Volkswagen Chattanooga
Efficiency and reliability from Trane and Ingersoll Rand.
Efficiency, reliability and quality are among the hallmarks of
Volkswagen automobiles. These same high performance characteristics
are critical in Volkswagen’s manufacturing processes and can be found
in the Trane air conditioning chillers and Ingersoll Rand Industrial
Technologies air compressors installed at Volkswagen’s new assembly
facility at Chattanooga, Tennessee.
Challenge
Volkswagen Group of America announced the construction of the new
assembly plant at Chattanooga in 2008. The new factory will create an
estimated 2,000 new jobs. Construction began in April, 2011. Initial
production capacity will be about 150,000 mid-size sedans per year,
designed specifically for the North American market.
Among the systems needed for the new Volkswagen factory were chillers
for cooling the plant and manufacturing processes including robotic
welders and painting areas. Volkswagen also needed industrial air
compressors to power the many pneumatic tools and processes. In
selecting chillers and air compressors, Volkswagen required efficient,
reliable performance plus on-time delivery to keep factory
construction on schedule. Chillers and air compressors are mission
critical. Without them the Volkswagen facility cannot operate.
Efficient and reliable operation translates to lower production costs
for Volkswagen.
Solution
Volkswagen is investing more than $1 billion in the two million
square-foot plant where they will build efficient mid-size sedans for
the North American market. Volkswagen estimates that the new plant is
35 percent more efficient than other standard buildings, thanks to
modern systems like those from Trane and Ingersoll Rand Industrial
Technologies. Trane and Ingersoll Rand provided the systems expertise
to make sure Volkswagen got the cooling and air compressor systems
required. The chillers were run-tested at a variety of cooling load
points on an ARI-certified test stand at the Trane factory, confirming
the specified capacity and energy efficiency. Trane delivered the
chillers on schedule and worked with contractors to help assure that
all equipment was installed correctly. A Trane Tracer Summit™ chiller
plant management system monitors and controls the chillers and
interfaces with the overall facility control system. In addition to
cooling manufacturing processes, the Trane chillers supply chilled
water to Volkswagen’s IT computer servers.
Ingersoll Rand
Industrial Technologies provided four centrifugal compressors and two
oil-free, variable-speed rotary air compressors. The compressors
provide compressed air for a variety of assembly and painting
operations. The compressors are equipped with Ingersoll Rand
energy-efficient dryers to make sure the compressed air is clean and
dry. Chris Johnson, Volkswagen assistant manager of facilities-plant
infrastructure, said, "Reliable compressed air is just as
critical to our operations as chilled water and electricity. Without
compressed air, manufacturing operations will stop in about a
minute."
Trane and Ingersoll Rand Industrial
Technologies are also providing services such as start-up and
commissioning, parts and labor warranties, and periodic inspections.
Results
Trane and IR Industrial Technologies both met or exceeded the
Volkswagen specifications for the chillers and compressors, and very
importantly, met the delivery schedule requirements. Trane delivered
the chillers in about half the time needed by other chiller suppliers.
As a result of their performance in meeting Volkswagen’s needs, Trane
and Ingersoll Rand Industrial Technologies have earned Volkswagen’s
Preferred Partner status.
Chris Johnson said, "The
chillers, air compressors and dryers,and chiller plant management
system are all performing well. We’re very happy with the performance
and we’re getting the support we need from Trane and Ingersoll Rand."
About Volkswagen Chattanooga
"The Chattanooga plant...will be the culmination of some of the best technologies and processes from Volkswagen plants around the world...the model for future plants." — Das Auto magazine
