[SLIDESHOW] How the Porsche 918 Spyder is made

By Glen White
The Porsche 918 Spyder manufactory in Stuttgart-Zuffenhausen is a real eye-catcher – both visually and in terms of the processes and variety of ne...

The Porsche 918 Spyder manufactory in Stuttgart-Zuffenhausen is a real eye-catcher – both visually and in terms of the processes and variety of new developments in the field of assembly and quality assurance that take place there. Patent applications are currently pending for some of these innovations, which fulfill the very highest standards particularly when it comes to ergonomics. These innovations emphasise the fact “that our definition of innovation goes well beyond the vehicle itself”, as explained by Michael Drolshagen, who, as Director of Production, was involved in the designing the manufactory and who oversees the activities that go on there today.

The examples below give an overview of the ergonomic innovations in use at the plant:

Scissors lift platforms

The scissors lift platforms enable ergonomic assembly of vehicles, starting with the interior and working outwards to complete the exterior. The scissors lift platforms move from station to station at the push of a button, making the technicians’ work considerably easier when they need to fit a 140-kg high-voltage battery at the rear of a vehicle, for example. In addition, the scissors lift platforms ensure that the bodyshell can be fitted without causing any damage.

Assembly elevating truck

The battery-powered elevating truck has been designed especially for the Porsche manufactory. The truck carries the two-seater monocoque, which is the starting point of assembling the Porsche 918 Spyder. The elevating truck allows the monocoque shell to be rotated, tilted, lifted and lowered, meaning the interior of the vehicle as well as the 12-volt battery and the high-voltage wiring can be positioned with great ease. The ability to position components with ease is, in fact, the key to preventing damage when fitting the components.

Drivetrain assembly

During the “engagement” process, the electric motor and transmission module is connected in a de-energised state to the engine with the help of a specially developed trolley. Together, these components form the vehicle’s drive unit. At this point, the specially designed scissors lift platforms are used: They position the unit carrier above the drive unit so that both elements can be screwed together at three different points. The next stage of the process is called the “marriage”. The marriage involves the unit carrier and the drive unit being connected to the monocoque via six bolts.

Wheel alignment platform

Thanks to the new wheel alignment platform in use at the manufactory, all the essential parameters can now be measured within a very small space. These parameters include properties such as the cross load, track and camber, and each one can be configured to the optimum setting for the vehicle.

Leather finishing and assembly tables

The leather finishing and assembly tables used at the 918 manufactory set the benchmark when it comes to ergonomics and flexibility. For example, interchangeable inserts allow different components to be manufactured, ensuring that station times are fully utilised. Furthermore, the height of the tables can be adjusted along with the angle so that the table corresponds to the needs of the individual employee.

Bluetooth-controlled cordless screwdriver

The Bluetooth-controlled cordless screwdrivers are being used for the first time at Porsche. These screwdrivers endorse the philosophy at the manufactory because they work virtually silently and require no wiring. These features give the technicians maximum flexibility, and the risk of damage to components is greatly reduced. What’s more, coupling the screwdrivers with the database via a Bluetooth interface ensures that the torque values for all safety-specific screw connections are complied with and can be documented and checked at any time.

Electronic vehicle tracking card

The electronic vehicle tracking card, known as the eWbk for short, may not be an innovation for the Porsche 918 Spyder manufactory, but it clearly shows how the Zuffenhausen site – home to the 911 production line for five decades – has been able to effectively combine small-scale and large-scale production. A standard feature of large-scale production for many years, the eWbk system used at the manufactory also contains a wealth of information that is essential to the production process, including drawings and test points to name just a couple. In addition, the card can be used to document potential problems – perhaps if the feedback from the Bluetooth-controlled cordless screwdriver indicates that a particular torque was not reached.

Porsche model range 911: combined fuel consumption 12,4–8,2 l/100 km; CO2 emissions 289–191 g/km; efficiency class: G–F

Porsche 918 Spyder: combined fuel consumption 3,1–3,0 l/100 km, combined energy consumption 12,7 kWh/100 km; CO2 emissions 72–70 g/km; efficiency class: A+”


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