Mercedes-Benz: The Factory of the Future
Mercedes-Benz has long been synonymous with innovation and excellence in the automotive industry.
From pioneering the internal combustion engine to leading the charge in electric-vehicle technology, the company has consistently been at the forefront of automotive advancements.
Producing more than two million products annually, including engines, transmissions, axles, components and batteries, Mercedes-Benz’s manufacturing prowess is unmatched.
Here, Manufacturing Digital explores the company's rich, 120-year history and its ongoing commitment to innovation, particularly in digital technologies.
Celebrating 120 years of innovation at Stuttgart-Untertürkheim
The Stuttgart-Untertürkheim plant, a cornerstone of Mercedes-Benz's manufacturing capabilities, celebrated its 120th anniversary in July.
Established in 1904, the plant initially focused on engines, transmissions and vehicles, before expanding to include comprehensive development and testing facilities. Today, it is a pivotal part of Mercedes-Benz’s global powertrain production network.
The plant’s recent inauguration of the eCampus, dedicated to developing cells and batteries for future EVs, highlights its role in the company’s shift towards electromobility.
Jörg Burzer, Member of the Board of Management, highlights the plant’s significance: “The Stuttgart-Untertürkheim site and its great team stand for the success story of Mercedes-Benz. With new, sustainable high-tech products, the plant is ready to continue this story.”
The anniversary event, attended by more than 50,000 guests, featured open production areas, exhibitions and a laser show, celebrating both tradition and innovation.
By 2024, the plant will begin producing electric drive units, with contributions from other sites like Bad Cannstatt, Mettingen and Hedelfingen.
This transformation is part of Mercedes-Benz's broader aim for net carbon neutrality across all production sites by 2039.
Advancing battery technology at the eCampus
In its pursuit of innovation, Mercedes-Benz has inaugurated the eCampus at its Stuttgart-Untertürkheim plant.
This state-of-the-art facility is dedicated to advancing battery technology, a critical component in the transition to electric vehicles. The eCampus focuses on developing high-performance battery cells and innovative manufacturing processes.
"Our goal is to reduce battery costs by more than 30% in the coming years," comments Ola Källenius, CEO of Mercedes-Benz.
To achieve this, Mercedes-Benz is investing €14bn (US$15.3bn) in research and development by 2024, with a significant emphasis on battery and electric drive system advancements.
The eCampus features the Industrial Cell Lab, which covers the full spectrum of cell development and production, aiming to enhance energy density and optimise industrial-scale manufacturing.
The facility's sustainable design incorporates recycled concrete, a green roof with photovoltaics and energy-efficient systems, highlighting Mercedes-Benz's commitment to environmental responsibility.
At the opening ceremony, Robert Habeck, Germany’s Federal Minister of Economic Affairs, praised the initiative, saying: "I am delighted that, with the new eCampus, Mercedes-Benz will be focusing its research and development activities for batteries at the Untertürkheim site in future."
Digital twin technology and the 'digital-first' approach
Central to Mercedes-Benz's modern manufacturing strategy is the utilisation of digital twin technology.
This innovative approach allows the company to create precise virtual simulations of its production lines, enabling comprehensive planning and optimisation before physical implementation.
Partnering with NVIDIA Omniverse, Mercedes-Benz has harnessed the power of digital twins to significantly enhance efficiency, reduce defects and save valuable time across its manufacturing processes.
A prime example of this technology in action is at the Rastatt plant in Germany. There, digital twins are used to virtually plan and optimise assembly lines, minimising disruptions and accelerating production ramp-ups.
This seamless integration of digital technology into manufacturing not only improves the precision and quality of production, but also reduces costs and environmental impact by cutting down on waste and resource usage.
Factory 56: A glimpse into the future of manufacturing
One of the most striking examples of Mercedes-Benz's commitment to innovation is Factory 56 in Sindelfingen, Germany.
This ultramodern production facility, which opened in 2020, embodies the company's vision for the future of manufacturing, leveraging cutting-edge technologies and sustainable practices to set new standards in automotive production.
Factory 56 is equipped with a fully-digital infrastructure that integrates all production systems and processes into a single, intelligent network. This includes the use of digital twins, 5G connectivity and a range of smart manufacturing technologies.
The factory's modular design allows for maximum flexibility, enabling it to produce different models on the same line without significant reconfiguration.
Sustainability is a core focus of the facility, which is powered by renewable energy sources and features a photovoltaic system on its roof to generate around 30% of its energy needs.
Mercedes-Benz’s commitment to innovation, particularly through digital technologies and sustainable practices, ensures that it remains at the forefront of the automotive industry and carries forward its legacy of innovation.
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