Background

Mercedes-Benz AG operates a forge for powertrain and chassis components at its Untertürkheim plant.

Mercedes-Benz wants to replace an old phosphating line while it is still in operation. The new plant is to be built parallel to the existing plant and then connected to the existing exhaust air, supply air and wastewater treatment systems. An old hall must be renovated for the new plant.

Mercedes-Benz commissioned PI with the detailing and implementation of the new phosphating line.

Results

• Fully automated, fully interlinked phosphating line put into operation, including
  • Batch system
  • Rotating drum containers
  • Gantry conveyor for transporting containers from tank to tank
  • 10 process-controlled tanks with respective process media
  • Bath heating from the district heating network
  • Continuous process and product data monitoring
• Approval documents for operation
• Integration into existing infrastructure (supply air, exhaust air, wastewater treatment)

PI services

Factory planning, process planning

Concept design
analogous to VDI 5200, phases 2 to 3

• Boundary conditions for the new plant clarified
  • Product range, capacity requirements
  • Hall
  • Media supply
• Layout Start created
• Master plan for implementation created

Detailing
analogous to VDI 5200, phases 4 to 5

• Technical details defined
• System technology specified, specifications drawn up
• System technology put out to tender, quotations obtained and prepared for award
• Interfaces with engineering offices for construction and technical development serviced
• Approval documents drawn up
• Budget and schedule drawn up
• Master plan for implementation drawn up

Implementation
analogous to VDI 5200, phases 6 and 7

• Details agreed with suppliers (R+I diagram, design, etc.)
• Interfaces with customers (planning, production, maintenance) and other suppliers or service providers (construction, media, crane service, etc.) coordinated, solutions developed
• Proper performance of individual services monitored and controlled
• Coordinated commissioning, defect rectification, MFU/performance tests and acceptance tests
• Monitored budget (investments)
• Recorded project progress: minutes, photos, schedule

Topics

Technology: Value stream, manufacturing processes, material flow, layout, plant engineering, media supply and disposal, control and monitoring technology, energy recovery, water protection

Trades

Charging, conveyor technology, phosphating, wastewater treatment, exhaust air, supply air, sound insulation, district heating