Major Project South Africa

New build and conversion Assembly Shop

Produkte & Lösungen » Group references » Major project South Africa – New build and conversion Assembly Shop

In the South African plant of a well-known German car manufacturer, the entire production had to be designed for the extended requirements and the integration of a new model. A large-scale order, which SPIE ROFA GmbH was able to win in the commissioning of the final assembly. Already before there was a collaboration at this site.

Since the 1970s, the work of the German manufacturer in the south of the country has already been in operation. The production of a new model beginning in 2020 required a profound change in local structures. Adjusted cycle times and a significant increase in production capacity to serve the global market from here – these two requirements were the focus. To do this, new buildings had to be built and existing systems made more flexible and enlarged. SPIE ROFA GmbH won the contract for several Greenfield and Brownfield sites, a total of seven linked systems. The conversions were made in system areas that SPIE ROFA GmbH had previously managed, so that an extensive knowledge of the local conditions was decisive in the contract assignment.

Numerous Interfaces, Large Distances

The manufacturer was searching for a partner who, as responsible general contractor, coordinates all trades and has the corresponding network in South Africa. At the same time, the activities had to be coordinated with an external planning office – another interface that came into play. Here SPIE ROFA GmbH was able to fully convince the client. Besides the main and pre-assembly lines, the powertrain was merged with the body. The technologies were provided by several companies of the group. The assembly conveyor systems (EMS, AGVs) were covered by SPIE ROFA GmbH, the joining station contributed by MOLL. Skid conveyor and slat conveyor from ROFA-LEHMER rounded off the portfolio.

International Manufacturing And Local Sourcing

The coordination on site was carried out by a German-South African dual leadership. The construction work, as the "heart" of the order, was carried out in Germany and at the Eastern European sites of the SPIE Automation Solutions GmbH. This is where the know-how is at home, in order to fully comply with the strict European quality standards and also the technical specifications of the manufacturer – even if the subsequent result is more than ten thousand kilometers away from the parent company. Local partners were involved in parts of the production (electrical and steel construction), while SPIE ROFA GmbH worked with network partners for the assembly, whose reliability they knew from many previous projects.

Time Pressure During Commissioning

Implementation started in November 2019. Christmas 2019 saw the big shutdown in the existing facilities to be retrofitted. The new production lines were integrated and put into operation under enormous time pressure and with considerable manpower. "The tension in this phase is enormous, because every minute of downtime generates high costs. Here our client could rely 100% on the professional implementation by SPIE ROFA GmbH and its partners. Everything was implemented in the agreed time frame and in compliance with all specifications,” summarizes Sales Manager Rainer Asner.

Showcase

Customer: Premium car manufacturer from Germany
Project: New build and conversion in South Africa
Production area: Final Assembly (Assembly Shop)
Contract volume: 37 Mio. Euro

Involved group companies:

SPIE ROFA GmbH: heavy duty EMS, engine EMS, doors EMS, AGV
MOLL Automatisierung GmbH: marriage station
ROFA-LEHMER GmbH: skid conveyor system, slat conveyor

Project duration from start: May 2018-January 2020 (SOP old model) or August 2021 (final acceptance new model)

PRODUCTS & PERFORMANCE

Final (Mech 1/2)

464 m track expansion
31 heavy C-carrier
51 electronical carrier upgrades
1 lowering rail
1 skid shuttle with transfer to EMS
2 scissors lifting carriers with roller conveyors for skid handling technology
2 turntables for skid handling technology
6 skid roller conveyors
reconstruction of one skid stapler to latest technology
2 control groups

Engine Line

286 m EMS KB240 loop with 22 work stations
41 carriers with chain unit
2 pallet conveyors incl. shuttle for transfer to EMS, stapler loading / unloading
1 semi-automatic unloading to AGV
1 control group

AVG Line