Porsche, in collaboration with Tesa SE has developed a new production process to seal the holes in the car body that are required to ensure the complete application of the anti-corrosion coatings
The new automated process uses adhesive sealing patches instead of plastic plugs and Taycan is the first model to use this new process. Once the anti-corrosion treatment is completed a special robot places more than 100 sealing patches automatically over the holes. Porsche says this solution is quick and reliable and helps to optimise efficiency in its paintshop processes.
The previous operation was performed manually and involved overhead work where up to 3,600 plugs per shift had to be pushed into the holes. So, another benefit of this solution is that it relieves considerable strain on employees.
One patch size can be used to cover all four hole types, so the new patches offer logistical advantages and reduce complexity. In addition, with a thick-ness of 1mm, the patches offer greatly reduced protrusion compared to the plugs, which extend up to 6mm from the body.
“It’s important not to confuse our adhesive solution with Tesa tape, which everyone knows from their office supplies,” explains Dirk Paffe, head of planning for Paint Shop Processes. “Once the special Tesa sealing patches have been applied, they can only be detached again with a great deal of effort. They provide a durable solution that can also withstand the stresses caused by the motion of the vehicle, and last longer than the lifetime of the vehicle.”
A project team from Porsche Innovation Management (established in 2016) worked on the development of this sealing solution, in conjunction with Tesa. As part of its remit the project team seeks out new developments, provides funding for them, and puts them to the test internally at an early stage. With the adoption of the sealing patches, by July 2020 more than two thirds of the approximately 150 plugs in the Taycan paintshop had been eliminated. The paintshop at the Leipzig plant will also make the switch by summer 2021.
Albrecht Reimold, member of the executive board responsible for Production and Logistics at Porsche notes: “Innovation has always been the driver of our commercial success. It is management’s role to ensure that this atmosphere is fostered in the day-to-day operations of the company.”