At John Deere, our passion for quality is much more than a philosophy; it’s our way of life. Quality permeates every level of design, development, engineering and production. It is typified by the words of our founder:
“I will never put my name on a product that does not have in it the best that is in me.”
This commitment has led to the name John Deere being synonymous with high quality products that exceed customer expectations because we believe every farmer and contractor deserves agricultural machinery built to the highest possible standards that will not let you down.
Every stage of development and production is subjected to the relentless scrutiny of our Quality Control Team. John Deere Zweibruecken is certified by the quality management norm ISO 9001. This ensures that John Deere harvesting equipment is always manufactured to the very highest standards of manufacturing precision.
As part of the development process, John Deere harvesting machinery undergoes many years of testing and development before reaching the customer. So we can be confident that our harvesters won’t let you down when you’re out in the field.
It’s not surprising that the service provided by our Customer Support Department is so highly appreciated. The support team is also located here in Zweibruecken, with direct access to the engineers who develop and manufacture our harvesters. This proximity eliminates potential misunderstandings and guarantees customer satisfaction.
The quality of John Deere harvesting equipment manufactured in Zweibruecken is guaranteed by the combination of high-precision machinery and the efficiency of lean production techniques. This enables us to produce high quality equipment on time and in a flexible way.
Cellular flow Manufacturing
John Deere Zweibruecken is organised around the principles of Cellular Flow Manufacturing. This is proven to maximise quality and efficiency while minimising waste and downtime. Our technicians work together in semi-autonomous, multi-skilled teams (“cells”) that manufacture complex components, modules or complete products. This is a more flexible and responsive method compared with the traditional mass-production line and means that quality improvements, maintenance and waste reduction are monitored and managed within the team.
The teams can exactly match their output to the demands of the prevailing production schedules and always have the flexibility to produce harvesting machinery with different specifications according to customer requirements. High quality is assured because it remains the responsibility of each member of the team.
High precision equipment for high quality products. Parts and components are manufactured with extreme precision, so that all assembled modules and finished products meet the rigorous standards for which the name John Deere is renowned.
Quality starts with the smallest part
Individual parts are manufactured on site using the most up to date high-precision machinery and techniques. Thanks to the John Deere common practice policy, the same parts can be produced to the identical exacting standards at any of our factories worldwide.
The precision tools at John Deere Zweibruecken guarantee the highest manufacturing quality, starting with the cutting and shaping of metal, through the welding and painting processes, to final assembly. The factory boasts six laser machines, two stamping and blanking presses and six CNC shaping and bevelling machines.
Investments in new processes and state-of-the-art precision technologies have enhanced manufacturing efficiency and provided superior levels of quality. Our latest equipment requires fewer production stages to manufacture parts, thus contributing considerably to our overall precision and efficiency. Up to 3200 different components for John Deere harvesters are produced in this way.
Strength and accuracy
Here, the individual parts are consolidated into sub-assemblies using precision welding equipment and techniques. The strength and accuracy of welds is carefully monitored and controlled throughout the whole process.
All of our load-bearing and stress-bearing components are robot-welded once the primary “fixing” weld has been completed manually. The welding robots perform with a repeatable precision of ± 0.15 mm and are also constantly monitored by our technicians. They combine 235 individual parts to produce 11 different components for John Deere combines and forage harvesters, including 6 different steering axles, axle carriers, cutter heads and compression rollers. These components are subjected to strenuous quality controls according to ISO 9001.
The largest units produced in the welding shop are the grain tanks, one of them being the world’s largest walker grain tank. All together there are 2 different designs and 3 different capacity variants.
Before final assembly, all parts and modules are carefully prepared for painting. The application of paint is precisely controlled to ensure that a perfectly even coating results, whatever the shape and complexity of the component.
In each of the 3 paint lines the parts are suspended on individual barcoded hangars before introduction to the conveyor. The monitoring system identifies which part, on which hangar and on which date the part was painted. The progress of each part is constantly monitored throughout the complete paint application process.
A series of immersion baths provide degreasing, rinsing and preparation procedures before the parts receive a cataphoretic bath prior to being spray coated with paint. They are subsequently baked at a temperature of 130° C. After one hour the paint is dry and the parts move on to the cool-down zone.
The contents of the immersion baths are sampled daily to ensure compliance with stringent John Deere quality and environmental standards.
It all comes together
This is where the harvesters take on their familiar shapes. The combination of state-of-the-art assembly machinery and the flexibility of our modular production system means that harvesters with differing customer specifications can be assembled alongside each other, without any disruption to the assembly process.
Combines and forage harvesters are assembled in adjacent halls, where a final quality audit is carried out before preparation for shipment.
John Deere combines pass through 14 assembly stations, in which the teams fit components and modules. Special protective handling apparatus presents components and modules conveniently at the point of assembly.
13 assembly stations are required to complete the assembly of John Deere forage harvesters.
A series of system diagnoses are carried out in a soundproofed booth. Electrics, electronics, hydraulics, engine characteristics, power and oil pressure are tested.