The automotive supplier DRÄXLMAIER is an experienced specialist in electrics and electronics, on-board power systems, and interiors – and in high-voltage systems for electric cars. When starting assembly of the battery system for the Porsche Taycan, DRÄXLMAIER relied on the data expertise of the Staufen partner AppliediT.
People involved
Gunther Wössner
Head of Plant Sachsenheim
DRÄXLMAIER Group
Christoph Zeihsel
Head of Operational Excellence
AppliediT S.L.
Michael Feldmeth
Principal
STAUFEN AG
“For us, the battery system for the Porsche Taycan was the first major foray into e-mobility,” says Gunther Wössner, head of DRÄXLMAIER‘s battery plant in Sachsenheim near Stuttgart, Germany. “We had to overcome all the typical challenges of starting series production of a completely new product.”
The Porsche Taycan uses a high-voltage network with 800 volts instead of the 400 volts that are common in other models. It offers a high continuous output and reduces the charging time. In addition to the high-voltage battery, DRÄXLMAIER produces various assembly parts and the control unit for battery management in other production facilities. The task for the start of manufacturing: to achieve a shift output of at least 90 units within a short period of time.
Digital production based on data
The collection and evaluation of process data is an important prerequisite for rapid and successful manufacturing. “The main challenge was to be able to read and prepare data structures,” explains Christoph Zeihsel, Head of Operational Excellence at AppliediT.
With the help of data analyses, quality deviations can be easily localized and the overall equipment effectiveness (OEE) Equipment Effectiveness (OEE) can be improved. The data can be used, for example, to track when a component leaves one station and moves on to the next. This allows the causes of errors to be found
more quickly.
The potential of this approach is evident in a typical detail in manufacturing: the screw connection of the individual components did not work as DRÄXLMAIER had expected. However, it was initially unclear what the cause of the difficulties was. The solution: two manufacturers had different quality levels when cutting threads. This led to challenges in assembly. Using data analysis from AppliediT, DRÄXLMAIER was able to quickly identify the manufacturer in question.
About DRÄXLMAIER
The DRÄXLMAIER Group is a German automotive supplier with headquarters in Germany. Founded in 1958, the familyowned company supplies premium vehicle manufacturers worldwide with complex on-board power systems, central electrical and electronic components, exclusive interiors, and storage systems for electromobility. In 2023, DRÄXLMAIER generated sales of 5.6 billion euros.
60+
Locations in over 20 countries
1958
founding year
70.000
employees worldwide
5,6
bill. € turnover
Many linked processes with accident risk
Battery production includes four stations, 85 robots, and 75 driverless transport systems. The production process begins with the positioning of the battery frame. The individual battery modules are placed there and screwed together. The next station places busbars between the modules.
The battery box is then glued to protect it against environmental influences. After placing the second battery level and the control unit, which were manufactured in parallel, the entire drive battery is assembled and glued again. This is followed by quality assurance with leak and function testing. “Around 80 percent of these processes are linked together, so DRÄXLMAIER faced additional challenges in terms of organization and coordination,” says Operational
Excellence expert Zeihsel.
Here, AppliediT was supported by Staufen. Together with DRÄXLMAIER, they worked out how to optimally adjust the team to the new line capacity and establish a perfect shift and transfer on site. “The DRÄXLMAIER example shows very well how strongly the Staufen/AppliediT combination supports the customer in digitalization,” says Dr. Michael Feldmeth, manager of the Practice Unit Digital & Industry 4.0.
Recognizing the benefits of data
In order to avoid bottlenecks, DRÄXLMAIER has unbundled all processes and automated them where it makes sense. For example: 800 volt batteries pose a high risk of serious accidents if handled improperly. That‘s why a lot of work on the high-voltage systems is carried out by robots. This means that employees do not have to
wear uncomfortable protective equipment.
For DRÄXLMAIER, the entry into battery production was a success.
We have recognized the importance and benefits of data.
Gunther Wössner
In the factory, we now have effective methods for dealing with large amounts
of data and evaluating them intelligently. This has proven to be extremely valuable.
Head of Plant Sachsenheim DRÄXLMAIER Group
REQUEST THE MAGAZINE NOW AS A DIGITAL VERSION OR PRINT EDITION
You might also be interested in
Magazine
Unleashing Operational Performance through Tailored Data Analytics
Company data is still the most underused asset. In the labyrinth of industry operations, where data flows are as complex as they are copious, AppliediT stands out, a Spain based technological beacon illuminating the path to improved operational performance by using tailored data analytics solutions and data engineering services.
Read more
Study
Study Digitalization
The Staufen study “Digitalization 2024” shows how difficult it is to exploit the full potential of data. The study underlines the need for a data-driven strategy and professional data analysis and points to a lack of expertise, resources and a data-centric corporate culture.
Read more