[Report] Benz 'Factory56' with Oil Stain-Free, Noise-Free Production Plant and Advanced Technology Integration

Natural Light Shines In, No Noise... Eco-Friendly & Automated Integrated
Flexible Production Line... Multiple Models Assembled on One Line

Mercedes-Benz Factory 56 in Sindelfingen, Baden-W?rttemberg, Germany (Photo by Mercedes-Benz)

Mercedes-Benz's cutting-edge production site, 'Factory 56,' was a bright and quiet automobile factory. Sunlight streamed through the ceiling windows, and the air was clean. The various metallic noises typically expected in a manufacturing plant were hardly heard. Car bodies weighing hundreds of kilograms were lifted and moved by robotic grippers attached to the ceiling, and various parts were transported on the ground by autonomous guided vehicles (AGVs). In this pleasant working environment, employees could fully concentrate on their tasks.

On the 23rd (local time), I visited Mercedes-Benz's 'Factory 56' located in Sindelfingen, Baden-W?rttemberg, Germany. This site is the culmination of Mercedes-Benz's future strategy focused on carbon neutrality, electrification, and automation in manufacturing, even within the largest Mercedes-Benz production base, the Sindelfingen plant. It opened in September 2020 on a 220,000㎡ site, equivalent to 30 football fields.

Bright Cutting-Edge Factory... Focused on Eco-Friendliness and Automation

Upon entering the production line, dozens of Mercedes-Benz S-Class vehicles were seen undergoing final assembly. The atmosphere typical of traditional manufacturing plants, symbolized by oil stains, was hard to find here. Natural light shone through numerous glass windows in the high-ceilinged roof, creating a bright environment. Factory 56's roof is equipped with a large-scale solar power system that supplies 30% of the factory's annual electricity consumption. Forty percent of the roof area is covered with greenery, and a rainwater storage system is also installed. This system separates pollutants from rainwater and reuses it as industrial water, among other uses. Additionally, recycled concrete is used, and paper consumption is minimized.

As a smart factory pursuing automation, it was quiet except for slight noises. Sounds of wheels rolling or heavy parts being set down were rarely heard. Most parts were transported autonomously by about 400 AGVs inside the factory. They busily moved along electromagnetic lines embedded in the floor. Even so, they automatically stopped when recognizing people or obstacles. A Factory 56 representative explained, "AGVs deliver various parts accurately, improving efficiency and enhancing worker safety. Even at busy intersections with heavy traffic, they recognize each other and yield, maintaining orderly flow."

On the 23rd (local time), robotic arms are moving car bodies at the Mercedes-Benz 'Factory 56' located in Sindelfingen, Germany.

From the ceiling, robotic arms resembling claw machines moved car bodies weighing hundreds of kilograms. Car bodies combined with powertrains such as engines and transmissions moved along conveyor belts to workers. A distinctive feature here is that assembled vehicles can be rotated about 80 degrees. This allows employees to work comfortably on the underside of the car body while facing forward, without bending their backs or looking up at the ceiling.

Flexible Production Line... Multiple Models Assembled on One Line

On the 23rd (local time), an Automated Guided Vehicle (AGV) is transporting car parts at the Mercedes-Benz 'Factory 56' plant in Sindelfingen, Germany. (Photo by Mercedes-Benz)

Another strength is the ability to flexibly change the production models. This factory produces Mercedes-Benz's luxury models such as Maybach, S-Class, EQS, and AMG. Internal combustion engine vehicles, plug-in hybrid electric vehicles (PHEVs), and electric vehicles are all produced on the same line. In fact, in the powertrain assembly area, EQS, S-Class, and Maybach models were being assembled side by side on one line.

A Factory 56 representative emphasized, "Previously, changing the line and maintenance to focus on producing different models took several months, but now it is possible to prepare to produce another model within a week. We have secured a level of flexibility that is on a different dimension from typical factories where only one model is worked on per conveyor belt."

The 'MO360' system, which integrates production information from factories worldwide, is also considered a core element of Factory 56. All parts and car bodies are marked with barcodes and QR codes. In the past, paper documents accompanied them, but now everything is computerized. Various information such as vehicle model and export country is displayed on monitors. It is possible to track when and where each task was performed.

Through MO360, supply chain information from Mercedes-Benz factories worldwide is managed in real time. Production speed is adjusted according to parts supply, demand, and process conditions. Additionally, artificial intelligence (AI), big data, and digital twin technologies are used to predict errors and prevent accidents.

People-Centered Despite Automation

An employee is performing assembly work at the Mercedes-Benz 'Factory 56' in Sindelfingen, Germany. (Photo by Mercedes-Benz)

Like the 80-degree rotating conveyor belt, Factory 56 still maintains a people-centered approach. Rest areas for workers are provided throughout the line. These spaces are equipped with dining tables, sofas, kitchens with cooking utensils, and refrigerators. Notably, these are open spaces without separate rooms or partitions. Thanks to the pleasant factory environment, there is no need to isolate these areas from the workspace. Food trucks are also stationed throughout the factory to reduce inconvenience when moving to the cafeteria during lunch breaks.

Even in this highly automated process where employees do not have to lift any heavy parts themselves, the role of people remains important. Many final inspection tasks are performed by skilled personnel. A Factory 56 representative explained, "Highly skilled workers can detect paint defects that laser inspection devices cannot find. The line can only be cleared once these defects are confirmed by the tactile and auditory senses of experienced workers."

In the future, Mercedes-Benz plans to operate a factory tour program for customers purchasing vehicles produced at Factory 56 starting next year. Customers will be able to directly observe the manufacturing and inspection processes of their vehicles and take commemorative photos before final delivery. A Mercedes-Benz representative emphasized, "It will be a unique experience that fosters affection for the vehicle."