Header Image: © thyssenkrupp Automotive Body Solutions
Automation and Robotics
With a comprehensive range of services spanning project-based production to series manufacturing, thyssenkrupp Automotive Body Solutions covers the entire vehicle development process. The company employs cutting-edge automation and robotics technologies to achieve this.
At the Mühlacker site, car bodies for the Audi e-tron and Porsche Taycan electric models are produced using automated and robotic technology.
High-Bay Warehouse Expansion
To accommodate the addition of a second aisle to the existing car body storage system with its established conveyor technology, an expansion and optimization of the Warehouse Management System (WMS) became essential. io provided project support for the implementation of SAP EWM with MFS, from conceptualization to go-live and subsequent support.
The project aimed to automate the transfer of car bodies into the high-bay warehouse using the existing conveyor technology. With the addition of the second high-bay system, the storage strategy had to be fully adapted. The new aisle required bidirectional traffic handling since shelves are accessed in one direction for storage and transported in the opposite direction for truck loading—both handled via conveyor technology.
Additionally, a new loading gate (Gate 2) was introduced in the shipping area, significantly increasing the number of routes and requiring advanced coordination. io addressed this with a custom-developed solution.
Successful Project Execution
One of the challenges of the project was the lack of an emulation (simulation) environment. As a result, a strong focus was placed on comprehensive test management to minimize the risk of errors later on. Particular attention was given to testing telegram sequences and interfaces, with all test cases listed and documented in detail.
The meticulous planning phase also proved invaluable. The initial solution design developed at the start of the project remained unchanged throughout. Regular weekly updates on status, timeline, and budget ensured transparency in communication and progress.
The project was a success for all parties involved: it was completed on time and within budget, with a seamless go-live. io continues to provide ongoing support for thyssenkrupp Automotive Body Solutions.
Key Facts
Client
thyssenkrupp Automotive Body Solutions, as a business unit within the Automotive Technology segment of thyssenkrupp AG, operates in the field of automotive body manufacturing with over 2,100 employees and global locations. The company offers project-based services, including plant engineering, toolmaking, and prototyping, as well as series production of body components, all from a single source. thyssenkrupp Automotive Body Solutions covers the entire automotive product development process, from pre-development to series production.
Project tasks
- Expansion and optimization of SAP EWM, including MFS, for the expanded body storage facility and loading area.
- Project support across all project phases: from conceptual design to go-live and support.
Highlights
- Commissioning of a second automated high-bay warehouse for car bodies, including adjacent conveyor technology and a new shipping area to increase capacity.
- Integration into existing container conveyor systems with bidirectional traffic handling.
- Implementation of customer-specific requirements for storage strategies.
- Optimization of sequencing for shipping readiness.
