How to make Opel
• How to make the Opel
Report from the Opel plant in Rüsselsheim. In 1863, Adam Opel discovered in Rüsselsheim factory for the production of sewing machines are now here is one of the largest and oldest car factories in the world. There are 16 000 and 180 000 cars produced annually.
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Employees move on bicycles. Right visible footpath.
It is delivered material from which stamped body parts. At the plant make Insignia and Astra, but in the press shop make a template for all models, which are then sent to other plants, including in Russia.
It is the largest injection molding at Opel.
The whole shop is busy with huge presses, there are hundreds of them. During operation, presses the floor tremble slightly as during small earthquakes.
Matrices are marked with different colors - depending on the vehicle model.
This machine is stamped to twenty small forms in a minute.
Stand with reference samples. From each batch randomly choose a few details, and compared to the benchmark.
And this new press. The machine is worth 40 million euros! It can be stamped at a time just one side of the machine. Press weighs 6500 tons.
After a few seconds out side of the three-door Astra
Then the details of the cut excess metal
And on the trolley are sent on a conveyor assembly shop.
In the welding shop are all fully automated, so you can watch only from above.
The welding shop is working in two shifts. At each change of 200 people. At the assembly of the body work 700 robots, each of which is worth 100 000 euros. 98% Production automated.
Robots may not in person where he worked. If anyone enters the area of robots - production stops.
Roof laser welded. At Opel Insignia - 4500 welds.
Naked body weighs 400 kg, and the painting takes 8 kg of paint and varnish. Unfortunately, the process to remove paint is not allowed.
In the assembly shop employs 2,000 workers in two shifts.
A total of 16 000 plant employees. Directly involved in the assembly of 7000, 5000 - the administration.
All the engines are different
Total conveyor fed up to 40 kinds of motors. Computer monitors that each motor is found his car.
Process, when the engine is connected to the body, called the "wedding ceremony".
The workers work in groups of 5 people. In this building a special step of time - 65 seconds. For 65 seconds, the worker must do some stage work. If he does not have time - the conveyor is stopped.
Everywhere there is a special rope, if to pull for it - the conveyor stops and starts playing music. Each team has its own music. According to her foreman knows who the problem and solve it quickly.
On the one conveyor can be discharged up to 9 different models of cars. Please note - on the line all the different machines. Not only color, but also the model. Since the assembly is automatic, there is no need to produce one model only. Assembly control computer.
Almost ready car.
After the assembly of the car passes a series of tests. For example, its pouring water in a special chamber to check for leaks. Then it passes through a small obstacle. The driver listens to the behavior of the car on the bumps.
Brand new three-door Astra.
Amps. It is a pity, in Russia, they are not supplied. And we do not have yet of chargers for automobiles.
Assembled cars from the factory takes away the train.
This is the hall where the fate of the new models! The screen shows the model, teams from different countries can work and condemn it.