Mercedes Factory 56: No Longer a Concept
Maryna Chut 🇺🇦
Chief BDM Europe | CPO | Custom Software Development Services | your most efficient resource planning tool
Hello to everyone curious about manufacturing news!
Today, let’s review the Mercedes Factory 56—not a blueprint but a real Industry 4.0 assembly line comprising all the latest technological advancements.
Short facts about Factory 56:
"In Factory 56, we have succeeded in combining flexibility, efficiency, digitalization, and sustainability."
Ola Källenius, Mercedes-Benz Group chairman
Take a closer look at all the top-tier solutions Mercedes has implemented.
#1 MO360 interconnected ecosystem
MO360 solution means that almost all the equipment and machines in the factory are interconnected. Moreover, the IT system is fully integrated with suppliers and transport service providers.
Solutions implemented: The digital infrastructure on the shop floor comprises high-performance WLAN and 5G networks.
The company has developed the “MO360 eco-system”—a bundle of software tools that communicate through standardized, shared connections. The MO360 set of tools enables:
Achievement: The paperless approach helps save about 10 tons of paper each year.
*Read more on shop floor connectivity in my recent post here → Integration in Plant Floor
#2 New model in 48 hours—automated lines
The factory has the maximum flexibility level. The assembly line offers the opportunity to create different vehicle models with custom exterior/interior configurations.
Solutions implemented: The company has developed a modular architecture of the assembly lines called TecLinesa. The conventional assembly line has been transformed by implementing 300 driverless systems. Furthermore, more than 400 automated guided vehicles (AGVs) transport the requested items to the assembly points.
Also, Mercedes has implemented the “Fullflex Marriage” system that adjusts the assembly lines to use different drivetrains, whether they comprise combustion, electrical, or hybrid engines.
Achievement: Less than 48 hours are required to add a new model to the assembly line.
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#3 Green goals, real results
The Factory 56 launch is part of the company’s “Ambition 2039” sustainability promotion strategy. The factory leverages the best practices for sustainable and zero-emission production.
Solutions implemented: Approximately, 40% of the roof's surface is covered with solar panels, generating up to 5,000 kW. Additional electricity is obtained from renewable sources, making the factory CO2 emission-free.
Moreover, the Factory 56 has giant batteries installed, capable of storing 1,400kWh of power. The factory uses reused vehicle batteries as an additional power source that helps get the required power supply during outages.
The eco-roof has a natural rainwater management system. Recycled materials were used to build the walls, ceiling, and the factory's interior.
Achievement: 30% of the electricity consumed by the factory is generated by the solar panels installed on the roof.
#4 Happy workers, happy business
Even though the shop floor is highly automated, labor performs many activities. Hence, the company has developed the factory with a human-centric approach in mind.
Solutions implemented: The "Pool of Shift Employees" helps workers choose desirable working conditions. Employees indicate the desired shift, assembly lines, people to work with, and more. Shift managers process all the information.
The best modern working practices implemented in Factory 56 include:
An app for self-managing shifts and working environments is currently under development.
Achievement: 85% of workers’ preferences are fulfilled.
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