Planung und Konzeption einer getakteten Montagelinie im Schwermaschinenbau am Beispiel der Firma Palfinger

This master¿s thesis focuses on the methodological planning and conceptual design of a paced assembly line in the heavy machinery sector, using the company Palfinger as a case study. Driven by increasing product variety, growing flexibility requirements, and planned product relocations, the need for a structured line concept for the assembly of crane models from Cluster 5 and Cluster 6 was identified. The objective was to develop a practice-oriented yet scientifically founded planning approach based on established methodologies and to apply it to the given industrial task. Building on the planning approaches of Bullinger, Lotter, and Konold, a hybrid procedure was derived that combines systematic phase structure, technical detail orientation, and practical work organization. In the subsequent case study, the existing assembly processes were analyzed, work contents structured, and various layout and supply concepts developed. Through line balancing, a realistic cycle time was determined, forming the basis for the dimensioning of the new assembly line. For the evaluation of the developed concepts, cost comparison calculations and utility analyses were conducted to jointly assess economic and qualitative criteria. The results show that the combination of an assembly in Hall 5 (MCC) with an automated rail-based transport system provides a balanced relationship between economic efficiency, flexibility, and technical feasibility. AGV systems demonstrate additional potential, particularly due to their flexibility and the possibility of automatic return transport of workpiece carriers. As part of the subsequent detailed planning, trial assemblies will serve as the basis for precise time studies, enabling the application of more accurate line-balancing methods and simulations. This allows further refinement of the work distribution diagrams and optimization of the line in terms of productivity and ergonomics. Given the low production volumes, the sequencing strategy is designed to remain pragmatic, as complex theoretical optimization models are of limited practical applicability in such an environment. Overall, this thesis demonstrates that combining scientifically grounded planning methodologies with industrial practice creates a structured and transparent decision-making basis for developing efficient and flexible assembly systems, thereby enhancing long-term competitiveness in the heavy machinery industry.