"ONE MAN - ONE ENGINE" MEETS "INDUSTRY 4.0"

OUR NEW M139 ASSEMBLY LINE.

The "One Man – One Engine" philosophy is a hallmark of the AMG brand. Each technician fully assembles an engine consisting of up to 570 individual parts. In recent years the complexity and variety of the engines has increased dramatically. Many engines have been assembled on the "One Man - One Engine" principle.

M139 – a new era for the engine manufactory

The decision made in 2016 to produce a 4-cylinder Performance engine – the M139 – was the starting point for the conceptual phase of the new assembly line with its future-oriented objectives:

Development of an ideal production concept according to the "One Man – One Engine" philosophy
Integration of Industry 4.0 technologies
A further 20% increase in efficiency

During the conceptual and prototype phase, the planning team followed the existing philosophy and focused on man and machine. The decision in favor of flexible and permeable line assembly with 100% baskets and a driverless transport system (FTS) was taken after examination and assessment of possible assembly and logistic concepts based on area requirements, profitability and future capability.

In the next steps the test stations were completely revised and minimized to 3 central stations, a major reduction compared to the 8-cylinder line. The basket principle so vital for the assembly and logistic concept was developed and perfected on the basis of several prototypes together with the CIP workshop in Sindelfingen. The same applies to the assembly carts and the accompanying IT developments.

The numerous individual components were combined into an overall concept for the new M139 production by the project team, as part of the conceptual and prototype Phase.

"Blue Sky": WLAN power wrenches with automatic operating fluid control. The new assembly concept employs the "Blue Sky" principle, with indoor tracking and the use of WLAN battery-powered wrenches. Operating fluid control is fully automated. The already outstanding quality standards have been further improved by the greater degree of automation.

Logistic supply of the workstations using baskets. The newly designed 100% basket allows completely rack-free provision of materials. All the components for engine-specific bill of materials are commissioned at the logistic center in Marbach, and the basket only includes the components needed for the relevant variant.

Driverless transport system (FTS) accompanies the assembly technician. The new concept uses driverless transport vehicles (FTFs) to move the basket in parallel with the assembly cart, and the line also has overtaking facilities. Autonomous control of the vehicles is by indoor tracking.

Test stations consolidated into central stations. The introduction of central stations significantly reduces the number of test stations and working procedures in M139 assembly. Here too, the processes are supported by the future-oriented use of FTS/ FTS, indoor GPS, WLAN bolting technology & tableaus.

JOB#1 – The future has already begun. On April 8, 2019 the new assembly line was ceremoniously handed over to Production by the planners. On an area of over 1500 sq. m., it will produce the M139 engines for the new 45-series models.

Although technological progress and greater automation in production plays a greater role in assembly operations, it is still people who dictate the pace. For more than six months, using "Day One Days", quality bays and line training, our technicians are comprehensively qualified and are currently assembling numerous engines each day.

We would like to thank the entire project team for this!

HOLD YOUR BREATH!

WE MAKE OUR COLLEAGUES STRONG.

HOME PAGE.