DEUTZ-FAHR Land kick starts tractor production

DEUTZ-FAHR has announced its state-of-the-art, 42,000-square-metre tractor factory located in the city of Lauingen, Germany, has started producing high performance tractors from 130hp since January 2017.

The brand's 6 Series, 7 Series and 9 Series tractors are manufactured at the factory, dubbed DEUTZ-FAHR Land, for the global market.

DEUTZ-FAHR purchased a total land area of 150,000 square metres for the project, and spent over 90 million Euros ($A100 million) on the facility, making it the single largest individual investment in the company's history. It claimed the plant is now the world's most modern and efficient tractor production facility.

More efficient layout

Planning for the plant commenced in 2013, and DEUTZ-FAHR received input from a series of experts, factory employees and advisers to come up with the most efficient production lines and facility layout.

For example, gates at sides of workshops are built to allow direct delivery of large components to the assembly line with fewer handling steps, ensuring a smoother production.

As part of a clean sheet process, DEUTZ-FAHR ensured all products, processes, IT systems and infrastructure are brand new.

A warehouse with 4,000 storage locations for large parts, and a small parts facility with 25,000 locations were integrated to supply the production process.

DEUTZ-FAHR has developed a robust and efficient assembly line to ensure minimal disruption to the production process. The tractor assembly line has been designed as an apron conveyor with worker travel conveyors on both sides. Both move in parallel at the same speed to facilitate the installation of parts on the tractor body while substantially reducing the daily walking distance.

Quality control

As part of DEUTZ-FAHR's new quality control process, in-line hydraulic testing and a pneumatic test take place at the end of powertrain production, in addition to individual quality checks at each installation step.

Up to three powertrains can simultaneously be tested for full functioning and tightness at a hydraulic operating pressure of 220 bar. Once this check is completed, the tractors move to the paint shop and then to final assembly.

After final assembly, the computer-controlled final acceptance of the completed tractor takes place.

All functions of all installed components are tested individually for each tractor, while engine and transmission are run through different speeds and load conditions. The front axle and front axle suspension are tested in the final phase, which DEUTZ-FAHR says is unique in tractor manufacturing.

DEUTZ-FAHR also invested heavily in the powertrain painting process, which costed the company 20 million Euros. The powertrains move through a mostly automated painting process to ensure the highest level of quality.

DEUTZ-FAHR Land is powered by its own power plant generating heat required for drying in the paint shop, and electricity for the entire production process. Any excess heat and electricity not utilised by the factory is fed into the public grid.

The company also focused heavily on work ergonomics and safety among workers, by installing and placing electric screwdrivers and wrenches within easy reach by workers; as well as fitting specialised lifting devices for lifting heavy components.

DEUTZ-FAHR's parent company, SDF, says the new factory plays a crucial role in reinforcing the DEUTZ-FAHR brand in the global market.

"The new manufacturing plant together with our modern and innovative tractor range will speed up the growth of DEUTZ-FAHR," says SDF CEO, Lodovico Bussolati.