Recommissioning of a camshaft production line for Mercedes-Benz

Scope

As part of the project, Faircom carried out the full recommissioning of a camshaft production line as a turnkey solution. The services comprised the overall project management and detailed construction site management. The main tasks included planning the entire installation plus commissioning and optimising the existing system. Faircom was responsible for producing an overall time schedule, including continuous tracking and risk management.

The quality inspections were also meticulously planned and implemented. Faircom undertook supplier management and coordination of all trades involved locally. Special emphasis was placed on budget responsibility and consistent reporting to management, including reporting to senior management at the Mercedes-Benz Group.

Another key integral part of the project was the production launch planning and control. The aim was to safeguard camshaft production for the Mercedes-Benz OM646 engine, which was used in the Sprinter T1N for the Russian market.

Project details

Sector: Automotive (combustion engines)/plant and mechanical engineering

Client: Mercedes-Benz Group (Daimler AG at the time)

Location: Yaroslavl, Russia (100%)

Undertaken by: Waldemar Graf, Rolf Thelen

Time period: 2013–2015

The camshaft production line was previously in operation in the Stuttgart district of Untertürkheim. As part of a strategic decision by Mercedes-Benz, it was relocated to Russia for recommissioning. The aim was to continue using the line, thus saving resources. It was also the first time that Mercedes-Benz had invested in industrial manufacturing in Russia, making it a pilot project marked by significant innovation and performance pressure.

The project aimed to put the production line into operation on schedule while meeting all quality requirements. The camshafts for the OM646 engine also needed to be produced on time. These components were intended for the Mercedes-Benz Sprinter T1N, which was being produced for the Russian market.

The project was defined by several complex aspects. The technical challenge comprised recommissioning a used production line which needed to be fully integrated into a new location. Efficient use of resources was a key priority. The timeline was also extremely tight. Moreover, intercultural aspects and coordination processes required sensitive, experienced project management.

The camshaft production line was seamlessly put into operation on schedule. All specified quality requirements were met. The production launch went smoothly as did the transition to mass production. Once all phases were completed, the project was successfully handed over to the operator.

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