Porsche Leipzig GmbH

The challenge for the Porsche plant in Leipzig lies in the wide variety of model variants, (optional) features, and drive concepts, combined with the absolute quality standards required for premium products. It masters this challenge through the consistent implementation of lean principles, combined with intelligent digitalization and technological innovations.

Lean has been an integral part of the plant's DNA since 2002 – the entire workforce has a remarkably high level of lean expertise. For example, the majority of the many CIP workshops in the production and logistics areas run without direct support from the “central” lean experts.

Porsche Leipzig has already implemented lean and agile production in preparation for future challenges in automotive manufacturing. Examples include front and rear axle assembly and body construction for the Macan Electric.

The former currently produces around 20 axle types with more than 800 safety-relevant screw connections. The best possible protection for screw connections is achieved through both innovative and clever mechanical solutions. Quality inspection is fully automated, which has the advantage of reducing the number of inspection processes while increasing the documentation and evaluability of building statuses and the possibility of traceability. Pre-assembly close to the production line enables a smooth line through flexible shifting of variance to the pre-assembly stage, resulting in high cycle stability and a high value-added share in the overall system. The concept of flexible cycle length also contributes to this, enabling spontaneous and efficient adaptation of the assembly line to changing customer requirements.

In the body shop for the Macan Electric, material flow has been largely digitized and automated. A truck utilization tool ensures that deliveries are optimized. Clarification cases and bottleneck parts are accelerated with a digital reporting system. Special load carriers are collected via RFID. Small load carriers are transported directly to the placement of parts on the line without manual intervention, starting from the truck. AGVs transport all large load carriers to their destination, with a high proportion also being automatically placed in the production facilities. The optimizations achieved in terms of truck utilization, lead times, space, personnel, and operating costs are significant.

Particularly noteworthy is the system-supported sequence formation for assembly, which is based on machine learning and uses qualitative labels. This helps to avoid overload situations and ensures high takt stability. This intelligent planning contributes significantly to the resilience of the plant – even in volatile market phases.

In Leipzig, automation and digitalization do not conflict with employee orientation but rather complement it: Ergonomically motivated rotation, customized ergonomic workstations, and a specialized service team for employees with diminished capabilities ensure good working conditions and thus enable productivity and quality. The integration of autonomous testing systems increases process stability, while the workforce is actively involved in continuous improvement processes.

In summary, the Porsche plant in Leipzig impresses with its compelling combination of consistent application of lean principles, digital intelligence, and a high degree of automation - always with a clear focus on quality and cost-effectiveness.

This makes the plant the deserved winner of the Automotive Lean Production Award 2025 in the OEM category. Congratulations!

The Porsche plant in Leipzig has grown steadily since series production began in 2002. The first Cayenne rolled off the production line in August 2002. A few years later, the first expansion stages for the assembly of the Carrera GT and the production of the Panamera followed. In 2013, the former assembly plant to produce the Macan became a full-scale factory. In 2024, Porsche Leipzig successfully completed its fifth plant expansion, thereby establishing itself as a center of excellence for electric mobility. In addition, production of the new fully electric Macan began. The site is now able to produce three different drive types with a high degree of flexibility within the existing production line: gasoline, hybrid, and pure electric vehicles. The focus is on people. For example, responsibility is delegated to the employee level, and the workforce is actively involved in improvement processes.