Cranes for growth programme
- 2 assembly lines for tractors and harvesters
- Material flow concept with 18 free-standing steel superstructures
- 35 suspension cranes and KBK pillar-mounted slewing jib cranes
John Deere assembles large tractors, combine harvesters, backhoe loaders, wheel loaders, timber harvesters and forwarders in an area measuring 20,000 m². Close to Russia’s largest airport Domodedovo and next to its production facility, John Deere built its new spare parts distribution centre, which measures some 27,000 m² for approximately 140,000 spare part and accessory items. John Deere now supplies its customers direct in Russia and the surrounding markets from the new facility.
Proven material flow
The installation layout in the Russian plant was based on existing manufacturing facilities in the USA. Consequently, John Deere created two production lines with indexed assembly operations in the building.
- Line 1: Assembly of large tractors; carriers pass through the individual assembly stations.
- Line 2: “Combined Line” for the completion of harvesters
All tractors and harvesters are indexed to pass through stations, which were installed along both assembly lines. The lifting equipment required for these operations was provided exclusively by suspension cranes and complementary pillar-mounted slewing jib cranes. The personnel are supported by a total of 35 cranes for the assembly of the John Deere products.
Order scope: cranes and steel superstructure
Demag Cranes & Components erected a total of 18 free-standing steel superstructures with a footprint of 9.1 x 12 m and a height of 8.45 m. The suspension cranes operate on runways which are installed on this support superstructure at an angle of 90 degrees to the direction of the material flow. The suspension cranes were specified to meet the particular requirements of the individual assembly stations. They range from 1 t EPDE single-girder suspension cranes with a rolled-section girder to EKDE cranes with box-section girders, which can lift loads weighing up to 15 t with their 7.5 t hoist units operating in tandem.
Greater flexibility: Thanks to the modular design of the manufacturing cells, they can also be moved if the production requirements change – regardless of the existing building architecture. The individual modules are pre-manufactured in the John Deere plants in America and shipped to the facility in Domodedovo in sea-worthy containers. Via loading docks, the parts are fed to the production lines and conveyed to the assembly stations under indexed control.
Line 1: Tractor assembly
Line 2: “Combined Line”
For loads up to 25 t
Production network with global structures
This will provide important support in production for John Deere’s growth programme in the country with the largest surface area in the world.
2 assembly lines with stand-alone steel superstructures for Demag suspension cranes