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Mercedes-Benz is presenting the future of production

Factory 56.

September 02, 2020 – Flexible, digital, efficient and sustainable: Factory 56 embodies the future of production at Mercedes-Benz and sets new standards for the automotive industry. With an investment of approximately 730 million Euros, the factory at the Mercedes-Benz plant in Sindelfingen is a clear commitment to Germany as a business location. In total, Mercedes-Benz is investing about 2.1 billion euros at the Sindelfingen site. At the same time, the company is increasing efficiency in Factory 56 by 25 percent compared to the previous S-Class assembly.

Production in Factory 56 is characterized by maximum flexibility; this applies to the number of models produced and the production volume as well as to material flows. New models – from compact cars to SUVs, from conventional to plug-in hybrid to electric drive – can be integrated into series production in just a few days. Production can be adjusted quickly and flexibly to meet market demand. In line with Ambition 2039 , Factory 56 is a zero-carbon factory – completely CO₂-neutral and with significantly reduced energy requirements. This is made possible, among other things, by its innovative energy concept with a photovoltaic system, a DC power grid and energy storage systems based on reused vehicle batteries. Innovative technologies and processes have been implemented consistently and comprehensively throughout the assembly hall, providing the best possible support for the employees in their daily work. The concept of Factory 56 will be gradually transferred to all Mercedes-Benz car plants around the world as a blueprint.

Maximum flexibility thanks to an innovative assembly system

The most important feature of Factory 56 is maximum flexibility. On only one level, Factory 56 can perform all assembly steps for vehicles of different designs and drive systems – from conventional to all-electric drive. The new generation of the Mercedes-Benz S-Class sedan and the long-wheelbase version were first rolling off the line at Factory 56. A little later, production of the Mercedes-Maybach S-Class, EQS, the first all-electric member of the S-Class family, and Mercedes-AMG EQS 53 4MATIC+ (combined power consumption (WLTP): 23.4–21.1 kWh/100 km, combined CO₂ | emissions (WLTP): 0 g/100 km | electric range (WLTP): 529–586 km) started on the same line. The assembly hall is 100 percent flexible, so that all Mercedes-Benz model series can be integrated into ongoing production in the shortest possible time, depending on demand – from compact vehicles to SUVs.

Marriage in the Factory 56

The assembly system of the future gives the entire production a more flexible structure. Two so-called TecLines serve to avoid fixed points in the assembly process, improving the flexibility of the entire factory. They bring together all the complex plant technologies at one point. This means that conversion work necessitated by the integration of new models, for example, is easier to carry out in the other areas of the assembly hall. In the TecLines, the traditional production line is replaced by driverless transport systems. To integrate a new product and incorporate any associated new technical equipment, it is only necessary to change the route of the automated guided vehicle (AGV). A total of more than 400 AGVs are in operation in Factory 56.

In addition, the so-called “Fullflex Marriage” sets a new standard for the process whereby the vehicle body is connected to the drive system. In Factory 56, this “marriage” consists of several modular stations and allows major conversion work and longer interruptions in production to be avoided.

Smart Mercedes-Benz production becomes reality

Factory 56 realizes the vision of smart production at Mercedes-Benz Cars. The centerpiece of all the digitization activities is the MO360 digital ecosystem, which is used to its full extent for the first time in Factory 56. MO360 comprises a family of software applications which are connected via shared interfaces and standardized user interfaces, using real-time data to support the worldwide vehicle production of Mercedes-Benz Cars. MO360 integrates the information from the main production processes and IT systems of the more than 30 Mercedes-Benz car plants worldwide, and brings together important software applications. It delivers significantly optimized KPI-based production control, for example. It also makes individual, needs-based information and work instructions available to each employee in real time. Major elements of MO360 are already in use at around 30 plants around the world. MO360 combines efficiency and quality tools in a functional unit for maximum transparency in highly digitized automotive production.

The 360-degree connectivity

In Factory 56, a new, digital infrastructure with a high-performance WLAN and 5G network provides an important basis for full digitization. It uses ultra-modern Industry 4.0 applications – from smart devices right up to big-data algorithms. Digital production technologies have been implemented everywhere. Furthermore, Factory 56 is completely paperless: Thanks to the digital tracking of each vehicle on the line via a positioning system, the vehicle data that are relevant to the employees are displayed on the line in real time, using digital devices and display screens. All in all, this will save about 10 ton of paper each year.

Machines and production equipment are interconnected throughout the entire factory; most of them are already internet-of-things (IoT) capable. This 360-degree connectivity not only extends throughout Factory 56 itself, but also beyond the facilities to the entire value chain: digital technologies such as virtual or augmented reality were already used during the development and planning of Factory 56, and also help to make series production more flexible and efficient. In dialog with suppliers and transport service providers, the benefits of tracking and tracing are also used, allowing material flows to be traced digitally around the world.

Sustainable production on a comprehensive scale

Like digitization, sustainability is viewed and implemented on a comprehensive basis in Factory 56. As well as environmentally compatible, resource-conserving production, this also includes social responsibility, always with due regard for cost-effectiveness. Factory 56 is therefore making a major contribution to achieving the company’s sustainability goals.

Conserving resources and reducing energy consumption are the cornerstones of this approach. Factory 56 is operating on a CO₂-neutral basis right from the start and will be thus a zero-carbon factory. All in all, the total energy requirement of Factory 56 is 25 percent lower than that of other assembly facilities. On the roof of Factory 56 is a photovoltaic system which supplies the building with self-generated, green electric power. This is enough to cover about 30 percent of the annual power requirements of Factory 56. Some of this power flows into an innovative direct-current network, which will improve the energy efficiency of the assembly shop in the future. It powers technical systems such as ventilation units, for example. A stationary energy bank based on vehicle batteries is also connected to the DC network. With an overall capacity of 1,400 kWh, it acts as a buffer for excess solar power from the photovoltaic system. Modern lighting consisting of LEDs and an innovative blue-sky architecture, which allows employees to work in daylight, creates a pleasant working atmosphere while saving energy.

Plants on approximately 40% of the roof area

Alongside CO₂ and energy balance considerations, the sustainability approach of Mercedes-Benz has other ecological aspects. There are plants on approximately 40% of the roof area. This not only compensates for the sealed ground area, but also improves the interior climate in the building by retaining rainwater. This is a new system which separates rainwater from contaminated water. By storing the rainwater, Factory 56 relieves the burden on neighboring water sources and new green areas are created.

The main building of Factory 56 is an architectural and also sustainable highlight. The concrete façade is constructed of recycled concrete for the first time, made from demolition material. This means that the construction of Factory 56 not only conserved resources, but also sustainably recycled waste products.

The human at the center

Social responsibility as an employer is also reflected by Factory 56 itself. The entire digital concept places people at the center of things. Following a successful start, more than 1,500 employees will work in two shifts at Factory 56. They will be supported in the best possible way in their daily work by numerous innovations. Work on the assembly line is designed to support employees in their desire for a healthy life balance.

Wherever possible, Mercedes-Benz involved its employees in Factory 56 from the start; for example, the production employees were asked about their personal preferences in an online survey. They were able to state in which shift, in which area and with which colleagues they would like to work. The employee response rate was very high, and more than 85% of the wishes expressed were granted.

Modern working practices

Modern working practices apply in both the production and administration areas of Factory 56. The sustainable organization of production is developed further with the Works Council. The layout of the production shop is also particularly attractive. The break areas in the building are modern and painted in appealing colors to create a pleasant working atmosphere for the employees. The factory has its own canteen so that staff can avoid having to walk long distances on the site. The office areas in the main building provide a modern, open working environment.

Ergonomics are a particularly important factor in Factory 56: all assembly stages were examined for their ergonomic compatibility at an early stage, so that any necessary improvements could be made. The vehicles on the line can be brought into the most favorable working positions for the employees by a choice of conveyor systems, for example, rotating overhead conveyors or mobile platforms. All stations are height-adjustable. Young and experienced colleagues work hand in hand in Factory 56, benefiting from each other as a team.

Facts & Figures about Factory 56

Construction time

220,000 sqm

Overall ground area

(corresponding to 30 soccer pitches)

700,000 cbm

Excavated earth

Steel used during construction

(almost as much as the Eiffel Tower in Paris)

Volume of concrete used

(corresponding to about 150 family houses)

photovoltaic modules

with an output of more than 5,000 KWp (kilowatts peak)

The production eco-system MO360.

The MO360 digital eco-system is being used in full for the first time at the new Factory 56.

Start of production of the EQS at Factory 56.

The first electric saloon from Mercedes-Benz high-tech production facility.

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Forging a future in Factory 56

By Michael Nash and Christopher Ludwig 2018-05-10T14:44:00+01:00

New car manufacturing facilities will need to be highly flexible as the trends of vehicle electrification and autonomous driving continue to evolve. Mercedes-Benz futuristic ‘Factory 56’ paves a new path. By Christopher Ludwig and Michael Nash

Mercedes-Benz has long been a champion of flexible and efficient manufacturing techniques, carrying out numerous projects to test innovative new processes and implementing many of them in production lines across the world. In November 2017, for example, the company announced that it would build the GLA SUV using Industry 4.0 solutions and manufacturing technologies that require a low degree of automation as part of a two-year pilot project called ‘Innovation Factory’. It is now looking to go one step further with the construction of ‘Factory 56’ – a new 220,000 sq.m vehicle assembly facility that is being built as an extension to the Sindelfingen plant.

Already described by the OEM as the “world’s most modern car production” facility, Factory 56 which opened in 2020 to house the assembly of the new S-Class as well as the first electric vehicle (EV) in the new EQ family – the EQC. Mercedes-Benz believes that, when completed, the factory will “define a new way of building cars”. 

AMS sat down with Markus Schäfer, member of the divisional board of Mercedes-Benz Cars, production and supply chain, to get more information.

Last minute changes

“Factory 56 is the blueprint for future production of Mercedes-Benz Cars,” Schäfer stated. “The production concept of the facility will allow us to make EVs, robo-taxis and multiple conventional vehicle architectures in the most flexible way, using Industry 4.0 processes and digital tools. The technical content as well as the production concept of Factory 56 is exemplary for our production strategy worldwide.”

Collaborative robots, otherwise known as cobots, will feature heavily in the new facility. Mercedes-Benz has been using these at its production sites for several years after signing an agreement with Kuka back in 2012, and Schäfer believes that they will continue to be crucial to vehicle manufacturing in the future. “The direct cooperation between people and robots means the cognitive superiority of people is ideally combined with the power, endurance and reliability of robots,” he said. “It facilitates different objectives: higher quality, increased productivity, new possibilities for ergonomic and age-conformant work.”

Factory 56 construction

An impact of Factory 56 construction underway in 2018, before Mercedes-Benz opened the extension to Sindelfingen in 2020 to produce luxury-class cars and electric vehicles

As well as receiving help from co-bots and AGVs, workers will also benefit from using augmented reality tools, virtual assembly solutions and wearables. Each of these, Schäfer suggested, will help to improve productivity. Driverless transport systems (DTS) equipped with baskets will also operate in the facility, ferrying the required materials and components to the appropriate work stations. These will all be fitted with radio frequency identification (RFID) tags, ensuring that each DTS and component can be digitally tracked and monitored.

“We will move away from conveyor lines that are fixed in the ground,” Schäfer continued. “We will have AGVs not only transporting the materials as we already do today, but moving cars in production to different stations. We will also be able to change not only the material flow, but the layout and configuration of a plant in as little as a weekend.”

Data from all of these robots and technologies will be gathered and used for predictive maintenance, allowing management and operators to spot potential faults and identify a fix without needing to stop work. Furthermore, some of the data will be transmitted to the Mercedes me app so that customers purchasing new vehicles can get information regarding production and delivery. “It is not simple to connect the customer to the factory, supply chain and engineering,” Schäfer commented. “But we imagine that customers could, for example, send a JPEG file of whatever they might want, such as a name or a signature to be printed in the car. We could then communicate that to the plant directly to a stitching machine or laser that would produce the image on the seat or cockpit.”

He also thinks that this connectivity between the plant and customer could allow for changes to be made to the vehicles at late stages of the production and assembly processes – a factor that could prove important as companies look to cater for individual consumer preferences. “If you combine this with 3D printing, we could become even more flexible and responsive to customer desires right up to the latest possible point. This gives us good ideas and opportunities for business in the future,” Schäfer asserted.

For more on technology advances and trends in automation for automotive and electric vehicle production, read the AMS digital edition on the Factory of the Future: Read AMS Factory of the Future: Redfining the production line

Bringing it together

Many of these technologies and processes are already used at various other car manufacturing plants across the world. For Schäfer, the fact that the technologies are all being brought together in one single plant will make Factory 56 unique. “We are combining all our knowledge and pilots in production technology into one greenfield factory, which will then be copied at other plants. It is a holistic approach that starts with the creation and planning of the product in R&D in a digital simulation. This means that before we see hardware, we simulate test crashes, factory planning, layout and even the movement of workers and the material flow. This makes us faster, more flexible, reduces investment and ensures we have the right quality of processes.”

Another strategy that will be demonstrated at Factory 56 before being implemented at other Mercedes-Benz plants is the increased use of sustainable and clean energy. Reducing the CO2 footprint of plants has been an increasingly important area of focus for many OEMs, as well as making their vehicles more efficient and eco-friendly. Some, like Audi, have even published lifecycle assessments of individual models to identify the emissions created along each phase of vehicle production.

Start of EV production

Markus Schäfer, pictured front left, pictured at the start of EQS electric vehicle production in 2021 at Factory 56 in Sindelfingen

Schäfer is convinced that Factory 56 will represent a “giant leap on our way to emission-free production”. He revealed that Mercedes-Benz intends to reduce the CO2 emissions that are created as a result of vehicle assembly by 75% per vehicle. It will do so by using a photovoltaic system on the roof of the building to feed 5,000 mWh of green electricity into the facility every year. Several methods will also be used to reduce water consumption and cut waste.

As well as sustainable energy, the German OEM wants to increase the use of sustainable materials when building its EVs. It its 2017 Sustainability Report, Daimler stated that it was aiming to reduce the primary raw material requirement for electric drives by 40% before 2030. Specifically, it wants to stop relying on materials that are only available in limited quantities and that have a big environmental impact when used and extracted from the earth. Furthermore, the company is looking to reduce waste at its plants by using its ‘MeRSy’ recycling management system.

Global flexibility

The construction of Factory 56 is one of many announcements that Mercedes-Benz has recently made in relation to manufacturing. It is also spending Ä 100m (US$123.74m) with its partner Thonburi Automotive Assembly Plant (TAAP) to expand its existing car plant in Bangkok, Thailand, and to construct a new battery assembly facility at the same site. The latter will start operating at the beginning of 2019, and will help Mercedes-Benz to keep up with “growing demand for electric mobility in the region”.

Plants that flex, but also grow

Flexible plants and supply chains are important to Mercedes-Benz’s growth strategy. For example, in recent years the carmaker has added production of the GLC SUV to its contract-manufacturing partner, Valmet, in Finland, where it moves down the same line as the compact A-class. In China, its joint venture with BAIC also includes sedans and estate cars like the C-class and E-class produced along with the GLA and GLC SUVs. The company is also building a new plant in Russia close to Moscow.

Fitting plug-in hybrid and electric battery versions of models to plants will be a significant efficiency. However, the increase in output together with the shift towards electrification also requires significant new investments, capacity and supply chain links. In the US, for example, the carmaker is investing $1 billion at its Tuscaloosa, Alabama plant to add production of an electric SUV. Factory 56, in Sindelfingen, will build the new S-class and the first electric vehicle of the EQ brand. In Hungary, Mercedes-Benz is adding not only the new A-class to its plant, which already produces nearly 200,000 cars per year, but construction of a second plant is underway. The carmaker is investing heavily 11.9 billion yuan ($1.87 billion) in its joint venture in China to expand capacity in Beijing, including taking over an existing BAIC facility.

Like many other OEMs, Mercedes-Benz is also looking to bolster its activities in the world’s largest new car market. In February 2018, it said it was making an investment of over 11.9 billion yuan ($1.89 billion) to take control of a former BAIC production facility in the Shunyi district of Beijing, which also establishing a “local production hub” in the city’s Yizhuang industrial park. The plant will be operated under the Beijing Benz Automotive Co (BBAC) name, and according to Mercedes-Benz, it will allow the company to better respond to increasing market demand for new energy vehicles (NEVs).

Schäfer referred to two trends that are acting as driving forces, spurring the company to make changes to both its supply chain and production network. “One is the growth that we continue to experience, which has run at around 10% year-on-year over the last few years,” he recalled. “In response, we are expanding and adding new facilities worldwide, and that has also been a challenge. But we are also seeing a move to more conventional combustion engines to electric plug-in and battery electric vehicles, as well as eventually towards autonomous cars. So growth and new technology are two big movements that we are trying to combine at the moment. Our answer is an intelligent network of production plants.”

With the rising trend of electrification and the push to perfect autonomous driving technologies, many experts have described the current period in the automotive industry as the most disruptive in its history. As a result, Schäfer emphasises the need to make manufacturing facilities smart and flexible while also having global coverage for each and every market.

“We must be able to move product from one plant to another,” he remarked. “We cannot predict with certainty what will happen globally in terms of protective trade measures, currency shifts, customer demands and preferences, or even in terms of the allocation of new models to plants in the future. Therefore, it is important that we can move product around the globe to fill plants to a maximum and make sure we meet customer demands.”

As well as helping it to meet customer demand, Schäfer thinks that this type of flexibility will also ensure that Mercedes-Benz can weather any storms caused by political issues. He referred to trade barriers in China and tariffs from the Trump administration for steel and aluminium. “Furthermore, India has high custom duties and Russia is changing its duty scheme. We can’t control these things, but a flexible production system gives us manoeuvrability,” he concluded.

For more on OEM production strategies, keep up with the AMS Livestream series, including on light-weighting and design-for-manufacturing strategies, featuring Ford, Gestamp, SSAB and ABB View AMS Livestream Hour on Light-weighting  

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Home › News Releases › Film and key visuals show concept and operating principles of “Factory 56”: Mercedes-Benz Cars significantly increases flexibility and efficiency with “Factory 56”

Film and key visuals show concept and operating principles of “Factory 56”: Mercedes-Benz Cars significantly increases flexibility and efficiency with “Factory 56”

For the first time Mercedes-Benz Cars gives a deeper insight in the "Factory 56". The German Premium carmaker explains the concept and the basic operating principles of one of the most state-of-the-art automobile production halls in the world

• By Maisie Priestner
• November 15, 2018

For the first time Mercedes-Benz Cars gives a deeper insight in the “Factory 56”. The German Premium carmaker explains the concept and the basic operating principles of one of the most state-of-the-art automobile production halls in the world.  “ In ‘Factory 56’, we are consistently implementing innovative technologies and processes across the board according to the key terms ‘digital, flexible, green’. We create a modern workspace with more attention to individual requirements of our employees. All in all, in ‘Factory 56’ we are significantly increasing flexibility and efficiency in comparison to our current vehicle assembly halls – and of course without sacrificing our top quality. In this way we are setting a new benchmark in the global automotive industry”, says Markus Schäfer, Member of the Divisional Board Mercedes-Benz Cars, Production and Supply Chain.

You can find a detailed video on concept and operating principles on the Mercedes-Benz YouTube channel:  https://youtu.be/UdDvDKC8FVM

New, flexible infrastructure with powerful WiFi and mobile network

In the “Factory 56”, the traditional assembly line is replaced by driverless transport systems in selected production areas – the so-called “TecLines” – for example at the beginning of the trim line. By merely redefining the tracks for the driverless transport systems, it will be possible to change from assembly operation to cycle operation, whereby the vehicle remains in position and is not continuously moved along the line. This makes sense for automated activities, among others, for example when installing the sliding glass roof. In addition, by using the driverless transport systems, individual assembly units can be expanded without interfering in the building’s structure. “By combining an assembly line with ‘TecLines’, on the one hand we have high-efficiency assembly for large-scale production at our disposal, while on the other hand we gain flexibility so that we can adjust our production without any great effort or interruptions to current operation”, Schäfer explains.

In doing so, machines and systems are networked with one another. Selected assembly facilities and materials handling technology are Internet of Things-ready. A high-performance and efficient wireless network and mobile network form the basis for this. The use of a powerful 5G-mobile phone technology is to be tested for the first time in assembly in a pilot application. The assembly hall is completely paperless. Employees work with monitors and Personal Digital Assistants (PDAs). Shopping carts are being used across the board in “Factory 56” to supply the assembly stations. These are equipped with the required materials for assembly in a so-called pick zone using intelligent picking systems. In total 300 driverless transport systems are in use. “Resulting data can be collected and evaluated using big data technology. The findings flow directly back into production. In this way, we can improve existing processes and can avoid plant malfunctions with predictive maintenance. We thus increase our business operating times and improve quality”, Schäfer emphasises.

360-degree networking – from the supplier to the customer

However, networking not only happens inside the factory. A significant feature of “Factory 56” is the all-round networking across the entire value-added chain – from development and design to suppliers, production and customers. In coordination with our suppliers, we use the benefits of tracking and tracing, for example, which allows load carriers to be traced digitally around the world. Tracking and tracing enables early detection of discrepancies in the supply chain and thus a quicker reaction time.

We are already connected with our customers today: Under “Digital Anticipation” in the Mercedes me app, customers purchasing new vehicles can gain exclusive insights into the production of their vehicles. For research and development as well as production, 360-degree networking means quick and transparent communication across all units. Digital tools are used for development and production, for example, production processes are visualised and optimized by “Virtual Reality” (VR) before a real production hall comes into existence. For example, the workstations and processes can be virtually tested and designed ergonomically.

Work of the future – focus on people

“Despite state-of-the-art technology and innovative Industry 4.0, in ‘Factory 56′ the focus is as always on people. Our employees’ expertise, flexibility and high level of motivation are the key to our success, and that applies to periods of transformation and digitalisation. This is, why we are cutting back on the level of automation in ‘Factory 56′ and creating the framework conditions to ensure that working in production continues to be fun”, Schäfer clarifies. To sustainably shape the production of the future, an innovative working organization and new working time models will be developed along with the works council. The aim is to reconcile the company’s requirements with the employees’ requirements via sustainable and practical solutions: While the company wants to increase flexibility, capacity and extend the operating hours, employees are often concerned with gaining more freedom for personal matters with flexible working times and places that can be arranged at short notice. In this context, a model for flexible teams, the so-called Pool of Shift Employees, is currently being tested. This means that an employee’s wishes regarding his/her shift plan depending on his/her personal situation can be better taken into consideration, thus promoting a balance between family and professional life. It is conceivable that one-day employees will be able to choose their working hours via an app.

“Green production” – CO 2 -neutral electricity supply

All German Mercedes-Benz Cars plants will have a CO 2 -neutral energy supply by 2022. New plants worldwide are already planned with this premise. “Factory 56” will already have a CO 2 -neutral energy supply upon commissioning. There is a photovoltaic system (PV system) on the factory’s roof, which feeds self-generated green electricity into the hall’s supply. In addition, there are a number of measures for reducing energy consumption. Approximately 40 percent of the roof’s surface will be extensively planted. Apart from offsetting impervious surfaces and aiding rainwater retention, this also translates into an improved interior climate in the hall. The hall is particularly translucent. The Blue-Sky architecture supports a pleasant working climate for the employees using daylight.

“‘Factory 56’ in Sindelfingen is the blueprint for all our future vehicle assembly halls around the world – this applies both to our existing plants as well as new locations”, Schäfer states of future prospects.

KeyFacts about the “Factory 56”

Right from the start, Mercedes-Benz manager Ulrike Graze is responsible for “Factory 56” at the Mercedes-Benz plant in Sindelfingen, about 20 Kilometres away from the Daimler headquarter in Stuttgart, Germany. Additionally Mrs. Graze is in charge of the S-Class assembly in Sindelfingen. The area of “Factory 56” measures 220,000 m 2 . This equates to about 30 soccer fields. While the cornerstone ceremony for the new assembly hall took place on February 20, 2018, the start of production is scheduled at the beginning of the next decade. Upper and Luxury class cars with combustion engines, hybrid drives and purely electric-battery drives as well as self-driving cars will be produced there. This includes, among others, the new generation of the S-Class as well as the first electric vehicle from the EQ product and technology brand “made in Sindelfingen”.

About Mercedes-Benz Cars Operations

Mercedes-Benz Cars Operations (MO) is responsible for passenger car production at over 30 locations worldwide. Two of them are currently being established. Within a flexible and efficient production network with around 78,000 employees, it includes the central functions of production planning, TecFactory, logistics and quality management. Last year Mercedes-Benz Cars produced more than 2.4 million Mercedes-Benz and smart passenger cars, making a seventh record in a row. The network is based on the product architectures front-wheel drive (compact cars) and rear-wheel drive (e.g. S-Class, E-Class and C-Class), as well as the SUV and sports car architectures. In addition, there is a powertrain production compound (engines, transmissions, axles, and components). Each of these production compounds is grouped around a lead plant that serves as a centre of competence for the ramp-up of new products, technology and quality assurance. Mercedes-Benz Cars is ready for the electro mobility: Around the globe electro hubs are built for the production of electric vehicles and batteries. The focus of day-to-day work is on the continuous improvement and refinement of state-of-the-art production methods, which allow future high-tech vehicles to be produced in a way that is efficient, flexible and environmentally friendly, according to the typical Mercedes-Benz quality standards. All of this revolves around the employees and their expertise, whose work is systematically supported by ergonomic workplace design and intelligent automation. In addition to its own production plants, Mercedes-Benz is increasingly leveraging partnerships and utilizing capacities at contract manufacturers as part of its growth strategy.

SOURCE: Daimler

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The average July temperature in Sindelfingen, Germany, is a moderate 24 degrees Celsius. This year, it reached 34 degrees. The town was not an outlier: throughout the summer months, record-breaking heat hit Europe. It was a season of scorched grass, liquified tarmac, warped metal, of staying inside during the day with the curtains drawn, of the constant hum of fans heard from the wide-open windows. This is part of an ongoing trend, with the World Meteorological Organisation warning that the past eight years are on track to be the eight warmest on record, fuelled by ever-rising greenhouse gas concentrations and accumulated heat. And we’re running out of time – if nothing is done, then irreversible global warming is no longer a case of if , but of when .

We already know that to tackle climate change we need to limit the amount of carbon being released into the atmosphere through more sustainable ways of living, working and manufacturing. The problem, of course, is understanding what form these might take. Mercedes-Benz’s new Factory 56 may have some answers. By rejecting the tenets of the traditional assembly line in favour of digital networks and driverless systems to create Mercedes-Benz’s new fleet of EQS electric vehicles, the Sindelfingen-based factory offers a vision of what a sustainable future might look like.

Underpinning this desire to tackle global warming is Mercedes-Benz’s wider commitment to reducing its footprint. This year, the company produced carbon-neutral emissions in all its plants worldwide, and ensured the electricity used came from renewable sources. This commitment to a green future is reflected in the core tenets of Factory 56 – and the factory is poised to become zero-carbon in line with ‘Ambition 2039’, Mercedes-Benz’s commitment to making the entire life cycle of their vehicles carbon-neutral by 2039. In practical terms, this involves using photovoltaic systems to supply the building with self-generated, green electric power – about 30 per cent of the annual energy requirements of the factory – as well as a natural rainwater management system through a partial eco-roof, a DC power grid and energy storage systems based on reused vehicle batteries.

Throughout, there’s a real emphasis on flexibility through design. Intelligent systems used to determine everything from number of models produced, production volume and material flows – meaning new models can be put into production pretty much instantly. And the impact of all these measures means that the factory total energy requirement of the building is massively reduced – 25 per cent – when compared to other factories.

Sustainability also means looking to the future of Sindelfingen. Mercedes-Benz has had a plant in the town for over 100 years, and the story of the company is inextricable with the history of the town, the Baden-Wurttemberg region, and the people that live there. The factory occupies a unique position: a long-standing centre of expertise that acts as the ‘competence centre’ for the production of Mercedes-Benz’s luxury electric vehicles all around the world. It’s a symbiotic relationship; an alliance between industry and region that’s equal parts neighbour and partner, and it’s this connection that the factory intends to underpin for decades to come.

The factory’s advancements in sustainability mean that it has become a blueprint for green ways of manufacturing, with its concepts gradually transferred to all Mercedes-Benz car plants around the world. As Ola Källenius, chairman of the board of management of Daimler AG and Mercedes-Benz AG, puts it: “Factory 56 thus sets the direction for the future of automobile production at Mercedes-Benz: resource-friendly, connected and flexible. Because we consider the transformation of our industry to be a holistic task that includes products as well as the entire value chain.” In other words, it’s only by paying attention to every aspect of manufacture that we might finally understand how to live, work and produce more sustainably.

mercedes-benz.com

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