5.2.2002
Rüsselsheim plant: World's most modern car plant opens

All-new Vectra is first model off the line at the brand new Opel plant. High productivity, strict quality assurance, maximum flexibility and exemplary standards of ergonomics are among the features of this advanced automobile production facility, which has been designed and constructed according to the Opel Production System at a cost of some 750 million Euro.

Opel's new production facility in Rüsselsheim was officially opened today by German Chancellor Gerhard Schröder. The new automobile plant sets new standards and can claim to be the most modern anywhere in the world. High productivity, strict quality assurance, maximum flexibility and exemplary standards of ergonomics are among the features of this advanced automobile production facility, which has been designed and constructed according to the Opel Production System at a cost of some 750 million Euro. This record investment, higher than any other German automobile manufacturer has spent in recent years on a similar new plant, will guarantee some 6000 jobs in component and vehicle production at Opel's Rüsselsheim facility.

Carl-Peter Forster said: "The start-up of our new plant signals the start of Opel's future. Our new production facility in Rüsselsheim sets the standards for the entire automobile industry." Among the guests at the opening event were the Prime Minister of the German State of Hesse, Roland Koch, and the Mayor of Rüsselsheim, Stefan Gieltowski.

Advanced Computer Simulation
The complete Rüsselsheim plant began life on the computer. Everything from the structure of the buildings to the plant layout and optimized work procedures was developed in virtual reality. The engineers and programmers made extensive use of three-dimensional plant and design plans and innovative simulation tools. Three-dimensional computer animation permits actual conditions to be depicted with such accuracy that the simulation experts' forecasts are never more than one percent removed from reality in the completed plant.

Final Assembly in the "Half-Star"
The 'half-star' measures 48,000 square meters and is the second-largest work area in the new Opel plant: the initial and final assembly stages. The planning team chose a star-shaped layout because this ingenious principle is the ideal way to satisfy the needs of modern motor-vehicle production: a clear overview of all production activities, the shortest possible distances between them – for both the employees and the flows of material – and efficient communication between production staff and teams working in adjacent areas.

As at all other production stages, ergonomics played a key role in designing the individual work points, with invaluable support from the Works Council in achieving the ideal work-area design. An example of this successful cooperation: powered conveyors move the bodyshells through the assembly and position them automatically at the ideal height for each successive stage of work. Having to work with one's hands over one's head for long periods, for instance when installing the fuel tank or the fuel and brake lines, is now a thing of the past. These parts are now placed on a mobile assembly platform that moves up against the floor pan and bolts the parts into position. Other such measures include mechanical handling devices that avoid the need to lift any parts weighing more than ten kilograms. Last but not least, the assembly area's star-shaped layout gives it an exceptionally long frontage, so that the remarkable total of 70 docking stations can be provided for materials to be delivered directly to the corresponding point on the assembly line. Materials and components are prepared for delivery to the line at intervals conforming precisely to production speed, either in the neighboring logistic center or in a newly built store for small components. This new logistic concept avoids the need for large storage warehouses and the complex pre-assembly work on the actual lines that was formerly needed.

The most important station of all in the assembly area is of course the 'marriage' between the pre-assembled body and the driveline and running gear. This too now takes place fully automatically. A photo-electric barrier synchronizes the body, on its overhead conveyor, with the assembly stand carrying the complete powertrain, suspension and exhaust system. The body is lowered and at the same time the assembly stand raised until these two main elements of the complete vehicle are united. At the next work station they are bolted together, also fully automatically, at 44 points. Electronic monitoring of the torque and tightening angle at all the relevant threaded connections ensures effective process control of all safety-relevant connections. This facility also avoids all trapped stresses and thus helps to eliminate noise being transmitted to the interior of the car that could disturb its occupants later.

Read more tomorrow on the quality assurance program for zero defects at the new plant in Rüsselsheim.