Following three years of planning and construction, the tractor manufacturing plant known as “DEUTZ-FAHR Land” is now producing high performance tractors from 96kW (130hp). Deutz-Fahr 6, 7 and 9 Series tractors are manufactured here for the world market.
A plot of 150,000M2 adjacent to the existing premises was purchased for implementing the project. The L-shaped building, with a covered area of 42,000M2 has revolutionised tractor manufacturing through the use of state-of-the-art technology in the areas of assembly and painting and for the hydraulics, electronics and chassis tests for quality assurance. Setting new benchmarks for efficiency, productivity, and quality in manufacturing.
Together with the customer centre “DEUTZ-FAHR Arena”, the overall investment of 90 million euros is the single largest individual investment in the company history.
Input from world experts has allowed Deutz-Fahr models to be built in the most modern production facilities available for tractors, where the following planning philosophies were implemented:
Line back planning philosophy: The production line is the starting point of the planning process – all delivery processes are planned “backwards” to the point of origin. This means that all upstream organisational units adapt their processes to the production plan.
In-line quality principle: Product quality has to be ensured during the entire production process. Accordingly, quality checks are integrated along the entire line to ensure maximum quality for the individual manufacturing steps.
Form follows function: The form of the infrastructure follows the functions defined by the specified processes.
Smart production: The organisational areas of production and logistics work together to allow not only ‘just-in-time’, but also ‘just-in-sequence’ production.
Workplace standardisation: Standards for processes and equipment (tools, equipment, etc.) are the basis for ensuring efficient and high quality work procedures.
A warehouse with 4,000 storage locations for large parts, and a small parts facility with 25,000 locations is integrated for supplying the production process. Logistics use proven elements of lean production, e.g. continuous movement of materials on trolleys, use of route trains, e-kanban goods call-off directly from the line and continuous visual management.
Where material flows can be bundled economically, targeted automation was introduced: The backbone is an automatic small parts storage system for handling the standard small load carriers. It is designed as a shuttle warehouse that dynamically adapts to the throughputs varying throughout the day and the on going production process.
Pre-assembly and order picking zones for add-on parts – the so-called supermarkets – are located immediately next to the assembly lines in a herringbone pattern, ensuring customised production and avoiding long paths and searches as well as extended waiting times and the corresponding safety stock levels.
Within the production process, the design of assembly line technology is one of the fundamental challenges. It not only has to be extremely robust and account for the complicated installation situation, but also permit ‘just-in-sequence’ manufacturing, i.e. components are only delivered at the moment when they have to be installed on the line.
DEUTZ-FAHR has developed innovative solutions for this: The assembly line is designed as an apron conveyor with worker travel conveyors on both sides. Both move in parallel at the same speed, significantly facilitating the installation of parts on the tractor body while substantially reducing the daily walking distance. This ensures constant production quality.
In addition to the individual quality checks at each installation step, in-line hydraulic testing and a pneumatic test take place at the end of powertrain production. Up to three powertrains can simultaneously be tested here for full functioning and tightness at a hydraulic operating pressure of 220-bar. Only once this thorough check is completed, the tractors move to the paint shop and then to final assembly.
After final assembly, the computer-controlled final acceptance of the completed tractor takes place. All functions of all installed components are tested individually for each tractor, while engine and transmission are run through different speeds and load conditions. The front axle and the front axle suspension are tested in the final phase, which is unique in tractor manufacturing.
See the end result of the world’s most current tractor production line by viewing a Deutz-Fahr tractor at your local dealer. Call PFG Australia for your nearest dealer on Tel: 1800 872 2867, or email: firstname.lastname@example.org