KUKA and Webasto Revolutionize Battery Manufacturing

In KUKA’s digital press conference series ‘Coffee with…’ experts from KUKA and Webasto discussed the mobility of tomorrow. At the center of the discussion: intelligent automation in electromobility. The two companies have been collaborating since 2002, resulting in a forward-looking project.

(Augsburg) At the beginning of the virtual discussion round, Dr. Joachim Döhner, Battery Senior Director Global Sales at KUKA, and Christian Gallner, Director Plant Schierling at Webasto, talked about the mobility transformation and the resulting strategic realignment of the two partners: “Our dual strategy includes, on one hand, the consistent strengthening of our existing core business areas, Roof and Thermal, and on the other hand, the exploration of new business areas that fit our competence profile. The focus is on electromobility,” says Christian Gallner. “In addition to high-voltage heaters and battery systems, the product portfolio also includes charging solutions for private and commercial customers.”

Mobility 2.0: Electric, Flexible, and Intelligent

 It is clear: The energy concept of the future is unimaginable without electromobility. The transformation of the automotive industry is in full swing worldwide. KUKA and Webasto are also facing new challenges to pave the way for more sustainable, climate-friendly, smarter, and lower-emission mobility. “The further development of electromobility is a forward-looking topic, and batteries from Germany and Europe will contribute to climate-friendly mobility,” says Dr. Joachim Döhner. “We will meet the increasing demands for speed, flexibility, profitability, and value creation with modular and automated manufacturing and logistics processes.” KUKA and Webasto have already taken the first joint step: the realization of a production facility for battery systems that ensures the essential components of Industry 4.0 as well as extremely adaptable production.

State-of-the-Art Manufacturing: Technology at the Highest Precision

 At the Webasto plant in Schierling, Regensburg County, Bavaria, the production of battery packs for a European bus manufacturer has already begun. With the highly flexible Multi-Product-Line, the partners have created one of the most modern production facilities for battery systems. “Since the end of 2019, we have been able to produce up to 40,000 battery systems per year,” explains Gallner. “Our technology plant in Schierling is now a blueprint for other Webasto battery plants, such as in Dangjin, Korea.” What is special about this facility? The realization of the three essential core aspects of matrix production: an extremely adaptable manufacturing process. A flexible plant connection with person-safe automated guided vehicles (AGVs) provides more flexibility and open floor spaces. The separation of logistics and production through a kiosk concept allows for variable parts logistics. And finally, the modularity: modular production stations ensure that production cells can be configured and expanded at any time. “With the Multi-Product-Line at Webasto, we have realized a production facility that consistently implements the requirements of Industry 4.0 in industrial production and also ensures a decisive competitive advantage,” explains Dr. Döhner.

The Key to Success: Concentrated Engineering and Market Expertise

 Since 2002, KUKA and Webasto have been collaborating on numerous projects in roof production. “Regarding the creation of the line, it was important for us to ensure a high level of protection for manual workers; on the other hand, we demanded robust automation solutions for our core processes,” says Gallner. “With KUKA, we have an experienced partner from the region who meets these requirements.” KUKA specializes in battery manufacturing, focusing on module and pack assembly, including end-of-line testing. Furthermore, KUKA counts the assembly of electric motors and all components for the electric drive train among its specialties. Fuel cell technology is also a focus of activities. Quality, flexibility, robustness, and digitalization are always top priorities. “The long-standing collaboration with Webasto has made this great and forward-looking project possible. We are proud to contribute our part to the energy concept of the future – electromobility,” concludes Dr. Döhner. Photo: © KUKA