Stuttgart. After a construction period of less than 48 months, Porsche opens a new production facility for its first all-electric sports car in the Zuffenhausen area. "The new plant reflects the brand's tradition and sends a clear signal about the future of Porsche," said Albrecht Reimold, a member of the Executive Board of Production and Logistics at Porsche AG. "It was a conscious decision to build Taycan in Zuffenhausen – the home of the brand's heart and soul."
Production of the first customer vehicles will begin as planned on September 9, 2019. Assembly will take place in a "factory of the future" ̵
The construction project covered several individual sub-projects, each with considerable scope. became a body shop, a paint workshop, a plant for the production of e electric motors and components, a vehicle assembly house and connecting transport technology. In total, 35,000 tonnes of steel were used for the new production plant – as much as for the 1401 Coupe bodies of the 991 generation of the 911 model line. The total area of the building is 170,000 square meters.
Construction start in late 2015
The positive response to the presentation of the motor show for the Mission E concept car in September 2015 marked the start of the largest construction project since the Zuffenhausen plant was first established. That same year, the groundbreaking ceremony was held for the new body shop, where the tall, yet lightweight bodies of Taycan and the current eighth generation of 911 will be built. In May 2016, old buildings set out to create space for the new paint shop and assembly building on several floors. "There were several sustainability requirements set by the city of Stuttgart," says Jürgen King, head of central construction, environmental and energy management in Porsche, "and Porsche expanded these. For example, we processed the material from the on-site demolished halls and reused it for the new buildings. "
Preparation for the construction work alone required 21 individual pre-projects and more than 5,000 staff removals. This also included the excavation pit for the multi-storey assembly building located on a slope: since the height is limited to 38 meters so as not to impair the flow of the fresh air to the center of Stuttgart from the north, the pit is 25 meters deep. 240,000 cubic meters of land was moved for this purpose.
A new factory inside a factory
“We have built a factory inside a factory – in the middle of the city and close to our neighbors, in the most confined space, in the shortest possible time and without disturbing the existing sports car production facility running at full capacity Now the factory is completed according to plan and without major setbacks, says Albrecht Reimold. "This was possible due to thorough planning and an excellent team." A total of 130 companies and suppliers were part of this team. One of the logistical masterpieces was to coordinate construction site traffic without impairing the significant regular flow at the facility. "Close dialogue with our neighbors was also crucial," says Reimold. "We kept them updated on developments throughout the project."
Some more figures: 10,000 building passes were issued, 530 construction site containers and three kilometers of fencing were erected and 35 kilometers of grid cables were added, including power for the 1000 linear luminaires distributed at the construction sites. Four kilometers of new road were also constructed in the facility.