Porsche 2003 Annual Report Download - page 86

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By providing in-depth training on new components, work
operations, and machines, we were able to ensure high stan-
dards of workmanship during and after the changeover. Such
standards are imperative in areas such as the characteristic
decorative stitched seams inside the car. Quality assurance in
the upholstery shop begins with the workers on the sewing
machines, where a computer now monitors the tension and
number of stitches. We also introduced new tools for locating
the seams and custom designed machinery such as a new
door-panel heat sealing machine.
Despite all these technological developments, our employees
remain at the heart of the manufacturing process. New pro-
duction technologies, however effective, are only one side of
the coin and successful manufacturing is only possible when
you have a highly qualified workforce.
Network Management in Demand
To guarantee first class workmanship on the 911 and smooth-
running logistics right from the outset, we involved our sup-
pliers very closely in our production planning. This has paid
dividends. Thanks to extensive collaboration with our sup-
pliers and our own thorough preparatory work at the plant, we
achieved troublefree, high-quality production (in line with the
growing expectations that our products are obliged to satisfy)
well before series production started.
In addition to collaboration with our suppliers, we devoted
close attention to the production and value-creation alliance
between Zuffenhausen, Leipzig and our Finnish partner’s plant
during the year under review. To ensure a high standard of
professionalism within this alliance, production management
had to coordinate the capacities of external suppliers as well
as those of both Porsche production plants. During the review
year, Porsche made allowance for increased logistical com-
plexity by installing a new organizational business area within
the Production division, with competences extending to all
locations. Within the Porsche production alliance, it uses
optimized processes to control the available capacity at sup-
pliers and production facilities. The aim is to satisfy market
demand at any given time by means of maximum flexibility,
individuality and punctuality.
As part of the network management process, finished-vehicle
transport movements were also examined intensively. It has
proved possible to optimize direct deliveries to our European
sales subsidiaries in a lasting manner by means of a vehicle
monitoring system that tracks both transportation time to the
market and the operating efficiency of the distribution chain
itself.
High Levels of Investment
We invested several millions Euros in Zuffenhausen in the run-
up to the production of the new 911. A completely new body-
in-white production line was built alongside the existing one
for the previous model. Much work was required to optimize
the shop floor in order to fit the new machinery and equipment
into the existing space.
We introduced new equipment and techniques in the upholstery
shop for production of the 911’s interior trim. Production
staff also reconfigured the assembly of the bodyshell on to
the running gear and driveline, in order to take advantage of
threaded-connection techniques and supply logistics.
We installed new test rigs to allow us to simulate driving condi-
tions repeatedly free from weather and traffic effects during
series production. We applied for patents on a number of in-
dividual items of equipment that are unique in the automobile
industry. New diagnostic rigs on the lines and new radio
diagnostics for the entire assembly area complete with entirely
new software are responsible for the quantum leap in vehicle
electronics that the new 911 model generation represents.
In addition to the 911 production start-up, Porsche began
production of the new V10 engine for the Carrera GT during
the review year. The production area created for this engine is
fully integrated into the Zuffenhausen plant. Despite its high
complexity and low production volume, the productivity of the
Carrera GT assembly operation benefits greatly from our
existing expertise in the production of longer engine runs.
Production 2003 ⁄ 04
Employees were prepared for
the start of production of the new 911
model by a comprehensive training
program designed to give them
the necessary additional qualifications.