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Cluster Report Transport, Mobility and Logistics in the Capital Region Berlin-Brandenburg

  • Text
  • Aerospace
  • Rail
  • Berlin
  • Mobility
  • Logistics
  • Automotive
  • Brandenburg

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8 | delivers to roughly 130 countries. The plant therefore fulfils an important function within the Mercedes-Benz global production network. Manufacturing according to Industry 4.0 principles at Mercedes Ludwigsfelde, © Daimler identify and – if necessary – establish suitable test sites. This includes urban areas that are equipped with smart infrastructure, for instance wireless networks and the necessary technical facilities, or with sensor systems for parking space management. The development and testing take place in a ‘real urban environment’, not in the laboratory. Companies, research institutions, and local administration cooperate with users on the ground to test new, smart, networked, distributed, and electric mobility. There is plenty happening on the EUREF Campus to bring together the mobility and energy transitions. This includes the ‘Future Railway Station Berlin Südkreuz’ by Deutsche Bahn. The densely built-up inner-city area of City West around Kurfürstendamm, Bahnhof Zoo and Ernst-Reuter- Platz is another possible test site. A modern traffic concept has also been introduced to develop the Campus Berlin- Buch in the borough of Pankow. Moreover, there are plans for smart mobility concepts using innovative technologies to ensure follow-up use of Berlin-Tegel Airport. Benchmark: Industry 4.0 at Mercedes-Benz in Ludwigsfelde While Olli is patiently completing its circuits at the test site in Schöneberg, driverless transport vehicles (DTV) are already automatically supplying the employees in the Mercedes-Benz factory in Ludwigsfelde with materials. Here, Industry 4.0 has become a tangible reality. Home to over 2,000 employees and 122 trainees and students, the factory is among the largest creators of industrial jobs in Brandenburg and Daimler’s third-largest van assembly plant worldwide. Ludwigsfelde is the only European production site to manufacture the ‘world van’, the Mercedes-Benz Sprinter, in its open versions (flatbed truck and chassis) for a broad variety of superstructures. Operating in three shifts, the factory produces around 250 vans every day, which it At the same time, Ludwigsfelde is a benchmark and blueprint for the manufacture of smart vehicles: Lean, sophisticated processes and an efficient logistics system indicate what factories may look like in the future. The process was launched at the end of 2012 to achieve significant improvements in the interfaces and collaboration between assembly and logistics. In an initial phase, the experts scrutinised the entire process from the supplier to the point at which a component is installed on the assembly line. At the same time, they worked on the establishment of high-quality, robust, and above all lean processes between assembly and logistics – with evident success. Where once the assembly lines were penned in by a jumble of countless wire baskets, shelves and load carriers stuffed with materials from which the employees were required to pick the right components for each van, we now find – thanks to state-ofthe-art IT technology – driverless vehicles transporting everything that is needed. Operating in a fully automatic capacity, they supply the employees working on the lines with component baskets prepared in the logistics and picking zones. “What sounds simple is actually a highly complex process. After all, our employees on the assembly line assemble the Sprinter in hundreds of different configurations, depending on the wheelbase, weight, motorisation, or colour. This means that the sequence applied for each vehicle varies, and so every Sprinter needs an individual set of parts,” says Sebastian Streuff, Managing Director at Mercedes-Benz Ludwigsfelde GmbH. Sophisticated IT networking ensures that precisely the right components are prepared in a car set trolley and then delivered to the assembly line for each Sprinter. The DTVs also handle fully automatic unloading: Upon arrival, the car sets are pushed right up to the belt. Employees only have to accept the right trolleys with their components, attach them to the overhead vehicle conveyor, and then start installing the parts. The benefits: Improved workplace ergonomics, less running around, direct access to the material, more space on the assembly line, and a reduced risk of accident due to the elimination of forklifts from the process.

Cluster Report I Transport, Mobility and Logistics – A Strong Location | 9 More efficient operation: Improved fleet availability thanks to real-time information The dynamic trend toward digitalisation spread to the rail sector some time ago. The smart integration and analysis of real-time data already allows rail customers to benefit from prompt information on delays and cancelations during their journey. The benefit: Customers appreciate the comprehensive information, even if individual circumstances mean that a connection cannot be reached as scheduled. In the near future, this kind of real-time information will also help in the optimisation of rail operations, contributing to smoother and safer processes – with positive repercussions for customers in personal and cargo transport. INNOWAG (INNOvative monitoring and predictive maintenance solutions on lightweight WAGons) is a good example for an ongoing project. It was initiated in November 2016 as part of the European research alliance Shift2Rail. Besides the rail vehicles department at the Technische Universität Berlin, Havelländische Eisenbahn AG is the other important regional player among the eleven project partners from seven European countries. The aim of the project is to make maintenance and repair of freight wagons more efficient and to substantially reduce costly downtime in the classification yards. At the moment, a laborious system is applied to check the operating safety and railworthiness of the wagons by hand. But this can take up to four hours before each journey. The use of digital technology and process automation could reduce this process to just 20 minutes. Sensors installed on each wagon will deliver the necessary real-time data for technical monitoring during downtime and also the journey, therefore obtaining information on imminent defects in wagon components. The measures required for maintenance, operation, and the installation of new components will then be inferred from this data. Rollout of so-called condition-based maintenance (CBM) is planned for the medium-term. It will mean the introduction of maintenance procedures precisely when they are necessary. This could even put an end to scheduled maintenance intervals. Implementation of the INNOWAG project findings in daily operations could therefore enable a tangible increase in fleet availability and therefore the economic efficiency of rail cargo transport. “Clusters foster collaboration between hugely different partners – in research, practice, and above all in an alliance between these two areas. This helps to develop new and innovative concepts and solutions for mobility and transport in Berlin-Brandenburg, and to use digital technologies to make them useful in a practical setting. The broad variety of actors in the region and their net working within the cluster transform Berlin into a showcase for mobility and transport.” Prof. Barbara Lenz DLR Institute of Transport Research Berlin-Adlershof Charting a course to the future: The Bahn technologie Campus Havelland It is no coincidence that Berlin-Brandenburg is such a major player in the European research projects within Shift2Rail. The region is known worldwide as a traditional hub of rail transport technology, and its more than 100 companies make it one of the most important industry clusters in Europe. The rail sector is among the mainstays in the industrial landscape of the German capital region. Besides important transport operators like Deutsche Bahn, S-Bahn Berlin and BVG, this also includes leading system manufacturers such as Bombardier in Berlin and Hennigsdorf, Siemens in Berlin, or Stadler in Berlin and Velten. Moreover, Berlin and Brandenburg in particular can point to an extensive supplier infrastructure that is dominated by specialised medium-sized companies. University institutions like TU Berlin, BTU Cottbus-Senftenberg and TH Brandenburg provide significant innovation potential and can strategically underpin the overarching engineering excellence.

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