2018 Mercedes S-class Production. Production with future-oriented industry 4.0 solutions.

The start of production for the new and fundamentally updated S-Class brings the introduction of state-of-the-art manufacturing processes and cutting-edge Industry 4.0 solutions in the assembly area. “Within our global production network, the Mercedes-Benz plant in Sindelfingen is the centre of competence for upper-range and luxury-class vehicles. Within the production of the new S-Class, we combine the advantages of Industry 4.0 methods with the expertise and cognitive skills of our employees. The manufacturing of a perfect Mercedes-Benz S-Class depends on high-tech methods, but most importantly, upon the commitment and passion of our employees. We see evidence of that every day here in Sindelfingen,” says Michael Bauer, site manager and head of production at the Mercedes-Benz plant Sindelfingen.

Close integration with sophisticated IT systems and communication technology results in the optimisation of the flow of materials, further improved flexibility and efficiency, and enhanced ergonomics for the workforce. Examples of this are:

State-of-the-art data transmission and the very latest hardware solutions, combined under the heading of "paperless factory", now replace paper documentation. Screens provide staff with the information they need about the specifications of each individual vehicle. Additional mobile devices such as tablets, mini PCs and smart PDAs support the employees during each step of the work process.

An innovative tracking system detects vehicles in a virtual image of the factory in real time. Mounted transmitters can accurately identify the position of the vehicles on the assembly line and can exchange data with devices such as wireless Wi-Fi screwdrivers. This enables for example the electronic documentation of data, such as the torque, for quality assurance.

The flexible delivery of small-load carriers to the production line is ensured by a system known as FLOW (Flexible Logistics Optimised Warehouse). This new driverless picking system provides the supply of materials to the production line as and when they are needed. The whole system is currently part of a pilot test that aims to validate the system for series production for the new S-Class. The small-load carriers are transported autonomously around the shop floor via a guidance system with reference magnets embedded in the hall floor and can be automatically allocated to any specific storage shelf. Safety is paramount at all times: the driverless picking system is equipped with laser scanners for safety, which prevent potential collisions.

The delivery of components for the interior and engine compartment demands lean and efficient processes. More than 500 different items must be delivered punctually to the assembly line. The filling of the so-called 'shopping basket' represents the interface to the logistics area. It is pre-selected with all necessary parts and components required to fulfil the specific customer order and then delivered directly and completely automatically to the line, negating the need to keep materials stored on shelves. This creates more space around the assembly lines, reduces walking distances and keeps the workstations tidier and more ergonomic for the workforce. Whether the specific model is a Saloon with long or short wheelbases, a Mercedes-Maybach or a Coupé or Cabriolet: all variants of this luxury car are produced on one line.

VaMoS (Variables Montagesystem, or Variable Assembly System) is a new, variable assembly system. VaMoS is comprised of mobile platforms which are synchronised with the production line to carry a worker and his or her tools alongside the vehicle being produced. The technology, developed by Daimler, is not only responsible for improving the ergonomics of the task, but can also reduce manufacturing time and the time spent by the worker to get from one job to the next.

A recent addition helping to improve the ergonomics for the workforce working on the S-Class production line is the so-called ErgoSkid. This fully automatic device raises the vehicles on the assembly line by 26 centimetres and then lowers them again. Employees working on the installation of the cable harnesses for the floor assembly are able to benefit from this ergonomic improvement. The ErgoSkid is used exclusively in Mercedes-Benz production facilities around the world.

In the S-Class production line the automatic assembly of seal plugs is currently tested: an intelligent lightweight robot takes on the task of inserting the plugs in the underbody. Until now this was completed bystaff having to perform overhead work on the vehicle. In the future, this robotic solution will be used in the production line for a range of Mercedes-Benz models and will thus make things easier for the workforce.