The assembly line

On the assembly line, we turn the Panamera and Macan bodies into vehicles that are in a class of their own. Meeting our customers’ wishes and desires is our priority here. Hardly any of our vehicles are identical, because at Porsche we offer a degree of customization which is usually only found in manufacturing.

In up to three shifts a day, our colleagues produce models with gasoline and diesel engines but also plug-in hybrid vehicles. To guarantee efficient, high-capacity production in the face of such complex tasks, professional logistics is key. Consequently, we rely on a “just-in-sequence” strategy (JIS), which means that the sequence of vehicle bodies delivered to our factory corresponds exactly to the production sequence. System suppliers deliver pre-assembled and model-specific components at the same time. As a result, we can implement the proven concept of lean inventories.

 

1. Interior line

This is the first step on the assembly line, when the doors are removed from the bodies in order to work on them separately on the door line. If the...

This is the first step on the assembly line, when the doors are removed from the bodies in order to work on them separately on the door line. If the doors were to remain on the vehicle, many of the subsequent interior line assembly steps could not be performed. Following this step, the cockpit, one of the largest complete modules, is installed in the Macan and Panamera. Depending on version and fitting, a cockpit may consist of up to 200 individual parts, weigh between 60 and 90 kilos and have a combined cable length of between 2 and 3 kilometers. Our colleagues on the assembly line perform this precision work using a handling device which is docked to the cockpit and allows them to guide the cockpit into the vehicle.

Other components assembled in this step include sliding or panorama roofs, control units and the rooflining, including grab handles and sun shades. The final step on the interior line is training the key, which is put into the ignition here for the first time.

2. Door line

All components belonging to the side doors of Macan and Panamera are fitted here. This includes windows, outside mirrors, exterior door handles and...

All components belonging to the side doors of Macan and Panamera are fitted here. This includes windows, outside mirrors, exterior door handles and door locks as well as seals, frame trims and the interior trim. At the beginning of the process, a door weighs approx. 8 kilos. After assembly, a complete door weighs around 25 kilos or more.

3. Underbody line

Here we complete the assembly of the underbody of both models, including brake and fuel lines and all kinds of cable harnesses. Fuel tank and park...

Here we complete the assembly of the underbody of both models, including brake and fuel lines and all kinds of cable harnesses. Fuel tank and park heating are also fitted into place here.

4. Exterior line

On the exterior line, robots fit the front and back windows and bond them into place. Main headlights, rear and front seats, side airbags, the battery...

On the exterior line, robots fit the front and back windows and bond them into place. Main headlights, rear and front seats, side airbags, the battery and accelerator pedal are also installed here. In addition, the Porsche crest is placed on the Macan and Panamera models. At the end of the exterior line the completed doors are once again fitted onto the body. Once they have passed this last part of the pre-assembly, the vehicles are conveyed to the mix line for final assembly.

5. Engine pre-assembly

In this area, gear transmissions and components such as a/c compressors, generators, starters and servo-pumps are attached to the engines delivered....

In this area, gear transmissions and components such as a/c compressors, generators, starters and servo-pumps are attached to the engines delivered. The engines are then subjected to meticulous quality control. If they pass, they are taken to the “engagement”. Engagement here means that the completed engine-transmission unit is placed onto the front axle of the vehicle.

6. Marriage

Following work on the exhaust system, axles and steering, the vehicle is ready for “marriage”, one of the most spectacular steps on any vehicle...

Following work on the exhaust system, axles and steering, the vehicle is ready for “marriage”, one of the most spectacular steps on any vehicle assembly line. Here, an automated guided vehicle system (AGVS) places the completed drivetrain underneath the associated vehicle body and bolts it firmly into place. In this way, the engine, chassis and body are virtually “married”. In a final step the tailpipes are installed.

7. Engine wiring

All systems are connected here to get the vehicle ready for subsequent filling. Among the systems connected in this step are the brake lines on the...

All systems are connected here to get the vehicle ready for subsequent filling. Among the systems connected in this step are the brake lines on the front and rear axles, the fuel pipes and the air line components for the pneumatic springs. The rear lettering is also fitted at this station.

8. Filling

Before filling, the radio or Porsche Communication Management (PCM) and gearshift are installed. Fuel, coolant and brake fluid are filled into the...

Before filling, the radio or Porsche Communication Management (PCM) and gearshift are installed. Fuel, coolant and brake fluid are filled into the vehicle swiftly and accurately using a state-of-the-art vacuum/pressure filling system.

9. Wheel mounting

Prior to installing the wheels, the steering wheel and driver airbag are installed. Subsequently, the wheels are mounted using a handling unit and a...

Prior to installing the wheels, the steering wheel and driver airbag are installed. Subsequently, the wheels are mounted using a handling unit and a bolter. Each wheel weighs 35 kilos and is fastened with 5 bolts.

10. Test line

In the test bay, the vehicle is placed on its wheels for the first time. After the programming of various control devices comes another exciting...

In the test bay, the vehicle is placed on its wheels for the first time. After the programming of various control devices comes another exciting moment: the engine is started for the first time. Further steps include some final chassis and headlight tuning and the calibration of the driver assistance systems. The wheel alignment is measured with tracking cameras and adjusted manually. A steering wheel balance guarantees the straight-ahead position of the steering wheel. On completion of these steps, the vehicles are then taken to the chassis dynamometer for a driving simulation at a maximum speed of 100 km/h for a total distance of 1.5 kilometers.

11. Test drive and final inspection

As every Porsche has to meet the highest quality standards we subject each vehicle to a very thorough inspection before delivery. During this final...

As every Porsche has to meet the highest quality standards we subject each vehicle to a very thorough inspection before delivery. During this final quality inspection, experienced colleagues test the vehicles on our own test track. They test the lights in a darkroom and water tightness using a sprinkler system. After that, each Porsche is taken to the wash box and the interior is cleaned. Having passed further quality check-ups the vehicle is finally released and packed for transport.

12. Audit

During the audit, individual vehicles of each model line are subjected to an even more thorough inspection, including functionality, lighting and road...

During the audit, individual vehicles of each model line are subjected to an even more thorough inspection, including functionality, lighting and road tests. The audit also focusses on aspects such as surface finish, paint finish and seams.

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