The market introduction of the new E 55 AMG and C 30 CDI AMG is one way in which Mercedes-AMG GmbH is celebrating 35 years of manufacturing excellence. Additions to its model range have been complemented, however, by the opening of new production, development and presentation buildings at its Affalterbach plant. The new engine factory, new showroom and two new development buildings have swelled the surface area of the facility from 18,500 m² to 39,610 m².

The 20 million EUR pumped into the new engine production factory and showroom has put Mercedes-AMG in the position where it can continue to meet the strong global demand for unique AMG high-performance cars. For the current Mercedes-AMG GmbH workforce of around 580 employees, the company’s sparkling outlook also means long-term job security.

The centrepiece of the expansion is the new engine factory. At 132 metres in length, 35 metres wide, 10 metres high and covering a 4600-m² area of ground, the silver building is an impressive sight to behold. No less remarkable is the scene inside: some 100 AMG engines are produced every day for a range of different vehicle models. Work takes place on three floors across a total surface area of 9950 m² and in a single shift. The manufacturing processes are designed for maximum flexibility: production of the various AMG petrol and diesel engines can quickly be adjusted in response to the incoming orders.

A total of 62 highly qualified specialists work in the new engine factory according to the strong ergonomic principles which underpin the AMG philosophy of “one man, one engine”. This means that a single engineer – identified by the signature on the engine plate – is responsible for the complete assembly of an AMG high-performance engine.

A prominent feature of the new engine factory is the concentration of the functional areas. The shorter distances and optimisation of processes which this allows has a positive effect on the working conditions. State-of-the-art logistics make for highly flexible and efficient production processes. After the manufacturing of an engine has been completed, an engineer checks the functioning of the finished unit on the “cold-test” testing rig, with the help of simulated resistance and pressure build-up. The AMG engines are then transported fully automatically in a lift from the ground floor to a high bay storage facility on the upper storey. Over 1000 engines are stored there, with stockkeeping continuously optimised by means of a leading-edge data management system, which allows the current inventory to be accessed easily and at any time.

It is not just the assembly of AMG engines which takes place at the new production facility – the plant equipment management, quality control, production planning, ordering and parts logistics departments are all accommodated there, as is the new 185-seat AMG cafeteria. Work began on the new AMG engine factory in December 2000.

Considerably smaller than the engine factory, but even more visually attractive is the AMG showroom. The steel/glass construction is a fascinating piece of architecture and, with a ground surface area of 590 square metres and a useable surface area spanning 750 square metres, offers ample room both for handling vehicle deliveries and for the presentation of eight AMG high-performance cars. On the upper floor of the new meeting centre is a gallery with numerous communications facilities, including Internet access. The second floor of the showroom offers generous office space where AMG sales advisors can hold conversations with individual customers.

The large-format vehicle images displayed on the front of the building have a dual function. On the one hand, they act as a clear signpost and business card for the new AMG showroom, and on the other hand they fulfil the function of a sun and heat protector for the AMG customers and staff inside. Construction of the show-room began in May of this year.

Other new buildings at Mercedes-AMG GmbH:

• Development buildings housing component development, AMG parts production, Mobile Media, a workshop for special vehicles, start-up management and the vehicle pool: ground surface area 2900 m², useable surface area 3760 m², around 110 employees.
• Test rig building for pre-development, plus engine construction and application: ground surface area 3000 m², useable surface area 6650 m², around 150 employees.

Mercedes-AMG GmbH has introduced a new integrated management system to complement the quality management processes already in place. The aim is to implement the legally and internally prescribed requirements regarding work safety, health and environmental protection, and to meet quality standards through a process-oriented, digitalised management system. Clear working and operating instructions ensure the implementation of these stipulations across all processes.

This new Mercedes-AMG organisational structure allows fast and targeted analysis of the working processes, whilst structured procedures with regular checks create the conditions for a continuous process of improvement in terms of precision, quality, work safety and environmental protection. A constant process of training for the employees, as well as their involvement in the design of their workplaces and working processes, creates the right framework for highly progressive production and working conditions.