Mercedes-Benz plots the most modern car plant of the future

Mercedes-Benz Cars today had the world premier of its 'Factory 56', at its Sindelfingen plant, which it bills as the most modern car production in the world.

"Our ‘Factory 56’ will define a new way of building cars. With its ‘Factory 56’, Mercedes-Benz Cars is creating the car plant of the future. It combines three trend-setting features: It is consistently digital and flexible - and it brings the term ‘green production’ to life. As the inventor of the car, we are reinventing production," says Markus Schäfer, Member of the Divisional Board of Mercedes-Benz Cars, Production and Supply Chain.

The construction site of Factory 56. In 2020, the plant will begin production of upper- and luxury-class cars and electric vehicles at the Mercedes-Benz Sindelfingen plant.

In 2020, the Factory 56, which is spread across 220,000 square metres, will start production of upper- and luxury-class cars and electric vehicles at the Mercedes-Benz Sindelfingen plant. Passenger cars, electric vehicles of the upper and luxury class and robo-taxis will be produced. These include the new generation of the S-Class as well as the first electric vehicle of the product and technology brand EQ 'made in Sindelfingen'.

Latest production technologies in series
Mercedes-Benz says the production concept of the Factory 56 is setting new standards. This includes man-machine-cooperations and digitally supported processes including work organisation as well as logistics and quality assurance. The plant is not only digitised consistently according to Industry 4.0, it is also connected to other productions in the global production network.

The 360-degree linkage along the whole value chain is an essential feature – from the suppliers, through to the development department, design and our production and to our customers. In the future, for example, the finished vehicles shall drive off the line automated to the loading station. Under 'Digital Anticipation' in the Mercedes me App and online, customers purchasing new vehicles can already today gain exclusive insights into the production of their vehicles and thus have a much more enjoyable wait for delivery.

In the assembly hall itself, state-of-the-art Industry 4.0 technologies are used. Driverless transport systems (DTS) with product baskets support logistics in the assembly and ensure the seamless supply of the required materials for the employees at the line. Innovative Radio Frequency Identification-technologies (RFID) are integrated into the Factory 56. Components and vehicles can thus be digitally tracked and linked with one another.

Artificial Intelligence, Big Data analyses and Predictive Maintenance guarantee high transparency and support in production planning, control and also in quality assurance. Through the analysis of existing production data, for instance, predictions on potential faults or due maintenance work can be made in advance.

Human ergonomics at their best
The human is at the centre of all activities in the Factory 56. The employees work at ergonomically optimised workstations and are optimally supported in their tasks by digital tools. The focus is on the use of intelligent, flexible technology. A new work organisation provides for flexible and modern working time models. The break areas are designed according to the latest standards – for example with a pantry, couch and info screen.

Sustainable and energy-efficient facility
Factory 56 is all about modular building structures which have a design that is both energy-efficient and green, so environmentally friendly. The assembly uses renewable energies and reduces CO₂ production, water consumption and waste significantly.

The roof has a photovoltaic system which feeds green electricity into the production supply. This leads to a reduction of yearly 5,000 MWh of electricity. An electric vehicle of the product and technology brand EQ, for example the electric SUV EQC, could be charged 72,000 times a year with this. That corresponds to around 36 million kilometres mileage a year. CO₂ emissions at the Factory 56 will be reduced by 75 percent compared to today's S-Class production in Sindelfingen.

The construction of the assembly hall is very translucent. The Blue Sky architecture supports a pleasant working climate for the employees in daylight. In addition, the temperature of the hall can be set at up to seven degrees below the outside temperature.