Background

SMA-Metalltechnik GmbH in Backnang ("SMA") manufactures high-leak-proof aluminum tubes for cooling media in the automotive sector, such as interior air conditioning and battery cooling. In addition to its main plant in Backnang, the company operates further production sites in Halle (Saale), Romania, China, and South Africa.

SMA received a major order for coolant tubes for an electric vehicle from the VW platform and would like to set up fully automated production with highly efficient logistics for this purpose. The production process includes the following steps: welding, mounting sealing rings, plug pressing, 3D bending, mounting sensors, leak testing, automatic final inspection, and packaging. Seven customized production lines are required for a (vehicle) set of 14 different lines.

SMA commissioned PI to design and implement the new production lines, the new plant layout, and the new intralogistics.

Results

• New production lines and new intralogistics systems put into operation
• Production lines
  • Fully interlinked, with internal buffers and infeed/outfeed stations 
  • U-shape for good accessibility and simple logistics
• Intralogistics with
  • E-Kanban (new) within existing ERP 
  • Route train with KLT trolleys for KLT towers on roll dollies and shelf trolleys for crates/containers 
  • Supermarkets
• Overall layout including construction stages for the plant

PI services

Factory planning, logistics planning, process planning

Concept design
analogous to VDI 5200, phases 1 to 3

• Simulated and designed capacity requirements, material flows, and logistics areas in scenarios 
• Created logistics concept (control principles, material flow, staging areas) 
• Designed conveyor technology and picking technology 
• Created layout for production lines, logistics areas, infrastructure, and entire plant 
• Determined investments for logistics

Detailing
analogous to VDI 5200, phases 4 and 5

• Conveyor technology detailed, specifications drawn up, quotes obtained and coordinated 
• Budget and schedule drawn up 
• Interfaces with engineering firms for construction and technical development serviced 
• Layout continuously updated

Implementation
analogous to VDI 5200, phases 6 and 7

• Technical details agreed and finalized with suppliers
• Proper provision of individual services monitored and controlled
• Interfaces with customers (planning, production, maintenance) and other suppliers and service providers (construction, media, logistics, etc.) coordinated

Topics

Factory planning: Value stream, production segments, material flow, layout, scalability, step-by-step expansion, facilities/infrastructure/buildings, cleanliness, environmental protection

Process planning: Plant engineering, capacity requirements simulation, automation, interlinking, energy efficiency, IT, control technology, machine and process data acquisition, Industry 4.0

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

Trades

Production line, high-bay warehouse, tugger train, KLT trolleys, supermarkets, IT interface E-Kanban/ERP, infrastructure