Porsche 2013 Annual Report Download - page 70

068 // ANNUAL REPORT PORSCHE AG 2013
households. At the same time, the plant saves energy
wherever possible. For example, a newly designed cooling
system for the robot welding guns reduced electricity
consumption by more than 365,000 kWh a year.
The new paint shop, which is 360 meters long, 72 meters
wide and 30 meters high, where Macan bodies undergo a
multi-stage paint process on several floors, also operates
in line with the latest insights into sustainability. For example,
a completely innovative separator system for paint mist
has been integrated. This rock-powder-based dry separation
method and downstream wet-chemical air purification helps
minimize the emission of solvents and fine dust during
the painting process. Another unique feature is the use of
waste heat from a wood chip power plant used to generate
electricity. This biomass power plant covers up to 80 percent
of the heating needs of the paint shop using natural resources.
With the Macan, Porsche has created 1,500 new jobs in
Leipzig. 1,100 of these employees work in production and
400 in planning. Porsche began preparing the new employees
for the launch of the new Macan back in the fiscal year
2012. The new employees in the picking zones (supply
centers) and on the production lines (body shell production,
paint shop, assembly) were systematically introduced to
their tasks. In addition, to enable highly flexible staffing at
the individual stations within the plant, the teams already
deployed on the Cayenne and Panamera were provided
with training on the Macan. To ensure they were well pre-
pared for their new tasks, each of the new employees went
through a graduated, personalized training program at the
beginning of their new career at Porsche. The existing core
team followed this example. Classrooms reflecting the pro-
duction system were created at special training centers.
In addition, the trainers developed a “professional room”
where plant- or model-specific tasks are practiced, and
which corresponds exactly to the workstation on the line.
Porsche also provides training in traditional automotive
apprenticeship occupations in Leipzig. In order to offer
optimal conditions in this area, the company expanded its
training facilities. This included the creation of a second
training workshop. It is centrally situated in the middle of
the assembly hall for the Macan and Panamera and is thus
integrated into normal operations. From their very first
day, trainees can experience what goes on at Porsche
and which jobs they are being trained for. The training
workshop includes the actual 600 square meter workshop,
a training room featuring the very latest equipment and a
supply area. The workshop offers leading-edge systems
that enable trainees to work to professional standards.
These include a welding area, workbenches, lifting plat-
forms and other technical systems. During the expansion
of the plant, the number of vocational training positions in
Leipzig will be trebled in the course of 2014 alone.
918 Spyder created in a manufacturing facility
At company’s main plant in Stuttgart-Zuffenhausen, the
fiscal year 2013 saw the integration the newly introduced
models of the 911 series: the 911 GT3, 911 Turbo and
911 Turbo S – both as coupé and convertible – and the
911 Targa 4 and 911 Targa 4S. Their integration into
ongoing production expanded the large mix of models
produced on one line still further.
On the plant site in Zuffenhausen, the manufacturing
facility for production of the new 918 Spyder super sports
car with high-performance plug-in hybrid drive went into
operation. This facility, where the sports cars are made
by hand, was established in the former paint shop. The
premises on the plant site had become free after the new
paint shop for the sports cars went into operation in the fall
of 2011. Production of the exclusive small series, which
is limited to a total of 918 high-tech vehicles, kicked off at
the beginning of 2014.
Porsche AG’s general development plan at the Zuffenhausen
site, which comprises total investments of around 700 million
euro, also includes the planned construction of a new en-
gine plant for V8 engines, scheduled to start in May 2014.
In the fiscal year 2013, the main plant’s systematic quality
orientation was confirmed yet again by the Initial Quality
Study (IQS) by renowned US market research institute
J.D. Power & Associates. In 2013, Porsche placed first in
the IQS. Alongside the Porsche brand, the Porsche 911