A Comparative Study of Automation Strategies at Volkswagen in Germany and South Africa

Abstract

The final car assembly lines at Volkswagen's production sites in Germany and South Africa are analysed to determine the best automation level based on cost, productivity, quality, and flexibility for a plant location. The methodology used is proposed by the Fraunhofer Institute. The final assembly processes are analysed and classified according to the automation level. The operations are evaluated at every level of automation based on information from existing factories. If the best levels of automation for all the parameters correspond, the optimal level of automation for a plant is reached. Otherwise, improvements and/or additional considerations are required to optimise the automation level. The result of the analysis indicates that the highest automation level is not necessarily the best in terms of cost and quality, and some de-automation is required. The analysis also shows that a low automation level can result in poor product quality and low productivity. The best automation strategy should be based on the analysis of all the aspects of the process in the local context.