opel/vauxhall manufacturing planning
TRANSCRIPT
www.opel.com
Flexible Production of Diesel- and Gasoline
Engines
Introduction to the new flexible GM Engine Plant in Szentgotthard (Hungary)
Dr. Dietmar Sahm, Adam Opel AG, Manufacturing Engineering Powertrain
May 2014
OPEL ZAFIRA TOURER 1.6 CDTI DIESEL ENGINE
• New family of all-aluminum
diesel engines
• Class-leading power
density
• Very low CO2
emissions
=> 109g/km
• Benchmark
for NVH
• Euro 6 emissions
compliant
OPEL CASCADA WITH 1.6 SIDI TURBO ENGINE (MGE)
• 13 % FE & CO2 improvement
• 30% torque increase
• Torque champion in its class
• Class leading refinement
National taxation schemes and
diesel/gas price gap have been
major drivers of diesel shares
High variations between countries
Leading Diesel countries Belgium,
France, Spain
Diesel Share by Country – Jan-May 2011 – Pass.-Car Market
Diesel Market Share varies significantly between European Countries
Wiener Produktionstechnik Kongress, Vienna, May 2014 4
European Diesel share expected above the 50% level in the 1st half
of this decade however within a Range of ~10% (+/-5%)
51%52%
54% 54%53%
52%
51%
49%48.5%
49.6% 49.8%49.0%
48.3%
47.3%
45.8%44.8%
52.4%
54.5%
57.1% 57.3% 57.2% 56.8%
55.7%
54.2%
30%
35%
40%
45%
50%
55%
60%
65%
2000 2002 2004 2006 2008 2010 2012 2014 2016
February update Range
Long Term Diesel Penetration Assumptions:
•Small gap b/w gas and diesel fuel prices
•CO2 taxation will increase
•Performance/Fun-to-drive factors will continue to have
a positive impact on diesel demand
Euro 6Euro 5
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Need for Flexibility drives Flex Plant Concept
• Uncertainty in Diesel-Gasoline-Market Share in Europe
~10% Range of uncertainty leads to a required
~+/-100k Diesel / Gasoline flexibility for Opel Vauxhall
• Manufacturing requirement: Low manufacturing cost
=> Avoid underutilization as well as uncovered demand
=> Flex. production to be able to react to market swings between
Diesel/Gasoline engines and achieve high plant utilization
Conclusion: Implement a Diesel Gasoline Engine Flex.-Plant
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• Midsize Diesel Engine
MDE introduced
Flexplant for 3 Engine Families
• Midsize Gasoline Engine
MGE introduced • Small Gasoline Engine
to be introduced
Site Szentgotthard Hungary
60.000 Sqm Annual Capacity 560 K ~500 Mil Euro Investment
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Strategy: Moving away from Transfer Lines to Flexible Machining Systems
Flex Plant Machining Concept
Transfer Machines
rigid System
Advantages: fast Reaction on
Product Changes and
Capacity Variations
CNC Machining Centers
flexible System
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Flex Plant Concept by Component and line
Cylinderblock Machining: Joint production of SGE/MDE aluminum blocks
in flexible adapter lines, MGE requires a separate block line due cast iron
Cylinderheads: Joint Production of SGE and MDE aluminum heads
in flexible adapter lines
MGE Cylinderhead production in existing flexible Headline (adapter line)
to save investment
Crankshafts: Machining of SGE/MDE and SGE/MGE/MDE in joint lines with
increased flexibility and scheduled tool changes
Assembly: 1 Gasoline Engine Assy Line for SGE and MGE and
1 Diesel Assy line for MDE
Flexibility by 100k additional capacity in each line
Flexibility by common machining lines and additional assembly capacity
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Schematic Flex. Plant Layout
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Fam1
MGE
100 K/Y
Head
MGE
(Cast
Iron)100 K/Y
Block
SGE /
MDE
180 K/Y
HeadAssy
Assy
AssyAssy
Hot Test
Logistic
SGE
MDE
(Alu)280 K/Y
Block
2 Step
Head
SGE /
MDE
280 K/Y
SGE
MDE
(Alu)180 K/Y
Block
SGE
MGE180 K/Y
MDE prov.
CrankCrank
MDE
SGE280 K/Y
2 Step
He
ad
Su
bH
ea
d S
ub
MD
E MDE
~380 K/Y
+~100 K/Y
2. Step
MG
E/S
GE
MGE/SGE
~380 K/Y
Staggered
Capacity
Installation
Wiener Produktionstechnik Kongress, Vienna, May 2014
Cylinderblock Machining enablers for flexibility
5 Axis Double Spindle Machining Center
Cylinderblock Adapter
Source: MAG IAS GmbH
4 and 5 axis single spindle and double spindle machining centers
Cylinderblock adapters
Flexible ancillary machines with robots
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Flexible Ancillary Machine with Robots
Wiener Produktionstechnik Kongress, Vienna, May 2014
Cylinderhead Machining enablers for flexibilityCylinderhead Adapter
AB-Axis Unit
Flexible Ancillary Machines with Robots
5 Axis Double Spindle Machining Center
Source:
GROB-WERKE GmbH & Co. KG
Source: JW Froehlich Maschinenfabrik GmbH
4 and 5 axis single spindle and double spindle machining centers
Cylinderhead adapters
Flexible ancillary machines with robotsInterface to Cylinderhead
Common Interface to Machine
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Crankshaft Machining enablers for flexibility
6 Axis CBN Pin and Main Grinding Machine
Internal miller with simplified
tool change
Source: Erwin Junker Maschinenfabrik GmbH
Source: Gebr. Heller
Maschinenfabrik GmbH
Flexible machines (grinders with double wheel heads on rotating axis)
Fixture and tool design for quick change over
Buffers between operations
Workpiece change overs based on production schedule
No batch size 1 capability
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Engine Assembly enablers for flexibility
Pedestal with Kit Box and Adapter Automatic Rundown Station with Robots
Source: ThyssenKrupp System Engineering GmbH
Pedestal with rotating and tilting capability and adapter
Kitting
Extensive usage of manual and semiautomatic stations
Flexible automatic stations with robots
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Summary
The Flex-Plant Concept allows Flexible Production across engine families
Machining lines for Cylinderblocks and Cylinderheads can handle
flexible production of multiple families with adapters and robots in
assembly and test stations
Crankshaft machining requires tooling and fixture change to handle
multiple family flexibility in addition to flexible machining concepts as far as
available
In assembly pedestals, kitting, robotized automatic stations and high level of
manual assembly are tools to support flexibility in the flex plant
Diesel Gasoline flexibility has been handled by 100k additional capacity
in each assembly line
Flexible Production of Diesel- and Gasoline Engines is being implemented in the
Szentgotthard Flex-Plant
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Thank you
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