Rosenbauer opens its new production plant

Published:  23 June, 2014

Following a 12-month conversion and adaptation phase, Rosenbauer has officially opened its new vehicle production plant. The central element in the Plant II Leonding now consists of two new, synchronized production lines for Panther ARFFs and AT municipal fire trucks.

Assembly takes place using complete process synchronization and in line with the industrial standards employed in the automotive and mechanical engineering sectors. Production at the Plant II Leonding commenced in April and the first vehicles to come off the new production lines were completed only a few days after start-up. The initial Panther from Plant II Leonding was supplied to Sibu Airport in Malaysia, while the first AT was supplied to the Thüngen Fire Service in Germany.

The new facility is designed for the annual production of around 150 Panther ARFFs and 250 AT municipal fire trucks in one-shift operation, although this capacity can be raised using shift models. 2013 and 2104 have seen investments of over €12 million in the new plant, which is future with employ around 350 people. The new premises are situated around 3 km away from the Rosenbauer Group’s headquarters and have an area of approximately 52,000 m² with some 15,000 m² of hall space and roughly 5,000 m² of office accommodation.

The Plant II Leonding provides an increase of around 60% in the production floor space available at the Leonding location. Dr. Dieter Siegel, the Rosenbauer International AG Chairman explained: ’We have thus obtained the room that we urgently required. In addition we have been able to completely reshape our production. Intensive competition demands technical solutions that facilitate the faster manufacture of top quality fire service vehicles. With this extremely modern plant, we have already set the stage for a continuation of our business success in the hotly contested, international fire industry market.’

Sequenced line production in spite of small batches and vehicle diversity
Assembly on both the main lines takes place at defined stations and in accordance with an established sequence. The vehicles and superstructures are moved automatically from one station to the next on rails and signals indicate the start of the next cycle. Assembly takes place in line with the flow principle, material supply according to the Kanban and pull principles. In addition, the working sequences have been systematically oriented towards the value flow concept and all the working processes and interfaces revised. Accordingly, the employees have also been provided with the necessary specialist, procedural and methodological competences.

Panther assembly consists of six stations for the 6x6 and 4x4 models and following a short run-up phase is now completed in a two-day rhythm. The pre-prepared chassis is carried on a transport wagon from one assembly station to the next. Adjacent to the main line is a 4-station, cabin line and two separate short assembly lines, each with three stations for special types and Panthers requiring specific equipment, two assembly workstations for 8x8 trucks and three finishing work stations. In June, the production of chassis for the 6x6 and 4x4 models also commenced in Plant II on a sequenced line.

The assembly of AT municipal fire trucks takes place in a one-day sequence via thirteen workstations, whereby as opposed to the Panther line, only the superstructure without the chassis is transported. The marriage between the superstructure and the chassis takes place in the final working cycle and then the vehicles receive their payload and are started up at various workstations.

  • Operation Florian

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