Body-in-white

of the
New C-Class
Development
Planning
Production
 Development Planning Production

1982 - 1993 1993 - 2000 - 2007 2007 - 2014

2000

The C-Class model series has grown to become an

important pillar for Mercedes-Benz.

The new C-Class continues the company's success

story in the compact class!

Over 9 million vehicles have been delivered to date.

As of 2014
 Development Planning Production

Active and
passive safety
Impression of
value Consumption

Telematics,
entertainment,
assistance systems Design of
interior and exterior

Drivability
Comfort
agility
 Development Planning Production

MRA: Mercedes-Benz rear-wheel-drive architecture

Different wheelbase
• New architecture in the high-volume model series of Mercedes-Benz
• C-Class sedan car as lead vehicle
• Highly efficient use of derivatives
Sedan short wheelbase Sedan long wheelbase Derivatives
• More than 10 additional derivatives on this architectural basis
Different bodies

Station
Wagon
Derivatives

Coupé
 Development Planning Production

Changes compared to the predecessor model

1,442 (+-5)
790 (+15) 2,840 (+80) 1,056 (0) 1,588 (+41)

4,686 (+95) 1,810 (+40)

 Development Planning Production

Changes compared to the predecessor model

1.404 (+14)

1.454 (+14)

260 (0) 308 (+4)

1,660 (+60) 815 (+20) 425 (0)

 Development Planning Production

SPORTS GRILL
LARGE AND UPRIGHT
DROPPING LINE
DISTINCT
SHOULDER

LUXURY GRILL,
UPRIGHT, WITH
DETACHED; TAPERING
FINS

HEADLIGHT WITH CONCAVE – CONVEX

"TORCH DESIGN" FLANK MOVEMENT
 Development Planning Production

New benchmark in coefficient of drag of 0.24 in the compact sedan car segment

The aerodynamics is an important component for reducing CO 2 emissions.

The drag area (Cw x A) could be reduced by 5 % compared to the

predecessor model.
 Development Planning Production

I. Safe driving II. Dangerous situations III. During an accident IV. After the accident
avoiding danger, Prevention action providing suitable preventing a
providing plenty of timely with PRE-SAFE® and protection deterioration of the
warning and offering driver assistance situation and offering fast
assistance systems assistance

Active safety Passive safety

 Development Planning Production

Optimal design configuration of the load paths is the basis for the highest level of crash performance

Front Side

The vehicle has four independent Optimized transition of force into the floor structure
load paths for the frontal impact Including the side opposite the crash; rigid sidewall
structure
 Development Planning Production

More than 150 trial tests were conducted to confirm the crash-related functions of the lead vehicle

Mercedes-Benz
Rating
Legislation
2

6
2

10 5

7 1
3

Front Side Rear end/roof

 Development Planning Production

W205 Euro NCAP rating, 2014 - Final result | 11.05.2014

92
92% 84 %
84% 77
77%% 70
70%%

ADULT OCCUPANT CHILD OCCUPANT PEDESTRIAN SAFETY ASSIST

Frontal ODB 15.460 Dynamic 20.649 Headforms 21.000 SBR 3.000

Side MDB 8.000 Vehicle based 9.000 Upper legform 0.800 ESC 3.000

Side pole 6.730 CRS installation 12.000 Lower legform 5.930 SAS 1.333

Whiplash 2.086 AEB inter-urban 1.826

AEB city 2.800 LDW/LKA 0.000

Totals score 35.076 41.649 27.730 9.159

Max. points available 38 49 36 13

Normalised score 92 84 77 70

Weight 0,4 0,2 0,2 0,2

92% 84% 77% 70% Total 83 % TEST 2014

Rating requirements

80 75 60 65

70 60 50 55

2 advanced awards presented (Attention Assist and PRE-SAFE ®)

14
 Development Planning Production

New C-Class body is designed to meet small overlap (IIHS rating) requirements

Additional/modified body-in-white parts

for reducing body-in-white intrusion
 Development Planning Production

Damage-free headlamps by optimized front structure

• Optimisation in 22 crash tests

• Increased number of components without damage

• Realization of the RCAR bumper test

• Initial insurance rating by the GDV (Germany): VK 24
 Development Planning Production

A highly rigid body forms the basis for an optimal comfort setup

High local stiffness at the discharge points of the

engine, drive train and chassis.

NVH relevant load paths and node structure was

further optimized and extended.

These include additional load paths in the rear and the

increased use of struts in the front area.

Discharge points
NVH load paths
 Development Planning Production

Diecast aluminium used in the vehicle

structure

1 st torsion 1 st bending
frequency frequency

58.0
56.0
54.6
51.6

The dynamic body rigidity is improved by

approximately 1.5 Hz due to the use of
diecast aluminium in the structure
 Development Planning Production

Realisation of an efficient ring structure concept with assembly braces and front-end design

Predecessor New C-Class

Rigidity [N/mm]
+300
%

Frequency [Hz]
 Development Planning Production

Increased requirements with respect to customer benefit, comfort and

safety

Body-in-white Chassis Active and Hybrid Premium

measures measures passive safety drive equipment

• High torsional rigidity • Integrated 4-link • Increasingly stringent crash • Flexible integration of • Integrated panoramic
front suspension requirements in different markets drive components sliding sunroof
• Optimised initial
rigidity • Integrated air - IIHS side collision • Protection for • Integrated Frontbass
suspension - ECE R95 (new) accumulator and high- audio system
- Pole impact, FMVSS214 (new) voltage components
- Small Overlap (IIHS rating)

Added weight of approximately 30 kg resulting from increased body requirements is compensated by an integral lightweight design
approach
 Development Planning Production

2 Best possible compromise for optimal customer

benefit.

1 Design/aerodynamics
Benchmark standard amongst the
competition

2 Integral Safety/function
Highest priority when it comes to occupant
1 3 protection

3 Lightweight design
Utilising hybrid technology
The right material at the right location
 Development Planning Production

The underlying concept of the hybrid aluminium construction

Exterior shell

Extensive use of aluminium

outside the safety structure Safety cell

Ultra high-strength steel

for minimising crash
intrusions

Rear-axle suspension

Diecast aluminium for

maximum initial rigidity
Front-axle suspension Front/rear deformation zones

Diecast aluminium for Ductile load path structure for

maximum initial rigidity maximum energy absorption
 Development Planning Production

C-Class (W204) C-Class (W205)

Aluminium-
0.7 % extruded sections 1.6 %
Diecast 1.2 %
aluminium

Aluminium sheetmetal
14.4 %

Low-carbon steel
18.4 %

3.7 % High-strength steel

1.7 % Ultra high-strength steel 1.3 %
C-Class (W205)
 Development Planning Production

Resolves conflict between pedestrian protection and meeting rigidity requirements

Material concept:
• Different sheet metal thicknesses that
target specific requirements
e.g. center as an single-piece area optimized for
pedestrian protection.

Joining concept:
• Clinching and bonding
 Development Planning Production

5 kg weight reduction and significantly lower centre of gravity

Material concept
• Aluminium sheet metal 1.15 mm

Joining concept
• body-in-white production station:
Automated positioning of roof panelling in
body-in-white via screws and “plastic
spacers”

• Assembly production station:

Fully-automated joining of roof panelling
with highly modular adhesive
 Development Planning Production

Weight was reduced by more than 30% while meeting increased crash requirements

Material concept
• Aluminium monocoque design
• Door hinges made from aluminium
• Structure components made from extruded
aluminium profiles

Joining concept:
• Laser welding at the door frame
• Self-piercing riveting, spot welding and bonding
 Development Planning Production

Aluminium outer skin – A challenge for realising small gaps and radii

-24 % -10 % -12 % -13 % -13 %

4.0 mm

3.0 mm

2.0 mm
F3 W204 W205 F4 W204 W205 F5 W204 W205 F6 W204 W205 F7 W204 W205
 Development Planning Production

Diecast aluminium console for rigid and adjustable connection for the trunk lid hinge bracket

+2,25 +3
-3 • Independent X and Z-adjustment

• Final adjustment is carried out once during assembly

+3
-3 -2,25
+1,25 -5

+5 -1,25
 Development Planning Production

C-Klasse (W204) C-Klasse (W205)

0,4 % Plastic 0,8 %

0,2 % Diecast aluminium 5,3 %
3,8 % Aluminium sheetmetal 2,3 %
9,8 %
Ultra high-strength steel
(hot formed) 11,9 %

Ultra high-strength steel 5,4 %

45,1 % Modern high-strength steel 8,9 %

High-strength steel 36,2 %

16,3 % Low-carbon steel

10,7 % C-Klasse (W205)
 Development Planning Production

Per vehicle weight reduction of 2.8 kg and component reduction from 10 to 2 components

Material concept:
• Two-stage heat treatment in line with ductile and rigidity requirements
• Weight reduction: 2.8 kg per vehicle

Joining concept:
• Self-piercing riveting and bonding
 Development Planning Production

Per vehicle weight reduction of 3.1 kg and component reduction from 8 to 2 components

Material concept
• Diecast aluminium
• Two-stage heat treatment in line with ductile and rigidity requirements

Joining concept
• Self-piercing riveting, bonding and ImpAcTing
 Development Planning Production

Per vehicle weight reduction of 4.5 kg and component reduction from 14 to 2 components

Material concept
• Diecast aluminium
• Two-stage heat treatment in line with ductile and
rigidity requirements

Joining concept
• Self-piercing riveting, bonding, flow-drill screwing,
ImpAcTing
 Development Planning Production

Per vehicle weight reduction of 3 kg and targeted deformation in the lower region

Material concept
• Partially hot-formed steel with ductile area below the beltline.

Joining concept
• Spot welding and bonding
 Development Planning Production

71 kg Weight-saving potential afforded by lightweight design

+2.2 kg -10.2 kg
∑+30,4 kg Corrosion Lightweight ∑ -71,4 kg
protection design
Other -6.7 kg
+8.4 kg Hot-forming
scopes
Design -13.2 kg
Vehicle dimensions Aluminium
Packaging structure
-41.3 kg
+15.6 kg
Aluminium add-
Function
on parts
+4.2 kg Aluminium doors

LC measure

403 kg

362 kg
-41 kg

W204 W205

Body-in-white weight incl. add-on parts and doors

 Development Planning Production

G * Aproj.
Lightweight index: L= m
Weight [kg]
Torsional stiffness 378 kg
[kNm/°] 400
374 kg
30 kNm/° 372
370 kg 4%
28.8 W205
366 kg
20 kNm/° 348
350
334
10 kNm/°
Projected area [m2]

W205 4.6 m2 300

4.5 m2 4.5
4.4 m2
4.3 m2 250
W205 W204 W205
Increase of the lightweight index
Weight as per OEM lightweight quotient
 Entwicklung Planung Produktion

Project
start QG I QG H QG G QG F QG E QG D QG C QG B QG A
Quality Gates

DPT-P ASA DPT-V E-Fzg. "_"

Digital phase

Hardware phase ASA E-Fzg. B-Fzg. PRO

Digital Phase Hardware Phase

Develop and secure design Gradually increase maturity „Digital becomes physical“

• Design/shape/aerodynamics
• Function (crash /durability/NVH …..) Costs • PPG workshops
• Lightweight design, concepts Costs
Function • Manufacturing feasibility
• Corrosion protection • Part release process
Weight Time
• Modular integration • Joining method validation
• Digital validation Maturity
• Preproduction supply from series
production equipment
 Development Planning Production

4x2 front-sub frame shared with all MRA derivatives

C-Class 204 E-Class 212 MRA

Weight 12.9 kg 13.7 kg 13.1 kg

• Steel construction

4x4 front-sub frame shared with all derivatives

C-Class 204 E-Class 212 MRA

Weight 20.5 kg 20.5 kg 14.7 kg

• Aluminium semi-finished product mix (casting, profile, sheet)
 Development Planning Production

Challenges and core topics from a planning perspective:

• Implementation of architecture strategy in body-in-white
• Complex product
• New body-in-white plants at all plants worldwide
• All plants have different number of units and cycle times.
Nevertheless, "copy-paste" effects should be maximized
• Ramp-up on four continents within eight months.

Planning premises
• Consistently implement mechanical and electrical standards at all plants.
• Use proven technology where possible.
• Validate new joining methods by carrying out preliminary trial tests in series operation.
 Development Planning Production

100,000 m² extension - 9 months between "first groundbreaking ceremony" and

"first robot ton dowel"

• Body-in-white area centrally located in plant

• Optimal production structure: Centrally organised C-Class production, incl.
optimised logistics concept
• Current series production in existing hall; plant facilities in hall extension area
• Total area of production building 70: 117,000 m², of which 63,000 m² for production,
41,400 m² for traffic, 12,600 m² for logistics, and additional 12,000 m² for LOG
building
 Development Planning Production

Implementation of architecture concept (line 1 and line 2)

• Line 1 all new: Z1, Z2, Z3.

• Line 2: Z1 new, Z2, Z3 reuse, conversion during ongoing production.

• Clear separation of LOG and body-in-white production on ground floor:

Block-storage for sidewall paneling and LOG building for supplying of Z1, Z2
(sidewall).
 Development Planning Production

Implementation of architecture concept (line 1 and line 2)

• Line 1 all new: Z1, Z2, Z3.

• Line 2: Z1 new, Z2, Z3 reuse, conversion during ongoing operations.

• LOG concept:
Delivery of parts by trucks via ramps;
one LOG area for the overall body-in-white production.
 Development Planning Production

Planning premises: Planning results:

• Mass production: Degree of automation: 99 % • 1,564 robots
• Mass production: 100 % LCA application • 540 welding guns
• Capacity of 1,000 vehicles per day on the main line; • 92 self-piercing-riveting systems
add. replacement parts and CKD in sub assemblies • 58 clinching systems
• Cycle time of main line: 53 seconds • 10 ImpAcT systems
• Three-shift model • 8 flowdrill systems
• Output simulation • 233 adhesive application
(sub-assembly / Z-area / overall body-in-white) • 40 laser welding optics
• 408 individual parts • 31 laser sources
• 91 bolt systems

Time schedule:
Start of hall ext.: 10/2011 Start commissioning : 4/2012 PRO1 W205 bodies., 6/2013 Job #1 W205 body-in-white, 12/2013
 Development Planning Production

W204 W205
Spot welding 4,818 (units)
(steel) 4,441 + 316 (units)
(steel + aluminium)
RobScan 507 (units) 180 (units)

Laser soldering/welding 2,459 (mm) 12,885 (mm)

Laser soldering Laser welding
Stud welding 302 (units) 363 + 32 (units)
(steel) (steel + aluminium)
MIG soldering 1,200 (mm) 1,323 (mm)

Clinching 160 (units) 202 (units)

Self piercing rivets 0 331 (units)

Flowdrill screws 0 20 (units)

ImpAcT 0 80 (units)

Adhesive bonding 116,898 (mm) 187,912 (mm)

Parts 421 (units) 408 (units)

 Development Planning Production

First mass production application in an automotive body-in-white

• Aluminium-steel hybrid construction in rear end with steel, aluminium sheet and diecast
aluminium.

• ImpAct (Impulse Accelerated Tacking) is a cost-effective application for hybrid joining

operations with one-sided accessibility.
One tack for all joining tasks.
Depiction of ImpAcT joining process
• Design advantage by one-sided accessibility (ImpAcT),
optimal structural design possible by profiled construction.

• Application of ImpAcT only in conjunction with structural adhesive.

1. Positioning 2. Piercing 3. Pushing 4. Return

stroke
 Development Planning Production

Mass production capability is validated by various operational tests

Optimization of tack
supply systems

Mass production
C-Class
Tape feed Blow feed Magazine feed

2007 2014

Component crash tests

Basic research
Operational tests:
• Validation of "mass production capability of joining systems“ in rear end of E-Class
• Validation of "focus on aluminium" in rear end of SL-Class
 Development Planning Production

Optimal maturity level prior to start of installation

• Application for complex systems (e.g. framers) but also for validation of new joining
methods (e.g. ImpAcT).

• Robot simulation 100 %, virtual commissioning 30 % - 100 %.

• Validated offline programs from robot and PLC prior to start of programming, fast
commissioning and acceptance/approval of special functions.

• Cells in cycle time very early => No subsequent retrofitting of hardware.

 Development Planning Production

Lessons learned from current SL and S-Class model series implemented

• Aluminium-steel hybrid construction in rear end with steel sheet, aluminium sheet and
diecast aluminium.

• Use of self-piercing riveting together with structural adhesive for joining operations with
two-sided accessibility.

• Digital validation of tool accessibility:

Focus on uniform/standard tools
Standardised spare parts; beneficial from the point of maintenance at all plants.

• Hardware validation of rivet-die combinations

(different cycle times at the plants, therefore identical product but different joining scopes).
 Development Planning Production

High level of process stability in mass production

• Weight reduction due to trimming of the flanges and the application of laser fillet welding.

• One-sided accessibility => Use of "RobScan" laser remote welding.

• Technological challenge:
Clamping technology for RobScan requires two-sided accessibility, i.e. laser process clamping
during the welding process on the outside and inside the longitudinal member assembly.

• Challenges with respect to component coordination:

Sheet metal thicknesses of 1.6 to 3.0 mm (high-strength steel).

• Solution:
Validate using series clamping technology from prototype vehicle phase, coordinate laser
process clamping  components  welding parameters.
 Development Planning Production

Multi-joining method replaced with aluminium hybrid construction

Z1 line:
• Robot transport – Proven standardised concept for the S-Class,
E-Class and C-Class
• Product supplied via "collective overhead monorail conveyor"
• Conventional joining methods (spot-welding, adhesive bonding,
stud welding)

Front end:
• In-line sequencing from front end assembly
• Multi-joining method (laser, self-piercing riveting, adhesive bonding,
spot-welding)

Main floor:
• Conventional production (spot-welding, bonding)

Rear end:
• Multi-joining method (ImpAcT, flowdrill, self-piercing riveting, adhesive bonding, spot-welding)
 Development Planning Production

Carryover of production concept from predecessor model series & high-speed conveyor as a process innovation

Inner sidewall (4 types):

• Production concept as for the E-Class and C-Class predecessor (RobScan, spot-welding,
adhesive bonding)

Outer sidewall (4 types):

• Conventional production (spot-welding, adhesive bonding)

Z2 line:
• Primarily conventional production (spot-welding, adhesive bonding, flowdrill, self-piercing
riveting)
• Chassis punch due to multi-link axle
• Standard framer, proven concept from predecessor
• "High-speed conveyor" innovation reduces transport time and creates more time for value-
added content.
• Assembly-joined aluminium roof => Roof bolted in body-in-white for paint thru-sequence
due to Δ problem.
 Development Planning Production

Highlight – All hang-on parts made from aluminium

All hang-on parts in aluminium:
• Multi-joining method (laser fillet weld, aluminium spot welding, adhesive bonding, clinching,
riveting), roller hemming as standard in mass production.
• "Wedge rabbet" with reduction in rabbet radii for "precision exterior".

Z3 line (4 types):
• Line as standard concept
(automated hang-on parts assembly with best fit).
• "High-speed conveyor" conveyor system.
• No need for boot lid preadjustment in body-in-white, fine adjustment is carried out in assembly.
 Development Planning Production

Z-areas from the same suppliers all over the world

Bremen Bremen East Tuscaloosa Beijing

line 1 line 2 London
• Same group of suppliers for the plants in
Z1 Germany, USA, and South Africa for the C-
Class.
• Global project management.
Z2 • International partners.
• All MB body-in-white project managers
known personally and networked.
• Transparent and efficient flow of
Z3
communication.
 Development Planning Production

"Recipe of success" for proper ramp-up of lead model

• Sedan + estate assembled simultaneously;

integration of derivatives ongoing.

• Following vehicles reserved and integrated

(component materials, safety guards, etc.).

• Equipment for coupé operable from a control perspective

Sedan + estate Coupé, N.N.
("ghost operation") 9 months prior to first part,
hardware (robots, grippers, assemblies, etc.) fully integrated.

Sedan + estate Coupé, N.N.

 Development Planning Production

Electro planning process for consideration of energy efficiency topics

• Use of energy-optimised components

(robots, drive systems, control cabinets, etc.)

• Consumption-optimised operation
(Deactivation of robots during breaks by Profi Energy, deactivation of technologies
and components, automatic and consumption-governed shutdowns.

• Reduction in use of materials

Reduction in feed lines and background lighting.
Energy [kWh]

Break Production Break Production

 Development Planning Production

7 start-ups in 3 years

2014

Complex start-up program requires special measures:

• Include planning and production in the development process at an early stage

• Safeguard a production-compliant product design
• Provide extensive training for all employees
• Ensure strict controlling for construction site and ramp-up
• Optimise self-piercing rivets in mass production start-up phase
• Fastest possible delivery of body-in-white assemblies out of series equipment in to
the pre-production phase

Unit-quantity ramp-up, MRA derivatives

 Development Planning Production

Safeguarding a production-compliant product design

Lessons
learned from • Initiated by Production 3 years prior to SOP
predecessor
• Detailed workshops (Production, Planning and Development) in 6-week intervals with
model series
direct involvement of management
• 95 % of topics coordinated at short notice
• Good networking allows problems to be solved quickly during ramp-up

Optimisation Cross-
of series functional
Product workshops
maturity
 Development Planning Production

International qualification & experience safeguard start-up operations

• Installation of 9 sample cells with all key technologies, e.g. laser welding, ImpAcT more than
2 years prior to start-up
• Coordination/alignment of technical standards
• Qualification of employees at all international production locations at the Bremen plant
• 25 technology training seminars, 50 trainers, 15 interpreters and 2,400 man days of training
• Involvement of production employees during line installation
• Extensive expert qualification of all locations during production testing in Bremen
 Development Planning Production

Quick response to minimal deviations

• Daily construction site talks with all general contractors

• Complete transparency on installation progress based on individual components => For detection of the slightest deviations/abnormalities
• Weekly escalation from employee to management
• Standardised "construction site controlling" methodology from Bremen implemented in all foreign plants
• Transparent assessment of supplier performance

Hall 70, ground floor Hall 70, upper floor

Bremen

Tuscaloosa Beijing

East London
 Development Planning Production

200,00 Early detection of bottlenecks

Downtime in minutes

150,00 • Safeguard readiness of factory with "technology tracking"

Downtime overview • Determine availability of technology during start-up
100,00
per body (riveting)
50,00
• Controlling of cycle times together with general contractors
• Performance tests for validating start-up plateaus
0,00
0 4 8 12 16 20 24 28 32 36 40 44 48 52 • Emergency concepts for dealing with process breakdown
CW in 2014

2,0
Downtime in minutes

Downtime overview
1,0
per body (ImpAcT)

0,0
0 8 16 24 32 40 48
CW in 2014
 Development Planning Production

Safeguarding of the quality of series equipment at the earliest possible time

• Pre-series production starting with commissioning of the

equipment

• Direct quality checks at the production site allow very

Bremen small feedback loops

• Effective verification of the series readiness of

product and process

• Optimal quality ramp-up

Sindelfinge
n
 Development Planning Production

Lead plant coordinates 4 parallel ramp-ups

"Snowplow function" at Bremen plant

paves the way for foreign plants
Bremen

• Safeguarding of product maturity in the context of

change management at the lead plant in Bremen

Tuscaloosa
• Frequent on-site workshops with foreign plants every
Beijing 2 months; personal networking ensures optimal
transfer of knowledge

• Joint development for an optimal start-up organization

and capacity and qualification planning of the foreign
East London plants

• Participation of the foreign plants in the production

tests carried out in Bremen
 Auto-Motor-und-Sport.de:
„Einen cw-Wert von bis zu 0,24 bietet
in dieser Klasse sonst keiner…“
motortrend.com:
“Truly, one of the finest automobiles the world has ever seen.”

Bild-Zeitung:
„Bild Urteil: S-Klasse im C-Format.“
edmunds.com
“Like the rest of the car, the features available inside
the C-Class are all at the forefront of technology.”
Autobild.de:
„So viel Varianz bietet in dieser Klasse keiner…“
„Der Konkurrenz mindestens um eine halbe
Klasse voraus…
caranddriver.com:
„This is a strikingly elegant car.”
Focus.de:
„So vornehm wie das Ambiente ist auch
das Fahrverhalten…“
Autoblog.com:
“It might be so good that there's no
need to climb any higher.”
Auto Zeitung:
„Fazit: Die neue C-Klasse passt.
Leistungsstark, effizient, komfortabel, dynamisch
– Mercedes lässt keine Wünsche unbefriedigt.“