Alfred Kärcher SE & Co. KG / Site Bühlertal

At its Obersontheim / Bühlertal site, Kärcher manufactures some of its top products on a single manufacturing line. When further developing this line, the team of product developers and production staff had to overcome several challenges: in addition to the high product variance, manual assembly and integration efforts dominated the production. Furthermore, high costs were incurred due to set-up times. Moreover, the spatial conditions at the plant limited the options for ergonomic workplace design and the implementation of advanced manufacturing technologies.

The team redesigned the assembly line using a holistic, modular approach, integrating the entire value chain from development to the end customer. The main objectives were to increase production flexibility, reduce costs, improve quality through worker self-inspection, and enhance the integration and networking of the line.

The Industry 4.0 solution incorporates several technologies and elements. It connects automation systems, robots, and digital workstations to create a highly efficient and interconnected production environment.

The project team developed a modular system for new product generations to reduce internal complexity. Key production experts were closely involved to ensure that industrialization requirements, particularly regarding automation potential, were optimally considered.

The result is a highly automated production line for a core product series, featuring fully networked systems, automated setup processes, and partially automated “Bin Picking.” Additionally, vertical manufacturing technologies are integrated, e.g. aluminum motor housing turning.

Demand is managed via APS (SAP APO), while order fine planning is handled within the integrated MES. Employees on the manufacturing line use standardized digital interfaces at their workstations, providing task- and workstation-specific information. Further elements include semi-automated material provisioning and AGVs for transport between the finished goods warehouse and shipping.