Golden Car Prize
In the German state of Saxony, there is a car factory that not only manufactures high-end luxury cars, but also houses European bison, Exmoor ponies, 3 million bees and many native wildlife species on off-road terrain. This is the Leipzig plant of the world-renowned sports car brand Porsche.
The green, clean, zero-impact and biodiversity-rich car factory is also the birthplace of Porsche's latest electrification – the all-electric Macan, which has been fully increased in 2024. The Porsche all-electric Macan made its world premiere in January this year, and the first two models, the all-electric Macan4 and the all-electric Macan Turbo, have already started pre-orders in the Chinese market and will soon be unveiled at the Beijing Motor Show. The new car, which is based on the all-electric PPE platform, will strengthen Porsche's presence in the field of electrification.
The Leipzig plant will increase production capacity for the all-electric Macan in 2024
Since its establishment in 2000, the Porsche plant in Leipzig has undergone five expansions and a cumulative investment of around 1.9 billion euros, and has been responsible for the production of many classic models such as the Porsche Cayenne, Carrera GT, Macan and Panamera, with a total production of more than 2 million units, accounting for 70% of the total production of Porsche sports cars worldwide. Following the guiding principles of "Smart, Lean and Green", the plant is laying the foundation for the brand's electrified future with innovative, efficient, flexible and environmentally friendly production methods.
"At the heart of the operational strategy of the Porsche Leipzig plant is sustainability, the goal of achieving quality excellence with innovative, efficient and energy-efficient production processes and production methods with the lowest possible environmental impact, as well as fulfilling corporate social responsibility," said Gerd Rupp, Chairman of the Executive Board of Porsche Leipzig AG. "At the same time, talent is a key factor in the success of the Leipzig plant, and we continue to train our employees in electrification technology and digital software in order to better ensure that our strategic goals are met and that the industry needs to be transformed and upgraded. ”
Three drive types are produced on the same line
The goal of the Leipzig plant is to evolve into a modern, future-proof plant in the best possible way and to continuously optimize its production processes to make them intelligent, digital, and connected. At present, the Leipzig plant has the flexibility to produce three types of drives: gasoline-fuel, hybrid and fully electric, depending on the required co-line. This maximizes the flexibility and efficiency of the production process, while at the same time preparing for complex market dynamics and industry transformations.
The Leipzig plant has the flexibility to produce three different types of drives: gasoline, hybrid and electric, depending on the requirements
The Leipzig plant uses a range of intelligent technologies to ensure not only efficient industrial production, but also high quality. The automatic error detection (AFE) system in the paint shop is one of the representative projects. The system can scan the entire exterior of the vehicle with a light strip in less than 70 seconds. During this time, the robot takes about 100,000 photos and uses the reflection of paint to identify the slightest irregularities. Over the next 30 seconds, five image processing computers evaluate the results. In this way, workers can see the location and type of identified irregularities in a 3D view of the car body as an additional monitoring support for body painting.
Lean concept from production to logistics
The "lean" concept of Porsche's Leipzig plant is reflected in its high-performance, efficient logistics. Production in the assembly hall is based on the principle of "just-in-time production" and "just-in-sequence" based on this optimization, and the production and logistics links are closely linked through a demand-oriented organization and control concept. Fine-tuned production and material flows along the supply chain ensure that each part arrives at the assembly line in the correct order and at the right time, ensuring that parts that can be installed immediately can be quickly transported to their counterparts on the production line.
The Leipzig plant connects production and logistics
The Automated Storage System for Small Parts (AKL) is an example of an advanced logistics concept. The system provides a small loader for tractor trains, and uses Driverless Transporter (FTF) technology to transport cockpits, seats, etc., directly to the production line. Around 90 shuttles at the Leipzig plant are equipped with an automatic drivetrain, which increases efficiency while reducing energy requirements by more than 30 percent.
A long-term strategy for sustainable development
Porsche aims to achieve net carbon neutrality across the entire value chain by 2030. A core component of this goal is a commitment to a "zero-impact factory" – that is, a factory that produces factories that leave no ecological footprint and have the lowest negative impact on the environment. In this respect, Porsche has reached an important milestone: Since 2021, Porsche's Leipzig plant and the Zuffenhausen and Weissach sites have achieved net carbon neutrality in their production.
The plant embraces sustainability through a number of action areas, including material efficiency, energy and resource use, and biodiversity. Since 2017, Leipzig has been using all clean electricity, some of which is generated on-site by four photovoltaic systems, with a total output of around 9.4 MWp (megawatt peak). There is also a biomass-fueled heating plant near the plant, which can meet the heating needs of about half of the rooms. In addition, Porsche has been supporting a number of animal diversity conservation projects for 20 years. On the factory's 132 hectares of off-road terrain, European bison, Exmoor ponies, 3 million bees and numerous native wildlife species live in harmony with nature and the plant.
Leipzig aims to be a "zero-impact factory"
For its focus on sustainability and environmental protection, Porsche has received numerous awards: in 2019, the Porsche plant in Leipzig received the Platinum Award, the highest accolade of the German Sustainable Building Council (DGNB), and in 2021, the plant received the "Lean & Green Management Award".
The Leipzig plant was recently named "Factory of the Year" in a joint poll by A.T. Kearney Consulting, SV Veranstaltungen and the trade magazine Produktion.