2012 – Start of our Project Gunskirchen2020
WE WILL BE THE LEADING MANUFACTURER OF PREMIUM POWERTRAINS WITH PREMIUM CUSTOMER FOCUS IN THE POWERSPORTS WORLD.
From the beginning, achieving this goal was built on three pillars: technology, agility and BRPMS. Gunskirchen2020 enables us to meet our customers’ needs faster and better and to respond to the requirements of the market more flexible and specifically. Our goal is to increase the satisfaction of our customers and dealers, to increase speed and economy and to offer all drivers the ultimate riding pleasure and experience. Today we look back on a long and successful path that has led us to the present and thus into the future.
We are all at the kick-off event on December 12th, when our Gunskirchen2020 project starts after two years of intensive planning.
OUR GOALS
We will be the leading manufacturer of premium powertrains with premium customer orientation in the powersports world.
TECHNOLOGY
We are expanding our core competencies in order to redefine the future requirements of the powersports world with new technologies and solutions.
AGILITY
We inspire our customers by delivering individually configured powertrains at the right time and with perfect quality.
BRPMS
We continue to rely on BRPMS, our unified, group-wide management system as the foundation for our drive of excellence in everything we do.
As a visible sign of our internal and external kick-off, visible changes are successfully implemented right at the beginning.
EVERYTHING NEW
The modern main entrance becomes the sign of our premium orientation. The open reception area gives a generous impression, our products are presented on site.
NEW WORKING CLOTHES
All employees are provided with new working clothes which contribute to work safety and work hygiene. The uniform look brings us even closer together as a team.
STATE OF THE ART WORKPLACES
The first lighthouse workplaces are created in the departments assembly and manufacturing. They are set up according to BRPMS and serve to ensure sustainable and optimal workplace organization.
OUR TEAM, NEW AND QUALIFIED
The Change Coordination Team (CCT) is put together to support ongoing changes, ensure smooth implementation and provide sufficient information.
All changes are made in record time during ongoing operations, the first business unit is set up, change-management-training and new communication channels are introduced.
OPENING OF ESTABLISHMENT
Within only six months, we managed to move 29 machines to the new establishment, and from February onwards we are already working in 3-shift operation.
FOUNDATION OF BUSINESS UNITS
During ongoing series production, the new business unit cylinder crankcase / cylinder head gets implemented. Our BRPMS goals are achieved, from cleanliness to lean logistics.
Change-Management-Trainings
Experienced trainers answer all questions during the change-management-training. By summer, 375 colleagues and 50 apprentices take part, the feedback is very positive.
EXPERIENCE ROOM & VIRTUAL CAFÉ
In the new experience room and Virtual Café you can inform yourself and exchange information about different Gunskirchen 2020 topics, which are illuminated under the aspects of technology, agility and BRPMS.
Progress can be seen everywhere: new plasma system, business unit charging systems and business unit crankshaft as well as AGVs on the pilot line.
BUSINESS UNIT CRANKSHAFT
The development of the value stream optimized business unit crankshaft begins. Machine relocations follow, automated grinding machines and new turning lathe are installed.
Conversion activities of new pilot line
The new pilot line with driverless transport systems (AGVs) is tackled, the production-control system with assembly line, kitting, one-piece-flow of lot size 1 becomes reality.
BUSINESS UNIT CHARGING SYSTEMS
The installation of the business unit charging systems starts. First, the assembly area is set up, then the machining centers are positioned and finally, the washing and deburring centers are delivered.
RECRUITING AND TRAINING PROCESS
In order to attract qualified and enthusiastic employees for the business units, the internal recruitment and training process is started. This includes team building, coaching etc.
Everything is progressing: assembly line south with AGVs, commission of the new cracking plant and move into the central office.
BUSINESS UNITS ON THE ROAD TO SUCCESS
The business units are taking shape: After the start of the business unit crankshaft and the area renovation in the business unit conroad, additional units are equipped with new machines.
New material pool
With its centralized service, the new material pool ensures that space is optimized and that all employees receive everything, from safety shoes to working clothes, from a single source.
ASSEMBLY LINE SOUTH
Series production starts on our assembly line south with AGVs. A kit contains all parts needed for assembling a product. Industry 4.0 is making inroads, from process logistics to pick-by-light.
New areas – central office & co
Due to the new central office in the manufacturing area, managers are close to the workplaces and decision-making processes are shortened. A central washing room ensures cleanliness, order and efficiency.
With the start of the business units in the assembly department, all production areas now work in the business unit structure. In addition to further capacity expansion, maintenance on the shop floor is centrally integrated.
Investments in next generation machines
We are investing massively in the expansion and renewal of plants and capacities. Moreover, almost 200 machines are repositioned in a value stream-oriented manner during ongoing shift operations.
Central maintenance
The new maintenance is implemented, distances and material transports are shortened.
BUSINESS UNITS ASSEMBLY
The new business units in the assembly department with the lines 3, 4, south, aircraft and pilotline are opened. They help us to produce customized powertrains.
COLLABORATIVE ROBOTICS
As a pioneering company for industrial production systems with digital control, we rely on collaborative robotics, which, in addition to 3D printing and system control, is also part of the program of our apprentice shop.
From the start of the assembly line north to the sustainable expansion of internal production capacities, we are getting closer and closer to our vision and goal.
NEW Core Components Special Parts-STRATEGY – everything one-stop
Small series, tooling and prototypes are combined in one business unit.
Training and education
The ROTAX Academy offers practice-oriented special courses on industry 4.0, mechatronics, production of the future in batch size 1, etc. to our employees and apprentices.
Under construction, line north
With help of the latest technologies such as AGVs, a new, highly flexible assembly line is realized.
Implementation Capacity Increase
Massive expansion of our production capacities through continuous investment in our machinery.
On December 12th, exactly seven years after the start, the final event takes place to celebrate the successful implementation of the project.
The entire shop floor in the value stream
Almost 200 machines and plants have been reorganized in a value stream-oriented manner, leading to an improvement in the material flow.
Start of the new assembly line north
The highly flexible assembly line North follows as a consequent further development of the assembly line South. The line North is equipped with state-of-the-art assistance systems. The work content is visually displayed on the workstations via touch screens. The walk-on toolrail allows maintenance work during ongoing operations.
The closing event
On December 12th, 2019, on the exact same day after seven years, an event to celebrate this success takes place in Gunskirchen. A big presentation shows how we managed to achieve sustainable change in just seven years.
Together we have achieved the goal
With the Gunskirchen 2020 project we have actively shaped the future. An excellent foundation for the future has been created. Together we win every race because passion is what drives us.