Unique insights into the factory of the future

Unique insights into the factory of the future

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Porsche Leipzig: Exclusive insights into the factory of the future

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In its 20th year of existence, the Leipzig plant is being expanded into an e-mobility area. On October 19, you can see firsthand the meaning of the words “smart”, “lean” and “green” of Porsche Production 4.0.

Exterior view of the Leipzig factory in 2019. The day before the Smart Factory Day from “Automobil Industrie”, Porsche offers exclusive insight into the inner workings of the factory.

(Photo: Porsche AG / Marco Prosch)

On August 20, 2002, the first car rolled off the assembly line at the Porsche factory in Leipzig – the Porsche Cayenne. The beginning of a success story. Since then, the Saxon location has stood for forward-looking automotive engineering. As part of a celebratory event at the end of August, the sports car manufacturer inspected the milestones of the Porsche factory in Leipzig.

“Leipzig has become a second home for Porsche. With the decision to build a new factory on a green field north of the city of Leipzig in 1999, the company broke new ground,” said Porsche Production Board Member Albrecht Reimold. “Since it started in February 2000 , we have invested almost 1.3 billion euros in the development of our Saxon region.”

Smart Factory Day and Porsche factory tour

To produce easily, network meaningfully and purposefully, improve capacity utilization and quality, create sustainability, motivate employees to do this: Production experts meet at the “Smart Factory Day” on October 20 in Leipzig; from suppliers, car manufacturers, start-ups and development service providers – and discuss common goals in a practical way. The day before, October 19, there will be two exclusive factory tours through the Porsche factory.

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Since 2013 “full work”

The decision to favor Leipzig as the second Porsche production site alongside Stuttgart-Zuffenhausen was made in 1999. The new assembly plant was built within three years and was officially opened on August 20, 2002. Shortly after the start of production of the Porsche Cayenne, the plant was first expanded to include a separate production area for the assembly of the Carrera GT sports car. Another production hall and equipment center were built in 2009 for the assembly of the first generation Panamera.

And the decision of 2011, new Porsche Macan model manufactured entirely in Leipzig, the location was expanded from 2011 to 2013 into a so-called complete plant, with its own body shop and paint shop. For the full production of the second generation Panamera, which has been coming off the assembly line in Leipzig since 2016, the plant received a second body shop and a quality center in the fourth extension.

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The best place for e-mobility

Since 2019, the Porsche factory in Leipzig has been expanded for the fifth time, becoming a center of excellence for electromobility. The company is setting a course for the future of the plant and for the production of future models. For the next generation of Macan, which will come to the market with electricity, a new body shop was created. The assembly line was also enabled to produce cars with three types of drive on one line in the future – combustion, hybrid and fully electric cars.

“With the possibility of producing three drives on one line, we can be flexible,” says Gerd Rupp, CEO of Porsche Leipzig GmbH. The plant can now look back over ten years of hybrid production. With more than 4,300 employees, the plant is one of the largest employers in the region. Around 550 Macan and Panamera are produced every day.

The Porsche factory in Leipzig celebrates its 20th anniversary on August 20. (Photo: Porsche)

Resource efficiency saves four million euros every year

The resource efficiency program is an integral part of the production system at the Leipzig Porsche factory. This includes regular energy audits and business workshops. The goal is to examine the procedures related to the efficiency of their resources and continue to improve them. “First of all, we always look at the current situation in each business and analyze the usage data,” explains Gerd Rupp. “On this basis, we identify potential and define measures for individual areas.” Self-styled environmental and energy spokesmen are responsible for consistent implementation, which keeps an eye on the use of resources in the relevant department and motivates their colleagues.

The resource efficiency program launched in 2014 focuses on savings in a total of five key indicators: energy consumption, CO.2– Production, waste generation, water consumption and solvent production. Particularly effective measures in 2021 include, for example, the environmental conditions of welding robots used in body building. These automatically turn off the welding guns after 60 seconds of inactivity, saving compressed air during non-production time. An energy saving method was also implemented in the conveyor system of the paint shop: 400 frequency converters automatically switch off the power supply there when not in use. Thanks to such measures, the Leipzig plant now achieves total savings of four million euros per year.

Smart Factory Day and Lean & Green Summit

In 2021, the Saxon location received the “Lean & Green Management Award” in the Automotive OEM category. As last year’s winner, Porsche Leipzig will host on October 20 this year Lean & Green Conference with the presentation of the Lean and Green Management Award 2022. In the morning and at the same place Smart Factory Day and “Automobil Industrie”. The day before there is an opportunity to participate in an exclusive factory tour. The number of participants is limited in each case. Here it goes registration.

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