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ContentsThis presentation will give you Overview of Production Facilities Plant Capacity/Production Range/ Localization Status Plant production History Press Shop Body Shop Paint Shop Assembly Shop Plastic Moulding & Paint Shop Support Facility & Technical Centre Each Shop will give you detailed list of Machine & Equipment List Tooling Process Flow for Matiz and Cielo Production Components produced by Daewoo Support Machines

Argentum AutoBrief history of Daewoo Motors plant Facility started by Toyota in 1985 as a Com. Vehicle plant. Daewoo added ETA, Press Shop, Aluminum Die Casting, Plastic Molding and Power Plant in 1998. Daewoo manufactured 3 models in this facility: Cielo in 1995, Matiz in 1998 and Nexia in 1999 Ownership of the plant moved to a consortium of banks and as a result it remained out of operation for 4 years. Plant was maintained on a daily basis by a company specialized in engineering and maintenance

FACILITIESCAR MANUFACTURING FACILITIES

PRESS SHOP ASSEMBLY SHOP

BODY SHOP

PAINT SHOP

PLASTIC PAINT & MOULDING SHOP

ENGINE & TRANSMISSION MANUFACTURING FACILITIES

ENGINE SHOP ALUMINIUM DIE CASTING SHOP

TRANSMISSION SHOP

FACILITIES

UTILITIES

POWER GENERATION EFFLUENT TREATMENT PLANTR&D

COMPRESSED AIR & HOT WATER GENERATION

VARIOUS TEST LABORATORIES ( EMISSION, ENGINE, VEHICLE, CHEMICAL & GENERAL ) DRAWING MANAGEMENT & DESIGN ROOM

Car Plant Over View Covered Arean

CAR PLANT a. b c. d. CAR BODY SHOP CAR PAINT SHOP CAR ASSEMBLY SHOP PLASTIC PAINT SHOP TOTAL AREA ( Car Plant ) : : : : : : : : 8,340 11,635 14,250 3,800 38,025 17,340 1,834 7,540 3,120 Sq. m Sq. m Sq. m Sq. m Sq. m Sq. m Sq. m Sq. m Sq. m

n n n n

PRESS SHOP PLASTIC MOULDING SHOP KD WARE HOUSE CIELO HEMMING SHOP

TOTAL COVERED AREA

:

67,859

Sq. m

Plant layoutNPROPANE STORAGE

Total Land Area : 825,610 sq.mTEST TRACKCKD STORAGDM WAT ER

Gate #4

ETP

LPG STORAGE YARD

ETPKD WAREHOUSE

ALDCHFO

W/HSE BODY SHOP

POWER

UTILITY CENTER

GREEN BELT

PLASTIC PAINT & BUMPER SHOP

PAINT SHOP

ASS'Y SHOP

CANTEEN

ENGINE & TRANSAXLE SHOP

PRESS SHOPDI WATER

INCINATORHSD STORAG

HEMMINGDG ROOM

GREE N BE LT

GRE EN BEL T

GREEN BELT

CVDCANTEEN

DELIVERY YARD

BONDED W/HOUSE

GREEN BELT

GREEN BELT

CAR PARKIN

TECHCENTER SECURIT

A/S

CAR STORAG

PARTS CENTER

MATERIAL

YARD

GREEN BELTGate# 2 Gate#1

BUS PARKING

Gate#3

Main

DELHI

DADRI

Total Build Up Area : 191,720 sq.m (23%)

Process Flowchart Car ManufacturingStagewis Proces flow details : Car Manufacturing e sPRESS( Forming of parts )

PLASTIC( Plastic painting & Injection Moulding )

BODY( Welding of parts )

PAINT( Painting of shell )

ASSEMBLY( Assembly of car )

INSPECTION( Inspection of car )

ENGINE / TRANSAXLE

VENDOR PARTS

POWER / UTILITY( Power , Compressed air, Water )

Process Flowchart Car Manufacturing3500 T TransferLine 2300 T Transfer LineA u t o C o m p o n e n t s

Pre Ass'y

Under Body Sub Ass'y

Main Body Side Body

BIW Line Hemming Line

Repair

Coil

White Body Stock

2400 T Tandom Line

Body Shop

Pres Shop sTop Coat Primer Sealing and U/Coat. PT & CED LinePaint Shop

Painted Body Stock

Trim Line

Chassis Line Sub Ass'y

Final Line

Assembly Shop

Final Inspection

Shower Test

C.S.Line

Guage LineInpection Line

Delivery To Marketing

Localization Status Matiz & CieloPRODUCT NAME PART S DET AIL S Items No of parts 1 MATIZ % Contrib'n No of parts 2 CIELO % Contrib'n 55.29% 22.35% 77.65% 22.35% 22.35% 39.91% 141 16.14% 57 56.05% 198 43.95% 57 43.95% 255 Local Parts In - House 89 36 Total Localisation 125 IMPORT PORTION Total Number of Parts 223

S.No

98

No of parts 3 TOTAL

230

93 19.46%

323 67.57%

155 32.43%

478 32.43%

% Contrib'n 48.12%

IN- House Manufacturing Body PartsPARTS S.No PRODUCT NAME Total Parts Parts Details ( No. ) ( No.) 9 1 MATIZ 36 11 16 15 2 CIELO 57 17 25 DESCRPT ION LINE NAME 2300 Ton TANDEM LINE 3500 Ton TANDEM LINE 2400 Ton TANDEM LINE 2300 Ton TANDEM LINE 3500 Ton TANDEM LINE 2400 Ton TANDEM LINE % Contribution 25.00 30.56 44.44 26.32 29.82 43.86

24 3 TOTAL 93 28 41

2300 Ton TANDEM LINE 3500 Ton TANDEM LINE 2400 Ton TANDEM LINE

25.81 30.11 44.09

IN- House Manufacturing Plastic PartsPARTS DESCRPTION S.No PRODUCT NAME Total Parts Parts Details ( No. ) ( No.) 2 1 MATIZ 3 1 3500 Ton INJECTION MOULDING 33.33 LINE NAME 1600 Ton INJECTION MOULDING % Contribution 66.67

2 2 CIELO 5 3

1600 Ton INJECTION MOULDING

40.00

3500 Ton INJECTION MOULDING

60.00

4 3 TOTAL 8 4

1600 Ton INJECTION MOULDING

50.00 50.00

3500 Ton INJECTION MOULDING

Plant Capacity2.1 PLANT CAPACITYWORKING Hrs PER SHIFT Normal Overtime Total ANNUAL PRODN .(Approx) (@293 Days )

S. GROSS EFFICIENC SHOP NAME No JPH Y

NET JPH

PRODN / SHIFT

PRODN / SHIFT ( 2 Shift )

1

OVERALL

17

95%

16.1

7.67

0

7.67

123

246

72,000

2 3 4 5

ASSEMBLY PAINT BODY PRESS

17 16 16 30

95% 95% 95% 95%

16.1 15.6 15 28.4

7.67 7.67 7.67 7.67

0 0.21 0.53 0

7.67 7.88 8.20 7.67

123 123 123 218

246 246 246 436

72,000 72,000 72,000 127,000

*

OVE RALL ANNUAL PRODUCTION CAPACITY* IS 72,000 Cars / Annum * ANNUAL PRODN. CAPACITY :7.67 ( Working Hrs ) X 16.1 ( JPH ) X 293 ( Working Days ) X 2 ( Two Shift )

Car Production HistoryS.No PRODUCT PRODUCT DETAIL DOMESTIC 1 CIELO / NEXIA EXPORT SUB TOTAL DOMESTIC 2 MATIZ EXPORT SUB TOTAL PRODUCT DETAIL DOMESTIC 3 TOTAL ( CIELO/NEXIA EXPORT + MATIZ ) SUB TOTAL P R O D U C T I O N D E T A I L ( Year-wise ) 1995 ~ 1996 1996 ~ 1997 1997 ~ 1998 1998 ~ 1999 1999 ~ 2000 2000 ~ 2001 2001 ~ 2002 Total

9,117 0 9,117 0 0 0

17,537 0 17,537 0 0 0

5,102 0 5,102 0 0 0

4,173 0 4,173 4,342 0 4,342

1,552 0 1,552 32,796 1,207 34,003

705 0 705 31,905 1,578 33,483

112 0 112 7,980 70 8,050

38,298 0 38,298 77,023 2,855 79,878Total

P R O D U C T I O N D E T A I L ( Year-wise ) 1995 ~ 1996 1996 ~ 1997 1997 ~ 1998 1998 ~ 1999 1999 ~ 2000 2000 ~ 2001 2001 ~ 2002

S.No PRODUCT

9,117 0 9,117

17,537 0 17,537

5,102 0 5,102

8,515 0 8,515

34,348 1,207 35,555

32,610 1,578 34,188

8,092 70 8,162

115,321 2,855 118,176

Engine , Transaxle & Aluminum Die Casting Plant

Engine Transaxle and Al Die-casting Plant Area Detailsl BUILDING AREA COVERED

p ENGINE

-

18,200 Sq. METER

p TRANSAXLE

-

20,800 Sq. METER

p AL. DIE CASTING

-

6,400

Sq. METER

p TOTAL

-

45,400 Sq. METER

PIM : Engine & Transaxle Plant

Engine & Transaxle plant with an annual capacity tomanufacture 400,000 engines and transaxles for passenger cars.

PIM : Engine Plant

Capacity to manufacture 400,000 units of engines and transaxles annually Transfer lines for Cylinder Block of 1.5L/1.6L capacity and Cylinder Head Flexible lines for Crankshaft (450MM), Camshaft (430MM) and Con Rod (Fractured-Alfing line) Automated assembly and test lines with 18 test cells.

ENGINE T/A SHOP LAYOUTPOWER STAT. CENTRAL COOLANT SYSTEM ( C.C.S.) RECEVING DOCK MAT'L CNT'L A M ON COOLANT SYSTEM TOILET IA R OOM POWER STAT. ELECT. UTY ROOM

RAW MATERIALDIFF.-HOUSING LINE BRG. PL ATE LINE SHIF T FORK LINE T/A - CASE L INE

EL EC. CONTROL ROOM

DG/B-3

DG/B-4

DG/B-5

HEAT TREATMENT

CYLI NDER HEAD LINE

CYL INDER BLOCK LINE

& BEARING CAP LINE

CRANK SHAFT LI NE

GEAR-1

GEAR-2

( HARD )

COOLANT SYSTEMCAM SHAFT LINE

ELEC. CONTROL ROOM

HEL / GCON-ROD LINE

REV/G MAIN SHAFT

INPUT SHAFT

C/ CL-5T/A ASSEMBLY LI NE

INPUT SHAFT

MAIN SHAFT

VENDOR PARTS

C/ CL-3&4 HEL / GEARGEAR-3 GEAR-4 GEAR-5

GEAR-1 GEAR-2 SH/SL-5 SH/SL-3&4 SL/GEAR REV/GEAR

C/ CL-5 GEAR-5 TOOL SHAR P GEAR-5 GEAR-5

T/A TESTING ENGINE ASSEMBLY ENGINE & T/A DELIVERY STOCK

GRI NDING WHEEL STORAGE

LAB

GAUG

DYNAMO TESTING

ENGINE TESTING

SPARE PARTS

MAINT. MECH. & ELEC.

DISPL AY

TOILET

TOOL CRIB

TOOL SHARPENING

SHAVING CUTTER AIR.-COND.

TOILET TOOL ROOM & WORKSHOP JIG BORG.

MAT'L WELD

MEASURING ROOM

Process Flow Chart Engine T/ACAM SHAFT CYL HEAD ENGINE SHOP CRANK SHAFT CYL BLOCK BEARING CAP CON RODCYL HEAD INPUT FROM ALDC

MACHINING

ASSEMBLY

TESTING

ASSEMBLED ENGINE

RAW MATERIAL

HEAT TREATMENT

TRANSAXLE SHOP

ISO THERMAL ANNEALING

SOFT MACHINING

HARD MACHINING

ASSEMBLY

TESTING

ASSEMBLED T/ AXLE

( GEARS, SHAFTS, SLEEVES, CLUSTERS)

T/AXLE CASE INPUT FROM ALDC

GENERAL MACHINING

D16 Transaxle plant Completio