Opel/Vauxhall Manufacturing Planning

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

5 Wiener Produktionstechnik Kongress, Vienna, May 2014

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


• 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


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


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


Schematic Flex. Plant Layout

10

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

11

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


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


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


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


Thank you


Opel/Vauxhall Manufacturing Planning

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