For the first time Mercedes-Benz Cars gives a deeper insight in the "Factory 56". The German Premium carmaker explains the concept and the basic operating principles of one of the most state-of-the-art automobile production halls in the world.
360-degree networking – from the supplier to the customer
However, networking not only happens inside the factory. A significant feature of "Factory 56" is the all-round networking across the entire value-added chain – from development and design to suppliers, production and customers. In coordination with our suppliers, we use the benefits of tracking and tracing, for example, which allows load carriers to be traced digitally around the world. Tracking and tracing enables early detection of discrepancies in the supply chain and thus a quicker reaction time.
We are already connected with our customers today: Under "Digital Anticipation" in the Mercedes me app, customers purchasing new vehicles can gain exclusive insights into the production of their vehicles. For research and development as well as production, 360-degree networking means quick and transparent communication across all units. Digital tools are used for development and production, for example, production processes are visualised and optimized by "Virtual Reality" (VR) before a real production hall comes into existence. For example, the workstations and processes can be virtually tested and designed ergonomically.
Work of the future – focus on people
"Despite state-of-the-art technology and innovative Industry 4.0, in 'Factory 56' the focus is as always on people. Our employees' expertise, flexibility and high level of motivation are the key to our success, and that applies to periods of transformation and digitalisation. This is, why we are cutting back on the level of automation in 'Factory 56' and creating the framework conditions to ensure that working in production continues to be fun", Schäfer clarifies. To sustainably shape the production of the future, an innovative working organization and new working time models will be developed along with the works council. The aim is to reconcile the company's requirements with the employees' requirements via sustainable and practical solutions: While the company wants to increase flexibility, capacity and extend the operating hours, employees are often concerned with gaining more freedom for personal matters with flexible working times and places that can be arranged at short notice. In this context, a model for flexible teams, the so-called Pool of Shift Employees, is currently being tested. This means that an employee's wishes regarding his/her shift plan depending on his/her personal situation can be better taken into consideration, thus promoting a balance between family and professional life. It is conceivable that one-day employees will be able to choose their working hours via an app.
"Green production" – CO₂-neutral electricity supply
All German Mercedes-Benz Cars plants will have a CO₂-neutral energy supply by 2022. New plants worldwide are already planned with this premise. "Factory 56" will already have a CO₂-neutral energy supply upon commissioning. There is a photovoltaic system (PV system) on the factory's roof, which feeds self-generated green electricity into the hall's supply. In addition, there are a number of measures for reducing energy consumption. Approximately 40 percent of the roof's surface will be extensively planted. Apart from offsetting impervious surfaces and aiding rainwater retention, this also translates into an improved interior climate in the hall. The hall is particularly translucent. The Blue-Sky architecture supports a pleasant working climate for the employees using daylight.
"'Factory 56' in Sindelfingen is the blueprint for all our future vehicle assembly halls around the world – this applies both to our existing plants as well as new locations", Schäfer states of future prospects.
