Mercedes-Benz Sprinter production at the Germany factory: Precision to a fraction of a millimeter - quality workmanship at the main van factory

Body-in-white: precision to a fraction of a millimeter
Paintwork: emu feathers and ultra-fine coats of paint
Assembly: 197 stations, choice of up to 14,000 parts

With a workforce of some 6600 and an annual output of around 150,000 vans, Düsseldorf is Daimler AG's main factory for vans. All the closed variants of the Mercedes-Benz Sprinter – i.e. panel vans and crew buses – roll off the production line here. The factory has a shop floor covering almost 700,000 square meters and produces almost 700 vans per working day by way of a three-shift system. Daimler invested almost 36 million euros in the factory in 2012. A new combined heat and power station which cuts primary energy consumption at the factory by around 20 percent accounted for over a third of this investment volume. A particularly notable asset from the employees' point of view is the new factory restaurant which sets a benchmark throughout the group. The Sprinter is also produced in Ludwigsfelde (Germany), Argentina, the USA, China, and Russia.

Body-in-white: precision to a thousandth of a millimeter

The body-in-white forms the essential basis for every vehicle. In Düsseldorf, the body shop is spread over two levels, on account of the limited scope for expansion of the factory due to its inner-city location. Various welding, soldering, and bonding processes are applied to join the delivered sheet metal components and produce a vehicle body. Each Sprinter has 7650 weld spots on average. Work on the body-in-white is shared between a workforce of 1150 and more than 500 robots – around 80 percent of workers in the body shop is automated. Production is carried out to an accuracy of one-thousandth of a millimeter. Various quality checks take place at the end of each production line.
The Sprinter's body-in-white covers an impressively diverse spectrum: different lengths, heights, door arrangements, weight classes, and right and left-hand-drive versions add up to well over 1000 possible basic combinations.

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Credit: Mercedes-Benz

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