Background

MAN Truck & Bus, a brand of the TRATON Group, is a leading manufacturer of diesel engines and produces more than 100,000 units annually at its Nuremberg site. MAN assembles the engines on three lines according to size and complexity. 

The V engines and particularly complex inline engines are to be assembled on a separate line.

MAN commissioned Projektingenieure (PI) with the design and detailing of the new assembly line, taking into account the MAN production system.

Results

• Flow assembly with JIS material supply via logistics train
• significant reduction in throughput times and increase in productivity
• Capacity expansion, relief of assembly of in-line engines

PI services

Factory planning, process planning, logistics planning

Concept design
analogous to VDI 5200, phases 2 to 3

• Flow assembly with defined assembly content per station, including pre-assembly (assembly priority chart)
• JIS supply warehouse > Order picking > Transport to assembly > Assembly buffer simulated and designed: frequencies, containers, control principles, buffers/stocks
• Assembly kits defined for JIS just-in-sequence delivery to pre-assembly or main assembly 
• Layout and material flow created for the new assembly line
• Conveyor technology designed: assembly trolleys, hoists, logistics train 
• Personnel requirements determined 
• Implementation schedule drawn up

Detailing
analogous to VDI 5200, phases 4 and 5

• Detailed assembly lines and stands
  • Machine layout plan created, in 2D and partly in 3D 
  • Plant and operating resources list created 
  • Plant technology specified
• Assembly trolley specified and prototypes put out to tender 
• Technical and organizational support for prototype construction 
• Plant engineering put out to tender and prepared for award 
• Budget and schedule created

Topics

Factory planning: Value stream, production segments, material flow, layout, facilities/infrastructure/buildings, cleanliness, environmental protection

Process planning: Plant engineering, simulation of capacity requirements, automation, interlinking, Industry 4.0

Logistics planning: Material supply strategy by part, simulation of movements/inventories, conveyor technology: Warehouse technology/transport technology, order picking technology, fire protection

Trades

Assembly lines, pre-assembly, main assembly, assembly technology, hoists, automation, interlinking, assembly trolleys, AGVs, logistics trains, dynamic supermarkets, automatic route train loading, production buildings, infrastructure