They also take a close look at how the exhaust gas turbocharger (abbreviated ATL in German) is mounted. “Last year alone, we were able to find 444 measures to make our line more productive,” says Ronny Bode (36), who is in charge of over 250 employees in engine assembly.
With his team, Bode also developed guided assembly for the ATL. Previously, an employee had to take the ATL, which weighs ten kilos, out of its box, lift it, and attach it by hand. And that had to be done more than 500 times per shift – an enormous physical exertion. Now, a pre- assembly table helps the employee in the guided assembly process. The employee places the ATL on it, operates a foot pedal, lifts the component, and pushes the ATL forward onto the stay bolts. Job done!