Ford divides manufacturing facility to control contamination between two areas

Company: Ford

Location: Köln-Niehl, Cologne, Germany

Overview: Segregation of production, assembly and storage areas

Solution:  Flexiwall with Flexicurtain

Ford, the global automotive OEM, sought to reconfigure one of its production halls in Köln-Niehl by dividing existing space into two distinct areas. The car maker was introducing an EV battery assembly line and battery storage space into a hall previously dedicated to engine production. The primary objectives were to address concerns related to control of oil, metal and dust particulates, as well as operational segregation. To achieve this, Ford engaged with Westgate Global, a renowned provider of flexible segregation solutions. Westgate Global recommended the implementation of their Flexiwall system to effectively segregate the engine production area from adjacent battery assembly and storage areas, enabling better control over contaminants and the creation of separate areas for logistics operations.

Key features and benefits to this project included:

Operational efficiency: The installation of Flexiwall would enable Ford to create two distinct operational areas, allowing production of diesel engines on the one side and assembly and storage of batteries on the other.

Containment of dust and debris: By dividing the old production hall into two separate areas, the Flexiwall system would minimise the risk of diesel engine production contaminating battery assembly. Furthermore, the segregation would help preserve the integrity and cleanliness of stored batteries.

Fire rated partition wall: In order to comply with requirements of Ford’s works fire brigade, Westgate Global’s recommendation was to manufacture the partition in a polyurethane coated glass cloth material type, tested to DIN EN 13501-1 A2 s1 d0. Critically, the material does not contribute to the development of a fire and produces no flaming droplets in the event of a fire.

Westgate Global collaborated closely with Ford to understand their specific requirements, designed and manufactured the Flexiwall system components to fit the production hall’s barrel roof architecture and dimensional requirements accurately. The system is engineered to be easily installed, allowing for minimal disruption to ongoing operations.

Westgate Global's expert fitting team carried out the installation process around existing machinery, gantries and in close proximity to live production, ensuring precise placement of the Flexiwall system. The system is easily installed in tight spaces, lightweight and only takes up millimetres of floor space. The flexible panels were hung at roof level, tensioned, and securely fixed to the floor.

There were 5 x runs of Flexiwall totalling more than 150 linear metres x 11.5m high with 3 x pedestrian access doors, 4 x integral Flexicurtains for forklift access and a 4m wide roller shutter door, all supplied and installed by Westgate Global as part of a turnkey partitioning solution.

The modular nature of the Flexiwall system allows for easy customisation and future adaptability. If Ford’s operational needs changed or if they required reconfiguration of the production space, the Flexiwall system could be easily adjusted or expanded to accommodate those changes.

By partnering with Westgate Global and implementing their Flexiwall system, Ford successfully addressed their diesel engine production and battery assembly challenges related to dust, debris and operational segregation. As a result, Ford achieved a controlled environment for their battery assembly and storage.