The new production line at the main Porsche plant in Zuffenhausen was a special challenge. The production facility for the new Taycan eCar was constructed amid the existing factory in the shortest possible time, despite sportscar production running at full speed in parallel.

Building restrictions The main plant at Zuffenhausen represents tradition for Porsche. That’s where the move toward electromobility begins with the Porsche Taycan. But space for the new construction was seriously limited by the existing buildings, which had to be partly cut back. Building upwards was therefore the order of the day. But there are also height restrictions for buildings in Zuffenhausen, to minimize the impact on air flow in Stuttgart. The result is a unique manufacturing concept that makes the most of every level and doesn’t waste a single centimeter of height. 

Maximizing flexibility Customization is very important for Porsche customers, and that also goes for the new Taycan. Customers want a car that meets their personal expectations, both inside and out. That means Porsche also had to ensure every station in the plant still offered the necessary flexibility when it came to the Taycan – a huge logistical challenge, since production is spread over several floor levels .

Tilt EMS hangers facilitate ergonomic operations Conveyor technology solutions from Siemens are used throughout the vehicle assembly process. In addition to the automated guided vehicles and the door conveyor system, tilt EMS hangers are used to ensure ergonomic working conditions. These enable the car bodies to be rotated 110 degrees in both directions so Porsche employees can access all parts without difficulty. Finally, heavy EMS hangers carry the full weight of the vehicle, including motor and high-voltage battery, to the final acceptance point, where it is transported using a conveyor belt. The entire final assembly was automated based on the SIMATIC portfolio from Siemens.

Autonomous Guided Vehicles(AGV) To achieve the necessary flexibility, Porsche decided against fixed conveyor belts and opted for a highly flexible system involving autonomous guided vehicles (AGV) using Siemens technology. Utilizing FlexiLine - concept of Porsche for the AGV system line, makes it possible to adapt operating cycles to actual needs and, for example, stop an AGV to perform automated tasks and then speed it up to move on to the next processing station. To ensure everything functioned smoothly from the outset, the entire system underwent virtual simulation and testing in advance to prevent clashes and optimize workflows.