Premium powerhouse Daimler is following the Volkswagen lead by slashing complexity and production times at its global factories.
The world’s oldest carmaker, Daimler is aiming to chop its chassis architectures down from five to just two by 2015, when it has cycled through a refreshment of all its major model lines. It had 15 architectures in 1995.
It’s also aiming to hack 13 hours from the average time it takes to build a smart or Mercedes-Benz, taking it from 2008’s average of 43 to just 30 hours in 2015.
“We have increased productivity by two percent a year over the last few years. We will be accelerating our productivity efforts,” Mercedes-Benz production head, Wolfgang Bernhard, admitted during an investor conference last month.
Bernhard made his name by ripping time and cost from car production at the Volkswagen Group, and he has planned and instigated a full system overhaul of the Daimler Group’s global production system.
If that’s not enough, Mercedes-Benz’s engineers will need to deal with not only a shrinking number of available architectures, but they are also expected to double the number of models to 30 by 2015 as well.
The first of the new family architectures is the Mercedes Front Wheel Architecture, dubbed MFA in internal Daimler codes.
The MFA already sits beneath the all-new B-Class and made its A-Class debut at the Geneva Motor Show last month. It will also find homes beneath a sexier, younger-looking sedan, a smart, a baby SUV and there are whispers that it will also host a coupe.
In its first major attack on the smaller market, AMG will build an all-wheel drive version of the MFA, powered by a turbo-charged, direct-injection four-cylinder engine.
It’s not just a German car brand anymore, with Daimler planning to build MFA cars in Rastatt, Germany, Beijing, China and the new Kecskemet plant in Hungary.
The heart and soul of Mercedes-Benz’s lineup is its rear-drive sedans and, despite much debate on changing it onto the MFA, the next all-new C-Class (due next year) will remain the smallest machine on the Mercedes Rear Wheel Architecture (MRA).
Its production will be spread far and wide, with Mercedes-Benz plans showing it will be built in Bremen and the home factory of Sindelfingen in Germany, East London in South Africa (for right-hand drive cars) and Vance, Alabama, as Mercedes tries to make a reasonable per-unit profit out of its US operations.
"In 2020, we believe that more than 50 percent of our assembly capacity will be outside Europe," Bernhard said. In 2010, that figure was just 10 percent. While German unions are outraged at Bernhard’s plans, he is also insisting that the same 2020 timeframe will see 40 percent of Daimler’s powertrains manufactured outside Europe, up from roughly zero today.
At the moment, Mercedes-Benz has a front-drive architecture for the A- and B-Class, an all-wheel drive architecture for the ML-, GL-, R-Class, a sports-car architecture, a rear-drive architecture for the C-, E-, S-Class and the CLS and CL coupe. It also has its own anachronism in the Land Rover Defender-style, with the 33-year-old G-Wagen chassis built in Graz, Austria, by Magna-Steyr.