Pioneering

Fully Electric Plant

Produkte & Lösungen » Group references » A legacy plant in innovative transformation

In recent years, the automotive site has invested to set the course for groundbreaking automobile production in Europe. The SPIE Automation Solutions GmbH is involved in this flagship project with a wide range of conveyor technology solutions that have enabled the transition from the old to the new production line.

Pioneer for E-Mobility

The new Electric Vehicle Center is part of the sustainability strategy aiming for carbon neutrality in production and logistics by 2035. The entire plant is based on the latest manufacturing technology, where AI plays a significant role: a digital twin monitors all production processes to ensure the highest quality and efficiency.

Tailored for Europe

The vehicles produced here herald a new era. Two fully electric models are specifically designed for the European market as the first large-scale production of electric models from this manufacturer. The well-tested MEB platform provides the basis for the production.

Sustainable Innovation

In line with the sustainability concept, the plant was set up as a brownfield project: existing manufacturing facilities were reused where possible. Completely new was the assembly line with a total of eleven stations and the preparatory and subsequent assembly steps. In the first year of operation, the plant ran in mixed mode, producing combustion models and new E-models in parallel. Since 2024, everything has been running fully electric.

Scope of SPIE Automation Solutions GmbH

The scope of delivery from the SPIE Automation Solutions GmbH includes a heavy-duty electric overhead conveyor (model EMS KB240) for chassis transport and EMS of type KB180 for transporting rear axles, front axles, and supply channels. The transfer shuttle to the final line, the expansion of the existing dual-track slat conveyor, and a new slat conveyor were also part of the order.

Floor conveyors and elements for the marriage line come from ROFA's subsidiary MOLL Automation. The dismantling of the old conveyor elements was also carried out by ROFA. A challenge in the project was the interaction between old and new conveyor elements.

Special solutions were developed for this, enabling, for example, the reliable transfer of bodies from the existing skillet system to the new heavy-duty EMS. Even after the SOP, ROFA is still on site to support the ramp-up and ensure the smooth functioning of the system.

Show Case

Project: Conveyor technology for final assembly
Project duration: approx. 24 months

Involved group companies:
ROFA INDUSTRIAL AUTOMATION AG: EMS Systems and Final Line
MOLL Automation GmbH: Marriage and Upgrade Course

Products & Performance

EHB KB 240: Chassis Transport

transport weight: 2,700 kg
EMS rail: 1,500 m
EMS vehicles: 130 pcs.
coupling and decoupling stations: 2 pcs.
transfer stations: 1 pc.
carrier arm opener & closer: 2 pcs.
EMS switches: 3 pcs.
lowerable rail: 1 pc.
adjustment gauges: 1 pc.
chassis transport trolley: 1 pc.
various overhead structures along the production lines

EMS KB 180: transport of rear axle, front axle, and supply channel

EMS rail: approx. 300 m
new carriers for rear axle: 37 pcs.
reused carriers for front axle: 78 pcs.
vehicle equipment sets and new supply channel carriers: 20 pcs.
lifting stations: 7 pcs.
adjustment gauges: 1 pc.
lowerable rail: 1 pc.

Final Line:

landing shuttle: 2 pcs.
hinged conveyor: 1 pc.
existing double-track slat conveyor (conversion/extension)

Marriage and Upgrade Course:

chain conveyors (longitudinal and cross conveyors): 35 pcs.
corner transfer pcs.: 6 pcs.
turn table +swing table: 2 pcs.
lifting stations: 2 pcs.
stilts conveyor: approx. 100 m
various automatic stations, e.g., axle transfer, battery transfer, battery screwing: 7 pcs.
transport frames: 57 pcs.
transport pallets: 186 pcs.