A Repeatable PDP Solution Combining Rittal Enclosure Technology, Automation and EPLAN Engineering
When a global automotive manufacturer needed to standardize its power distribution panels across 52 facilities, the challenge went beyond selecting a common enclosure. The solution needed to simplify sourcing, streamline engineering, improve manufacturing consistency, and remain flexible enough to support local projects around the world. Here is the project briefly:
The Challenge
- Inconsistent power distribution panel standards across global plants
- 40 unique part numbers increasing sourcing complexity
- Need for one repeatable solution across 52 manufacturing facilities
The Solution
- Standardized power distribution panel based on the Rittal TS 8
- 40 part numbers consolidated into one configurable solution
- EPLAN engineering combined with Rittal automated enclosure machining
- Local and global support for repeatable implementation
A Bit More About the Project
Automotive manufacturers rely on a global network of OEMs, system integrators and suppliers to keep production moving. But when different partners work with different standards, suppliers and panel configurations, complexity can quickly multiply.
For one major North American automotive manufacturer, the challenge was to develop a standardized power distribution panel (PDP) architecture that could be replicated across 52 facilities worldwide—while maintaining engineering flexibility, local support and reliable product availability.
Rittal and EPLAN developed a standardized solution that brings together modular enclosure technology, digital engineering and automated machining to create a globally repeatable approach to PDP design and manufacturing.
The Challenge
The automotive manufacturer works with OEMs and system integrators around the world to support its assembly operations. Over time, different partners had introduced varying standards, suppliers, components and panel configurations, creating additional complexity across the customer's global manufacturing network.
The customer needed to:
- Standardize power distribution panels across multiple facilities
- Reduce the number of unique parts and suppliers
- Make outsourced projects easier to reproduce and scale
- Simplify engineering changes and documentation
- Improve product availability for future builds
The objective was clear: establish a global PDP standard that local OEMs and system integrators could reproduce consistently.
The Rittal Solution
Rittal developed a fully assembled power distribution panel based on a modified Rittal TS 8 modular enclosure.
Rather than managing 40 unique part numbers, the customer can order a single configurable solution built to its specifications. This significantly simplifies sourcing and makes projects outsourced to local OEMs easier to reproduce across facilities.
Connecting Digital Engineering with Manufacturing
EPLAN provides the digital engineering foundation behind the solution. Engineering documentation and component data—including bills of materials, CAD data, schematics and other project information—remain connected throughout the design process.
This connected approach makes engineering changes easier to manage while reducing the manual work involved in recreating designs and component information.
Rittal Automation Systems adds another layer of standardization and repeatability through Rittal Perforex automated machining centers.
Instead of relying on traditional manual cutting and modification processes, enclosure modifications can be performed with greater speed, precision and consistency.
Together, these technologies create a connected ecosystem that brings the following processes together:
- Standardized Rittal enclosure infrastructure
- Automated enclosure machining
- EPLAN Pro Panel engineering and 3D design
- Centralized BOMs and engineering documentation
- Repeatable manufacturing across multiple locations
Implementation
Rittal in North America provides local enclosure modification capabilities using the Rittal Perforex, giving engineering and production teams greater capacity for fast and precise enclosure customization.
EPLAN Pro Panel supports the manufacturing process with 3D panel design, collision checking, thermal considerations, component data and manufacturing documentation.
The digital engineering foundation also supports sourcing and manufacturing activities, helping ensure that the information required to reproduce a design remains readily available.
To further support product availability, Rittal and the automotive customer established transparent monthly forecasting. Forecast data helps Rittal plan availability for the specific enclosures and accessories required for upcoming PDP builds, reducing the risk of supply-related production interruptions.
Results
The combined solution delivered improvements across standardization, engineering, manufacturing and global support. Here are the results:
40 Part Numbers Reduced to One Configurable Solution
A standardized configurable solution simplifies sourcing, ordering and repeatability.
52 Manufacturing Facilities Supported
One PDP architecture can be deployed across the customer's global manufacturing network.
Faster Enclosure Modification
Automated machining helps replace slower manual cutting and modification processes with a more consistent approach.
More Efficient Engineering
Reusable digital engineering data reduces the need to recreate designs and component information for each project.
Reduced Error Risk
EPLAN Pro Panel supports precise 3D design, collision checking, thermal planning and manufacturing documentation.
Lower Change-Order Risk
Improved engineering accuracy can help reduce build errors and downstream corrections.
Simplified Spare Parts and Sourcing
Standardization reduces the number of unique components that need to be managed across projects.
Greater Global Scalability
Local OEM and system integrator projects can start from an established architecture rather than developing a new solution from scratch.
Improved Service Response
Digital documentation, combined with Rittal's global network, supports faster troubleshooting and localized service.
Conclusion
Global standardization requires more than selecting a common enclosure. It requires connecting engineering, sourcing, manufacturing, documentation and service so successful designs can be reproduced wherever production expands.
By combining Rittal enclosure and automation technology with EPLAN digital engineering, the customer established a standardized power distribution solution that is easier to engineer, source, manufacture, modify and support across 52 facilities worldwide.
The result is a more connected and repeatable manufacturing ecosystem designed to reduce complexity, improve consistency and accelerate deployment.
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