a 718 and 911 array per day.
The new prolongation also sets standards in terms of apparatus potency and sustainability, a third simple element of Porsche Production 4.0 – “green”. For a sports automobile manufacturer, it is a settled idea from a opening to set standards in terms of environmental friendship with a brand’s initial electric sports car. Porsche follows a prophesy of a “Zero-Impact-Factory”, a prolongation but environmental impact. Accordingly, it is obvious for a code to also furnish a locally emission-free vehicle in a CO₂-neutral manner.
The concentration is always on people during Porsche. And for a foreseeable future, rarely particular vehicles will be built by people for people. Modern technologies and digital assistance systems support and soothe a colleagues in their daily work. This also includes human-robot cooperations in that employees are upheld by robots and ergonomically relieved. In a paint emporium and assembly, a subject of ergonomics is also really important, explanation being for instance a 110-degree rotatable and forever height-adjustable automobile hanger or electronic automobile concomitant cards that surprise employees invariably about apparatus sum and work stairs on screens on a vehicle. An appealing work sourroundings promotes a intensity and creativity of a employees and so also creates a poignant grant to a standard Porsche quality.
Layout beliefs of Porsche Production 4.0
- Layout beliefs of Porsche Production 4.0
- AI-based decisions
- Adaptable processes and structures
- Situationally variable bureau control
- Flexible worker deployment
- Assisted and ergonomic workplaces
- Networked, communicating means of prolongation and products
- Resource-saving processes and technologies
- Problem solutions tighten to a shopfl oor
- Proactive qualifi cation and active regeneration
- Transparent, live and experienceable for customers