Capacity expansion in the Hungary plant to at least 2,500 units, productivity increase in a two-digit percent range
In contrast to the decreasing registration figures of motorhomes and caravans in Europe, the so-called camper vans are constantly becoming more and more popular. In line with this trend Knaus Tabbert GmbH, a leading manufacturer of recreational vehicles in Europe, modernised its Hungarian plant in Nagyoroszi for more than Euro 1 million. In a construction period of only seven weeks an absolutely unique, continuously conveying assembly line was developed that in the future is expected to process up to 2,500 vehicles per year. In combination with the simultaneously implemented Knaus Tabbert Production System (KTPS) the new camper van production plant, which at the end of October was officially opened with the complete staff attending, will reach a two-digit productivity increase already this year.
“We are proud to set standards in European camper van production with these implemented measures”, emphasised Michael Tregner, managing director of Knaus Tabbert GmbH, at the opening ceremony.
Unique conveying technology and lean production philosophy
Employing highest areal productivity in the new designed production hall, the new Knaus BoxStar and Weinsberg CaraBus models for the first time are transported laterally and one after the other over a continuous conveying system. This special conveying technology makes it possible to now assemble the camping buses in a flow production process that so far is absolutely unique in the production of camper vans. At the same time the pre-assembly of technical modules and furniture components also was reorganised and arranged synchronously to the installation place at the assembly line. The strict separation of logistics and value creation thus made it possible to realise a continuously flowing process with minimum staff deployment. Every workplace furthermore is exactly adapted to the specific tasks with respect to timing, functionality, and ergonomics.
The lean production philosophy that forms the basis of the KTPS to a large extent also includes production-supporting logistics and stock-keeping. For this purpose a full-length parallel annex to the existing assembly hall was completed early in September and now is used as a buffer stock for the production of camper vans. The stocking of articles that are required exclusively at short notice or in larger quantities both minimises the tied-up capital and ensures low stock and processing costs.
Knaus-Tabbert-Production-System ensures efficiency benefits
The consistent improvement of products, processes, and systems is the central objective of the new-developed KTPS. This provides the necessary framework conditions for trouble-free, transparent, high-quality, and employee-oriented production. The results are products of more-than-competitive quality that can be produced under attractive cost structures in order to meet individual customer requirements. The KTPS thus was implemented as a pilot project in the Hungarian plant in Nagyoroszi. In the near future the new system also will be introduced at the other group plants in Jandelsbrunn, Mottgers and Obermeitingen.