142142

143143

Advanced Factory Solutions

Survey : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : 144 - 145

Planning

Dürr Consulting : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : 146 - 149

Material Flow Simulation : : : : : : : : : : : : : : : : : : : : : : : : 150 - 151

Digital Factory : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : 152 - 153

Cross Functions

FASmotion – Non-Contact Energy

and Data Transfer : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : 154 - 155

Control & Manufacturing Execution Systems : : : : : : : : : 156 - 157

FAScontract

Turnkey & Systems Integration : : : : : : : : : : : : : : : : : : : : 158 - 161

Project Management : : : : : : : : : : : : : : : : : : : : : : : : : : : 162 - 163

FAStplant® – the Modular Final Assembly : : : : : : : : : : 164 - 167

144

Dürr Consulting

Digital Factory

Customer-oriented solutions for a well-engineered plant layoutcan be simulated and planned best via the Digital Factory.Analysing assembly processes beforehand ensures a most process-oriented and optimized implementation.

FASmotion

The contact-free transmission of energy and data called FASmotionopens up new vistas for all types of conveyors. Pre-tested modu-les abridge the process of installation and commissioning with main-tenance efforts and malfunction times being reduced significantly.

Material Flow Simulation

Material flow simulation guards against problems before they arise during production. That is how we reduce ramp-up time and increase plant availability.

For turnkey solutions or parts of plants: Dürr Consulting spans the entire range of how to successfully plan a factoryand unite an extensive know-how for plants and processes and offer individually developed solutions.

145

Advanced Factory SolutionsSurvey

FAStplant®

With FAStplant® Dürr developed a new and future-oriented concept for final assembly plants. This most flexible way of erecting, dismantling or retrofitting an assembly line is currentlysetting new standards for the reduction of time and invest efforts.

Control Systems

When controlling complex plants the key to success lies in a per-fect interplay of many components. Dürr offers innovativesystems to merge all of them to a well-cooperating entity fromthe supervisory level to decentralized module control.

Turnkey & Systems Integration

Full-service projects with an in-house content of up to 70% of all technologies and products – this balance of services helpsDürr FAS to successfully compete among the world’s leading suppliers in final assembly.

Project Management

Professional project management by Dürr stands for an optimizedand successful project flow. Our project information managementtool, PIM for short, bundles and administrates all relevant projectdata worldwide and ensures keeping both schedule and budget.

146

Pl

an

ni

ng Factory Planning

Planning of complete factories

and parts of factories for auto-

mobile production is our

strength. For vehicle assembly

we plan the general layout and

the logistics, develop the work

processes and carry out the

Quality Assurance

at the End of Line

We plan all test procedures for

the end of line – from wheel

alignment via the end of line

functional testing and headlight

aiming right up to checking the

vehicle electronics. In doing

Systems for Assembly

and Logistics

We have comprehensive know

how in planning of assembly

systems, from preassembly

and component assembly up

to mechanical solutions in final

assembly. Here we deal with

entire planning for fitting out

the factory. Our planning there-

by covers the entire range, from

the first concept to support

when starting up the completed

factory.

all kinds of engineering services

from concept up to start of pro-

duction including logistics, qua-

lity, cost per piece, technology,

and personnel requirements.

this, we create comprehensive

quality assurance concepts and

develop the entire layout of the

end of line including the flow

of vehicles.

147

Service Range

Factory planning

General planner for auto-mobile production and R&D

Project management for single up to large scale projects

Planning of vehicle assembly and testing systems

Planning of developmentcenters

Testing technology, consultancy, planning

Logistics planning

Services “Digital Factory”

Simultaneous engineering

Approval and expertise

Relocation

Analysis of processes and process design

ROI analysis

Looking after realization

Active presence in the market

and close attention to the

customers have become the

focus of our thoughts and

actions. Only in this way we are

enabled to develop and imple-

ment practicable and future-

oriented general concepts for

the factory of tomorrow. Dürr

Schenck Engineering (DSE) is a

visionary enterprise looking

back on a long company history.

Integrated into a large-scale

mechatronic group we have

direct access to a wide spec-

trum of knowledge and exper-

tise. We bundle our core com-

pentencies and make it

available to solve your individual

problem no matter whether

planning of a turn-key factory or

individual problems are con-

cerned. DSE stands for factory

planning to cover the entire pro-

cess – from first feasibility stu-

dies up to continued

support after the production

start. We counsel you in all

questions emerging around and

inside the factory. DSE experts

have available complete know

how of both the machines and

the processes. Our innovative

power is the driving force for

tailormade problem solutions.

Successfully implemented

concepts stand for the trust

we enjoy from our customers.

Continuous expansion of our

scope of supply and staff make

the industry prefer us as their

counterpart all over the world.

You may rely on the profes-

sionality and creativity of a

partner with worldwide repu-

tation and activities!

PlanningDürr Consulting

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Pl

an

ni

ng Planning of Test Plants

We design testing plants for the

development of vehicles and

engines - from single test stands

up to complete development

centers. Optimum testing con-

ditions and repeatable results

require the provision of suitable

equipment of the test cell,

media supply, safety systems,

Relocation

In this way we take the chance

to establish future-oriented

company structures.

Optimization of material hand-

ling and manufacturing proces-

ses as well as streamlining of

Approval and Expertise

Our qualified personnel will

take care of these time-con-

suming procedures for you; and

they will be thorough, reliable

and right on time.

Such procedures involve e.g.

approval procedures acc. to

BimSchG, noise and emission

expertise and environmental

audits.

logistics and buildings. The

specialists employed by Dürr

Schenck Engineering provide

their technical skills and exper-

tise gained through a wide range

of experience.

the product range and reorga-

nization are only a few of the

goals to be achieved.

Of course, effort is also put

into smooth moving and coor-

dination of rebuilding.

149

PlanningDürr Consulting

2004 Planning and realization of seat sets delivery,Volkswagen AG, Wolfsburg, Germany

2002 - 2004 Realization support of automotive final assembly BMW-X3,Magna Steyr Automotive engineering, Graz, Austria

2003 - 2004 Complete final assembly for transporters - open construction types, DaimlerChrysler GmbH, Ludwigsfelde, Germany

2004 Planning assistance for 3 European plants,Adam Opel AG, Antwerp, Ellesmere, Bochum

2004 Heavy duty trucks: Layout planning for end of tape – overhead noise barrier and supply and disposal systems for roll-test stands and environment, MAN, Salzgitter

2000 - 2004 General planning in the course of a turnkey project,Adam Opel AG, Rüsselsheim, Germany

2003 Integration of follow-up vehicles into the existing production,Adam Opel AG, Eisenach und Zaragoza (Spain)

2003 Concept planning of a new plant for light-duty commercial vehicles, DaimlerChrysler AG, USA

2003 Automatic delivery of axles to the marriage, Porsche AG, Zuffenhausen, Germany

2003 Integration of further vehicles into existing marriage system,Jaguar Ltd., Castle Bromwich (Great Britain)

2003 Flexibility study Hall 1,Magna Steyr Automotive engineering, Graz, Austria

2003 Feasibility study and concept planning for vehicle assembly in Brownfield, Magna Steyr Automotive engineering, Graz, Austria

150

Planning Projects since 2004

2005 Kia Zilina (Slovakia) Final assembly (detailed simulation entire assembly)

2005 Kia Zilina (Slovakia) Paint shop (detailed simulation entire paint shop)

2004 VW Poznan (Poland) Optimization paint selection buffer (detailed simulation)

2004 Hyundai Alabama (USA) Offline-test of control computer (EcoEMOS-SM / sequence optimization)

2004 SMART (Brazil) Paint shop (detailed simulation entire paint shop)

2004 Audi Neckarsulm (Germany) Vehicle body cleaning in pretreatment (detailed simulation)

2004 GM Holden (Australia) Final assembly supplying logistics (FASmatic® simulation)

2004 BMW Mini Oxford (UK) Extension paint shop (type concept simulation)

2004 VW Shanghei (China) Paint shop (detailed simulation entire paint shop)

2004 General Motors Shanghai (China) Final assembly (simulation of an assembly line)

2004 General Motors Shanghai (China) Paint shop / final assembly (detailed simulation)

2004 DaimlerChrysler Tuscaloosa (USA) Marriage, engine preassembly (FASmatic® planning simulation)

CAD Layout

Process Data

SimulationIntegral Element of the

Digital Factory

INPUT OUTPUT

Key Data

- Throughput- Filling level (buffer)- Lead time etc.

Visualization

PLC / MFCOff-line Test

Simulation

Parameter List

Electrical Design - Body Shop - Paint Shop - Final Assembly - Supplying Logistics(FASmatic®, EMS etc.)

Pl

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151

In recent years, simulation

engineering has produced com-

puter-based tools with which

it is possible to model and opti-

mize virtually all processes –

from production development

to material flow and production

sequences. Dürr utilizes the

diverse capabilities of simu-

lation, e.g. integration of time

and attendance models, CAD

layouts, order data, fault in-

fluences and availabilities, in

a simulation model. This allows

the dynamic behavior of the

planned system to be analyzed

even before the implementation

phase. Simulation engineering

has become an indispensable

instrument of planning for Dürr

and, even today, supplies the

basic tool for an integral

concept of the Digital Factory.

13 years of experience in the

sector of material flow simu-

lation speak for themselves.

Today, our range of work and

services extends over the entire

production chain of vehicle pro-

duction. Material flow simu-

lation for paint shops and final

assembly shops and the supply-

ing logistics with Electric Mono-

rail Systems (EMS) and Power

and Free systems are a part of

our strengths. The range of

simulation models extends

from planning simulation, e.g.

for protecting the scope of a bid

in the canvassing phase or for

version planning of various

system concepts, through to

detailed simulation of an already

planned system, which can be

used to simulate and validate

material flow and control of it

with accurate detail.

Range of Performance

Optimization of material flow systems by simulation

Capacity limit and performance limit analysis

Influence of time and atten-dance models, availability and breaks etc. on thedynamic behavior of systems

Evaluation, statistics and analysis of the simulation results in the form of diagrams and tables

Concept simulation:Protecting the scope of bids, version planning

Detailed simulation:Simulation, with accurate detail, for validation of the planned system

Presentation of the simulation results including final report

Visualization of simulation studies: 2-D layout-specific representation, 3-D visualization

Validation / optimization of control systems

Offline-Testing of Control software by coupling of con-trol computer (EcoEMOS-SM)with simulation model

Evaluation of the sequence of order in final assembly by sequence keeping ratio

The Production Chain in Vehicle Production

Material Flow SimulationScope of Services - Automotive

Material Flow, Vehicle body/vehicleMaterial Flow, Assembly Parts

Sequence Optimization

Paint ShopVehicleBody Shop

VehicleFinal Assembly

SupplyingLogistics, e.g. EMS

SupplyingLogistics, e.g.

FASmatic®

PlanningMaterial Flow Simulation

152

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Benefits of the Digital Factory

Speeding up of the planning and development processes

Enhanced planning reliability

Enhanced planning quality

Faster production startowing to simulation-aided system optimization

Design /Engineering

Graphics

Graphics

Planning / Design Simulation

Planning Database

Implementation

EcoEMOS SM(PSA)

Layout

Information

SimulationVisualization

MFC Poka Yoke Andon

Visualization

153

PlanningDigital Factory

Customer Solution

Besides optimization and

speeding up the internal plan-

ning processes on the basis

of the central process and

planning database, one other

focus is on participating

actively in configuration

design of the Digital Factory

interface of our customers

by means of proposals and

concepts. This allows joint

data structures to be genera-

ted and corresponding inter-

faces to be defined, both of

which assist the planning

processes and data acqui-

sition in the subsequent

project sequence, as early

as the run-up phase of

implementation of the

Digital Factory.

Requirements in respect offactory planning:The use of a large number of

different planning tools which

are used in the individual plan-

ning sectors, such as CAD

design (project origination),

CAD layout planning and simu-

lation of material flow and

processes, is characteristic of

the current situation in product

and factory planning. Our aim

is to integrate these insular IT

solutions within the framework

of the Digital Factory to such an

extent that the planning speed

and planning quality can be

enhanced despite increased

planning complexity.

Digital Factory as a solution approach:All relevant data on product,

process and resources is ma-

naged by a data management

system for integration of the

individual planning tools.

The focus is on access to a

common, consistent database

and not on exchanging the data

via interfaces. This means that

changes, e.g. in the CAD lay-

out, can immediately be recog-

nized by all those involved in

the planning process. At Dürr,

CAD data of layout planning

(Microstation) in future is

managed in a process and

planning database (Oracle) in

order handling. The data rele-

vant to material flow simulation

can thus be utilized for automa-

tic generation of a

simulation model. There is no

need for time-intensive pro-

curement of data. The planning

status of simulation corresponds

to the planning status of layout

planning.

Process Simulation

Product Origination Process Planning Time Management Layout Planning

Series Planning

Logistics

Ergonomics

Robot SimulationMaterial Flow-/Factory Simulation

Processs- and Planning Database

Product ResourcesProcess

154

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Data Transfer

Mobile Systems in Conveyor Technique

Control

Drive EngineeringNon-contact

Energy Transfer

Advantages in relation to energy transfer:

No wearing parts

No pollution

High system reliability and safety

Insensitivity against pollution and environmental influences

Reduced noise emission

Can be used in the explosion-hazard area

Advantages in relation to data transfer:

No wearing parts

Insensitive to dirt

High flexibility of application

High transfer reliability

High transfer rate

No restriction on vehicle numbers

Advantages in relation to automation:

Flexible adaptation to the production process

Dynamic travelling performance

Preventive maintenance

No block section control

Exact vehicle tracking thanksto unique identification

Production data handling

155

In systems partnership with SEW,

Dürr has developed a modular

system for mobile data tags and

electrical loads to solve the prob-

lems associated with dirt, wear

and a lack of flexibility in materi-

als handling. FASmotion – the

non-contact system for transfer

of energy and data – opens up

new capabilities for all moving

systems. The costs of mainte-

nance and servicing are cut sub-

stantially since the system is

not subject to wear and shut-

down time is minimized. Pre-tes-

ted modules of function do abbre-

viate time schedules for assem-

bly and commissioning. This al-

lows a faster start up of plant.

The mechatronic solution FAS-

motion which combines com-

ponents of materials handling and

electrical components of energy

and information transfer, drive

engineering and control and auto-

mation enhances the perfor-

mance of classic systems and

implements entirely new

functions.

Cross FunctionsFASmotion - Non ContactEnergy- and Data Transfer

Field of Application

Electric monorail system (EMS)

RoDip 3 + E

Skillet conveyor

Automated Guided Vehicle FASmatic®

TTS-Skillet

FAStplant®

Types of Line Equipment

Design for floor-level transfer

Design in accordance with VDI-C1 Directive

Design with U-section

156

Cro

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Field bus

Sta

ndar

dize

din

terf

ace

Functional description

EcoDBH

EcoDBH is the basis of all

Dürr control systems. There

is a EcoDBH data block for

each module. The EcoDBH

modular system allows fast

and controlled integration of

new requirements. The

standardized control cabinet

and control console units are

manufactured and supplied

workshop-tested from our

own production facilities.

EcoDBS

EcoDBS is the PLC software

module system for all Dürr

control systems with stan-

dardized and time-proven

function blocks for sensors

and actuators with tested

function. EcoDBS is tar-

geted at the requirements in

conveyor systems. The time-

proven structure and func-

tionality can be transferred

to numerous control plat-

forms of our customers.

Standardized interfaces

allow easy integration and a

nearly fully-automated com-

missioning with EcoEMOS.

EcoDIM

EcoDIM allows series pro-

duction of mechatronic

units. Pre-tested function

modules shorten assembly

and commissioning times.

They also decouple proces-

ses by decentralizing the

control intelligence and thus

enhance system availability.

Fault clearance times are

shorter thanks to inter-

changeability of the modules.

EcoDIM enhances system

flexibility and reduces the

system complexity.

EcoEMOS

EcoEMOS is the software

module system with the Eco-

Screen functions for opera-

ting, monitoring and parame-

ter assignment of conveyor

systems as well as all ad-

advanced functions in logis-

tics. This are e.g. controls

for paint selection storages,

high-bay warehouses, identi-

fication and tracking functions

and modules for optimizing

the sequence of vehicles in

the final assembly process.

In addition to the require-

ments of material flow and

logistics, the software mo-

dule system offers modules

of a Manufacturing Execution

System (MES) for control

and monitoring of production

in Body Shop, Paint Shop and

Final Assembly.

= Positioning of the EcoDIM Modules

157

Dürr control and manufacturing

execution systems offer an in-

tegrated and standardized solu-

tion for the firmly established

control makes. This includes

PLC software and visualization

as well as historical and control

functions on databases. The

overall system is subdivided

into functional units, the

function groups. Each of these

function groups consists of

standardized and time-proven

function elements.

Knowledge gained from com-

missioning and maintenance is

incorporated continuously and

leads to an increasing product

quality. Thanks to system expe-

rience and process knowledge,

we have been optimizing our

control engineering for decades

now to increase customer bene-

fit. A universal control concept

is available for any requirement

in conjunction with EcoDBH,

EcoDBS and EcoEMOS.

Cross FunctionsControl & ManufacturingExecution Systems

Vertical and Horizontal Integration of Production Control

Customer specificenterprise and plant IT

level

MES level/ Super-visory control level

Visualization level

Control level

Process level

EcoEMOS

Body Shop

EcoEMOS

Paint Shop

EcoEMOS Plant

EcoEMOS

Final Assembly

PLC PLC, PC PLC, PC

Body Shop Paint Shop Final Assembly

EnterpriseResource

Planning System

Supply Chain

Management

Quality

Management

System Elements

EcoDBH - Dürr Basic Hard-ware

EcoDBS - Dürr Basic Soft-ware

EcoDIM - Distributed Intelligence Module control system

EcoEMOS - Software module system from visuali-zation with EcoScreen up to MES functions

Your Advantage

Specially developed for the automotive industry and conveyor technique in auto-motive plants

Extensive software functions covering the requirements of a broad customer basis

Integrated scalable software modules for PLC, visualiza-tion, production control and historical functions on databases

Open interface and data modelfor the automotive industry

158

FA

Sc

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ac

t FAScontract defines our pro-

cess-oriented way of realizing

turnkey and full service pro-

jects. Our main task is the opti-

mization of assembly projects

based on Dürr’s leading techno-

logy and know-how.

159

FAScontractTurnkey & Systems Integration

Your Advantage

Reliability and safety owing to technology leadership

One interface

One contact

One responsibility

Minimum coordination effort and expenditure

Processes in final assembly are

characterized by high complexity

and the need for maximum effi-

ciency. Thus, FAScontract‘s ap-

proach is a holistic one and de-

fines the implementation of an

assembly as a product with the

main emphasis on the process.

We offer the three main factors

for a successful project imple-

mentation in-house: the enginee-

ring and planning, the products

and a sophisticated project ma-

nagement.

FAScontract by Dürr means

more than a sequence of single

production steps. It is the intelli-

gent conversion of Dürr‘s exten-

sive know-how for technologies,

systems and solutions.

Our strengths are a close coope-

ration in partnership with our

customer, the reduction of costs

per unit, the consistent use of

modern methods such as value

engineering during implemen-

tation and of course keeping the

schedule and the fixed budget.

The results are customer-orien-

ted solutions from the first con-

cept throughout process plan-

ning to innovative technical so-

lutions and a precise realization.

FAScontract - Leading edge through competence

Process Partnership - Dürr FAS is a process realization partner

Dürr FAS can also act as a classical turnkey supplier

Slat Conveyor Roller Test Stand Brake fillingSkillet Conveyor

ProcessF A S

EOL/FinishTrim Chassis Final

Door EMS Body EMS

Glazing Station Decking Station Tightening Robot

Wheel Aligner

Water Proof

Wheel Manipulator

Logistic Process

160

FA

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t Dürr Factory Assembly Sys-

tems has assumed a leading

position within a very short

time and is operating amongst

the top group of final assembly

system suppliers with its con-

vincing product and service

portfolio.

Production systems for vehicle

final assembly – to date one of

the highest-volume markets in

the automobile value-added

chain – is a market sector

which is continuing to grow pri-

marily owing to the growing

model diversity and the need

for more production and more

flexible vehicle assembly.

FAScontract is a future-oriented

and convincing turnkey concept.

It bases on our process know-

how, a sophisticated project

management worldwide and

highly innovative products par-

ticularly for turnkey solutions

such as FAStplant®.

That is why Factory Assembly

Systems is a strong mainstay of

the Dürr technology group.

FAScontract

EngineeringPlanning

3rd party

ProfessionalTools

InnovativeProducts

High-endequipment

Assembly facilities

based on customers

needs and worldwide

standards

161

FAScontractTurnkey & Systems Integration

References

KIA Complete vehicle final assemblyZilina, Slovakia

Peugeot-Citroën Complete finish areaTrnava, Slovakia

VW Mosel, Complete vehicle final assemblyGermany

Peugeot Porto Complete vehicle final assemblyReal, Brazil

Opel Rüssels- Complete vehicle final assemblyheim, Germany

Magna Steyr Complete vehicle final assemblyGraz, Austria

Bentley Complete vehicle final assemblyCrewe, UK

Land Rover Complete vehicle final assemblySolihull, UK

DaimlerChrysler Conversion and extension of theTuscaloosa, USA complete vehicle final assembly

Scope of Work / Services

Bid Processing

Planning

Project Management

Construction Site and Commissioning Coordination

Acceptance Testing and Launch Management

Service Management

Scope of Delivery

Filling technology

Automated glass installation

Marriage technology

Handling devices

Conveyor technology

Heel alignement teststands

Headlamp aiming

Roller / Brake / ABS test stands

Electronic checkout system (ECOS)

Water test cabins

Car wash systems

Spot repair

Cavity preservation

Final waxing

Systems Integration

Filling Technology

Planning Production Implementation Construction TGA

Interfaces CE ISO 9001

Detailed deadlineSchedule

Overall deadlineSchedule

Cost Tracking /Optimization

HardwareSoftware

Conveyor Technology Automated Glass Installation

Overall Responsibility Interface Coordination

Quality Assurance Standardization

Deadline and Cost Controlling

FAScontractSystems

Integration

162

As project completion periods

become shorter and shorter, more

and more pressure is applied on

all sides to cut costs, technical

complexity increases and the

number of interfaces grows with

the large number of contractors

involved, project management

must be developed to deal with

these demands.

Dürr is responding with the intro-

duction of a Center of Excellence

that will focus particularly on pro-

ject management. The Center's

tasks will include the further

development of processes, tools

and training courses; methods

based on the generic project pro-

cessing procedure implemented

globally by Dürr.

Modern IT tools are used in sup-

port of these methods with which

all project managers are very fami-

liar. At Dürr the closely linked

use of SAP, MS Project and Dürr's

own PIM (Project Information

Management) tool ensures opti-

mized data communication and

processes. It is also possible to

include customers and suppliers

in interactive use of these tools.

Comprehensive training of

project managers ensures con-

sistent application of the same

methods and standards.

Handling and processing of

complex projects poses ever

greater challenges that require

a modern and global approach

to Project Management.

Generic Project Processing

Organization & Responsibilities

Interface Required Optional Deviation Mandatory InterfaceMarketing & possible ServiceSales

Commis-sioning

Quotation Hand overP0 P1 P2 P3 P4 P6P5

Planning Design Manufac-turing

Instal-lation

Procedures & Tools

Controlling & Reporting

Project Change Management

Procurement & Supplier Management

P SM

S1

S2

S3

S4

S5

M00 M0 M1 M2 M3 M4 M5 M6 M7 M8 M9 M10

Conzept freeze Design freeze External kick-off customer Design

Internal kick-off freeze Pre-acceptanceOrder intake Start of installation

Quote Start of ClientComis- acceptance

Receipt of RFQ sioning Final acceptanceFinal report

FA

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FAScontractProject Management

Your advantages

Shorter processing periods

Project transparency

Standardized procedures

Efficient change management

Customer satisfaction

The PIM Tool is a database appli-

cation offering an HTML user

interface to assist internal and

external members of project

teams to carry out their project-

related tasks and to manage the

communication of relevant infor-

mation resulting from them.

Project management today ... Project management with PIM ...

Use of many different systems and data file types

Varying customer and supplier standards

Non-uniform status of information available to project participants

Insufficient availlability of information

Lengthy communi-cation routes

High level of cost and effort involved in obtaining and distributing information

Use of one single tool to access and track a wide range of project-related information

Consistency copled with ease of data retrieval

HTML interface for worldwide availability

Simplicity of use via a standardized user interface

Greater transparency for all project participants

More efficient information management

PIM

PIM

Tasks

Minutes

Site Reports

Request for Information

RFI

1

2 3

4

5

67

8

Project Change Request

PCR

Customer Change Request

CCR

Project Change Supplier

PCS

Punch Lists

164

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FAStplant®, supplied by Dürr FAS

represents a new approach to

providing really flexible systems

for final assembly. The concept

is based on three different, pre-

assembled standard modules that

can be combined and arranged

into process lines to suit all

assembly shop requirements.

And in principle there is no need

to suspend anything from the

roof or to dig pits.

Each of the basic modules com-

prises a steel structure, con-

veyor equipment, an inductive

power and data transfer system

FASmotion, lighting and control

elements.

The modules are equipped to

suit the specific requirements of

the work station involved so they

can be designed to handle all

aspects of final assembly - from

trim stages right through to the

end of line area.

No matter whether the require-

ment is for a new assembly line

or for adaptation, extension or

shortening of the line –

FAStplant®'s modular structure

makes all of these simplicity

itself. Complete plants can also

be dismantled then rebuilt else-

where very quickly.

Technologies – Systems –

Solutions: FAStplant® is Dürr

FAS's response to the increasing

need for flexible and adaptable

concepts for final assembly

operations.

FAStplant® the system that

combines pre-assembled

standard modules and equips

them to suit the specific re-

quirements of the work

station involved.

FAStplant® - tomorrow's modular factory concept

165

FAScontractFAStplant® - the Modular Final Assembly

The essentials

Pre-assembled and pre-tested standard modules

Self-contained units indepen-dent of the building structure (no pits necessary and no sup-port required from structural steelwork of shop)

Uniform conveyor system

Flexible assembly lines that can be extended, shortened or adapted easily.

Modification/retrofitting within a few days

Can be reused if lines need to be moved to new locations

Can be dismantled and rebuilt fast

Steel structure complete with maintenance walkways

Utilities

Power supplyPneumaticsLighting

Conveyor equipment

TTS / EMS conveyorFASmotionLifting equipmentCarrier

Electrical / control system concepts

Work stationequipment

Standard module

Handling equipment

Man movers(available as optionalequipment)

Pilot lines

New factories

Retrofitting

CKD lines

FAStplant® – flexible and reusable

166

FA

Sc

on

tr

ac

t Modular rail units

for inductive power supply -

FASmotion

Connection for

data transfer

Distribution module

for power transfer

Wheel alignment

in the line

Filling

Cockpit assembly

B

D

C

A

C

B

A

E

F

D

E

F

167

Your advantages

Shorter installation times

Lower investment costs

Reusability

More easily adaptable

Higher availability

Greater flexibility

Optimized processes

Layout advantages

Only one conveyor transfer

Only one back-up vehicle type

Only one conveyor repair loop

Only one conveyor diagnostics station

FAScontractFAStplant® - the Modular Final Assembly

Reference list

2004 DaimlerChrysler at Sindelfingen, Germany

Load capacity 2,500 kg

Lifting height 1,500 mm

Speed TTS 4.7 m/min (2.8 – 6.6 m/min)

Lifting speed 6 m/min

2005 Toyota at Valenciennes, France

2006 Audi at Neckarsulm, Germany

2006 BMW at Chennai, India

168

DÜRRWorldwide

Deutschland

Dürr AG

Stuttgart, phone: +49-711-136-0corpcom@durr.com

Carl Schenck AG

Darmstadt, phone: +49-6151-32-0schenck@schenck.net

Dürr Systems GmbH

Stuttgart, phone: +49-711-136-0corpcom@durr.com

Bietigheim-Bissingen, phone: +49-7142-78-0durr.apt@durr.com

Braunschweig, phone: +49-5 31-2159-0FAS@durr.com

Darmstadt, phone: +49-6151-32-42 01FAS@durr.com

Ochtrup, phone: +49 -25 53-9 27-0rebekka.paul@durr.com

Dürr Assembly Products GmbH

Püttlingen, phone: +49-68 98-6 92-0durr-ap@durr.com

Dürr Somac GmbH

Stollberg, phone: +49-37 29-65 47-0somac@durr.com

Dürr Special Material Handling GmbH

Grenzach-Wyhlen, phone: +49-76 24-310dsmh@durr.com

Dürr Ecoclean GmbH

Filderstadt, phone: +49-711-70 06-0info.filderstadt@ecoclean.durr.com

Monschau, phone: +49-24 72-83-0info.monschau@ecoclean.durr.com

Schenck Pegasus GmbH

Darmstadt, phone: +49-61 51-32-30 98pegasus@ecoclean.durr.com

Schenck RoTec GmbH

Darmstadt, phone: +49-61 51-32-2311schenck.rotec@schenck.net

Australien

Dürr Pty. Ltd.

Adelaide, phone: +61-8-82 38 34 63chris.kennedy@durr.com.au

Brasilien

Dürr Brasil Ltda.

São Paulo, phone: +55-11-56 33 35 00durrbr@durr.com.br

China

Dürr Paintshop Systems Engineering

(Shanghai) Co. Ltd.

Schanghai, phone: +86-21-6219 3719general@durr.com.cn

Schenck Shanghai

Machinery Corp. Ltd.

Schanghai, phone: +86-21-62 65 96 63 ssm-rotec@online.sh.cncontact@durr-ecoclean.com.cn

Schenck Shanghai

Testing Machinery Corp. Ltd.

Schanghai, phone: +86-21-3 06 45 99

Frankreich

Dürr Systems S.A.S.

Montigny-le-Bretonneux, phone: +33-172-82 00 00general@durr-ai.com

Dürr Ecoclean S.A.S.

Loué, phone: +33-2-43 3978 00info.france@ecoclean.durr.com

Schenck S.A.S.

Cergy-Pontoise, phone: +33-1-34 32 90 00ssa@ssa.schenck.net

Großbritannien

Dürr Ltd.

Warwick, phone: +44-19 26-4188 00sales@durr.co.uk

Schenck Ltd.

Warwick, phone: +44-19 26-4188 98rotec@schenck.co.uk

Indien

Dürr India Pvt. Ltd.

Chennai, phone: +91-24-32 36 20/21sgupta10@durrindia.com

Schenck RoTec India Ltd.

Noida, phone: +91-120-2 56 3174/179sal@schenck-ind.com

Italien

Olpidürr S.p.A.

Novegro di Segrate, phone: +39-02-70 2121sales@olpidurr.it

CPM S.p.A.

Beinasco, phone: +39-011-3 98 8411dir@cpm-spa.com

Polisistem S.r.l.

Turin, phone: +39-011-6126 26polisistem@polisistem.it

Verind S.p.A.

Rodano, phone: +39-02-9 59 51 71direzione@verind.it

Schenck Italia S.r.l.

Paderno Dugnano (MI),phone: +39-02-91 00 24 31schenck.italia@sit.schenck.net

Japan

Dürr Japan K.K.

Yokohama, phone: +81-45-4 75 36 71s-katayama@durr.co.jp

Nagahama Seisakusho Ltd.

Osaka, phone: +81-726- 96 33 01nso@nagahama.co.jp

Mexiko

Dürr Systems Mexico

Queretaro, phone: +52-442-192-57 00durr.mexico@durrmex.com.mx

Niederlande

Carl Schenck Machines

en Installaties B.V.

Rotterdam, phone: +31-10-4 1175 40info@schenck.nl

Österreich

Dürr Anlagenbau Ges.m.b.H.

Zistersdorf, phone: +43-25 32-25 46duerr.zistersdorf@durr.com

Polen

Dürrpol Sp. z o.o.

Radom, phone: +48-48-3 610100durrpol@durrpol.pl

Russland

Dürr Systems GmbH

Moskau, phone: +7-495-789 35 68durr@durr.msk.ru

Spanien

Dürr Systems Spain S.A.

Madrid, phone: +34-915-5176 63durr-spain@durr-spain.com

San Sebastian, phone: +34-9 43-3170 00durr-spain@durr-spain.com

Valladolid, phone: +34-9 83-39 70 02durr-spain@durr-spain.com

Viladecans, phone: +34-93-6 47 25 25durr-spain@durr-spain.com

Dürr Ecoclean S.A.

Barcelona, phone: +34-93-2 92 1100info.spain@ecoclean.durr.com

Südafrika

Dürr South Africa Ltd.

Port Elizabeth, phone: +27-41-3 93 54 00durr@durrsa.co.za

Südkorea

Dürr Korea Inc.

Seoul, phone: +82-2-5 69 22 44koch@durr.co.kr

Tschechische Republik

Dürr Ecoclean spol. s.r.o.

Oslavany-Padochov phone: +42-05 46-42 35 22-3info.czechia@ecoclean.durr.com

USA

Dürr AIS Inc.

Plymouth, phone: +1-7 34-4 59 68 00PSIsales@durrusa.com

Dürr Inc.

Plymouth, phone: +1-7 34-4 59 68 00jeanie.cotton@durrusa.com

Dürr Systems Inc.

Auburn Hills, phone: +1-2 48-745 85 00APTsales@durrusa.com

Plymouth, phone: +1-7 34-4 59 68 00PSAsales@durrusa.comEESsales@durrusa.comACTsales@durrusa.com

Warren, phone: +1-5 86-7 55 75 00FAPsales@durrusa.com

Dürr Ecoclean Inc.

Bowling Green, phone: +1-4 19-3 52 75 01henry@henryfilters.commail@hrblack.com

Wixom, phone: +1-2 48-9 60 46 30info.usa@ecoclean.durr.com

Schenck RoTec Corp.

Orion, phone: +1-2 48-3 77 21 00sales@schenck-turner.com

Schenck Trebel Corp.

Deer Park, phone: +1-6 31-2 42 40 10sales@schenck-usa.com

Paint and Assembly Systems

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