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Porsche AG: Project Shipping Department Axles at the Zuffenhausen Plant

2022; Springer International Publishing; Linguagem: Inglês

10.1007/978-3-658-35882-2_9

2365-6395

Karsten Seidl, René Baron,

Flexible and Reconfigurable Manufacturing Systems

At Porsche AG's main plant in Zuffenhausen, which has been in operation since 1954, currently, approximately 3100 production employees (including salaried employees) work in two shifts, five days a week. True to the Porsche production system, 200 vehicles of all sports car derivatives of Carrera and Boxster series are manufactured daily on a mixed production line. The core of the Porsche production system is produced according to pearl necklace principle, in which the sequence of assembly of individual vehicle orders is determined as early as eight days before start of assembly and is consistently adhered to. Another key aspect is the lean arrangement of pre-assembly operations in close proximity to final assembly site. Pre-assembly of various modules is synchronized with the assembly cycle. Since 2012, the Boxster and Cayman series have been manufactured in a production network with the Volkswagen site (VW OS) according to same principles. As part of connection of Osnabrück production site, a shipping department had to be designed and implemented for the component delivery of axles at the Zuffenhausen site. Following Porsche production principle, it was decided to manufacture the axles for both sites on the same pre-assembly lines and to locate the shipping department in direct vicinity of last pre-assembly step. Shortly before planned start of the project, significant changes in general conditions arose and resulted in higher volume of work than originally planned. This was to be carried out before planned commissioning of the shipping department. Starting with a description of project organization set up and the project management instruments used, practical experience with their application is presented as an example. This experience report is divided into three phases—conception, detailed and implementation planning, and realization and handover. Finally, factors are derived that made the project a success or from which conclusions (lessons learned) can be drawn for future projects.