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IZHEVSK AUTOMOBILE PLANTCompany profile
Izhevsk, December 22, 2009
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LOCATION ADVANTAGES & LOGISTICSLOCATION AREA DETAILS
POTENTIALS FOR TRANSPORT LOGISTICS
POTENTIALS FOR STOCKING LOGISTICS
PRODUCTION CAPACITIES & TECHNOLOGY
CONTENT
HISTORY OF PRODUCTION BUILDUP
SPECIFICATION OF CURRENT LINEUP
PRODUCTION SITE
BASIC PRODUCTION
COMPONENTS PRODUCTION
ENGINEERING INFRASTRUCTURE
INFORMATION TECHNOLOGIES (IT)
ENGINEERING SUPPORT & DEVELOPMENTS
DEALERS NETWORKDEALERS NETWORK DATA
QUALITY SYSTEMQUALITY SYSTEM DETAILS
QUALITY SYSTEM BENCHMARKS
HUMAN RESOURCESLABOR STAFF SELECTION & ADAPTATION
FLEXIBLE SYSTEM OF STAFF SELECTION
SUMMARY
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Pages
IZHEVSK AUTOMOBILE PLANTCompany profile
Izhevsk, December 22, 2009
The additional information on technical and economic indicators "ОJSC
IzhAvto" and market conditions in which the enterprise works, is available on
demand via e-mail. Please, enclose the following information: company
name, official information, personal information and Contacts.
E-mail address: [email protected]
http://localhost/var/www/apps/conversion/tmp/scratch_1/[email protected]://localhost/var/www/apps/conversion/tmp/scratch_1/[email protected]://localhost/var/www/apps/conversion/tmp/scratch_1/[email protected]://localhost/var/www/apps/conversion/tmp/scratch_1/[email protected]://localhost/var/www/apps/conversion/tmp/scratch_1/[email protected]://localhost/var/www/apps/conversion/tmp/scratch_1/[email protected]://localhost/var/www/apps/conversion/tmp/scratch_1/[email protected]://localhost/var/www/apps/conversion/tmp/scratch_1/[email protected]
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LOCATION ADVANTAGES & LOGISTICSLocation area details
Moscow agglomeration
S.-Petersburg agglomeration
Rostov
agglomeration
Nizhny Novgorod
agglomeration
Chelyabinsk agglomeration
Vladivostok agglomeration
Mining operations
Samara-Togliatti
agglomeration
Удмуртская
республика
Kazan agglomeration
Ekaterinburg agglomeration
Krasnoyarsk
agglomeration
Irkutsk
agglomeration
Khabarovsk
agglomeration
Manufacturing activities
17%
83%
Volga Federal
District (PFD)23%
77%
Mining operations Manufacturing activities
Крупнейшие агломерации России
1. Urals Federal District = 45%
2. Volga Federal District = 17%
3. Central Federal District = 11%
LOCATION OF MINING AREAS & INDUSTRIAL SITES OVER RUSSIA.
Good geographic & economic position ofОАО IzhAvto adds to its competitive advantages.
Located between the major agglomerations of
Central, Volga and Urals Federal Districts, in
close vicinity of metallurgical, oil-refining,
chemistry and machining industrial centers,
Izhevsk automobile plant possesses ample
opportunities in selecting suppliers.
Izhevsk, Udmurt Republic, IzhAvto
3
1. Central Federal District = 31%
2. Volga Federal District =23%
3. North-West Federal District = 12%
Volga Federal
District (PFD)
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LOCATION ADVANTAGES & LOGISTICS
Location area details
Location of major CAR ASSEMBLY PLANTS IN RUSSIA (passenger cars & LCV).
AVTOVAZ
950,000 units per year
Ford Motor Manufacturing Rus
150,000 units per year
IzhAvto (KIA)
220,000(360,000) units per year
Toyota Motor Manufacturing Rus
200,000 units per year
TagAZ (Hyundai)
180,000 units per year
AVTOFRAMOS (Renault)
160,000 units per year
Sollers (Fiat)
75,000 units per year
Sollers (Fiat, SsangYong)
80,000 units per year
GM Manufacturing Rus (Chevrolet, Opel)
90,000 units per year
GM-AVTOVAZ
102,000 units per year
NISSAN Motor Manufacturing Rus
50,000 units per year
AVTOTOR (KIA,Chevrolet, BMW)
170,000 units per year
Sollers (Isuzu)
25,000 units per year
GAZ
65,000+200,000 units per year
IzhevskTaganrog
N. Novgorod
ElabugaUlyanovsk
Togliatti
Kaliningrad
Kaluga Moscow
Nab. Chelny
St. PetersburgVsevolozhsk
Sollers
50,000 units per year
UAZ
110,000 units per year
8%
92%
Available
production capacities
in Russia amount to
2,880,000 units per year
Production capacities of
IzhAvto plant
(220,000 units per year
with potential buildup
to 360,000 units per year)
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Volkswagen Group Rus (VW, Skoda, Audi),
150,000 units per year
4
Vladivostok
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LOCATION ADVANTAGES & LOGISTICS
Location area details
COMPONENTS PRODUCTION SITES IN RUSSIA.
Udmurt Republic: plastic goods, foam polyurethane products, metal roll,
fuels & lubricants, components, materials, automotive wiring harnesses
Bashkortostan republic: materials,
components, fixtures, technical chemistry,
chemicals, automotive glass
Republic of Tatarstan: automobile tires, electric equipment, components, fuels &
lubricants, tools, foam polyurethane products, materials, technical chemistry,
chemicals
Orenburg
region: units
Chelyabinsk region: units,
plastic products, steel sheet, steel band
Sverdlovsk region: rubber technical goods,
tools, paper goods, catalytic converters, pipes
Ryazan region.:
units
Kirov region: paints, chemicals
Perm area: rubber technical goods, units,
fuels & lubricants, tools
Vologda region: steel sheets,
steel band, section steel
Moscow region: electric equipment, units,
components, metal roll, paints, materials, tools
Vladimir region: lightingequipment, components, electric
equipment
Kaluga region: electric
equipment, components
Yaroslavl region: brake systems, plastics,motors, paints and sealants
Tver region:
compressors, electricequipment
Leningrad region: compressors, batteries, wheel tires, plastics,
brake systems, filters, paints and sealants, tools
Samara region: climate control units, electric equipment, units, plastic goods,
components, hot lead-coated sheet steel, materials, tools, wiring harnesses,
plastic goods
Ulyanovsk region: units,
components, materials, electric
equipment
Saratov region: rubber
technical goods
Nizhny Novgorod region: components,
materials, fuels & lubricants, technical
chemistry, automotive glass
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IzhAvto
6
Udmurtia is a republic with a well-developed industry and
diversified agricultural production. Udmurtia boasts the highest
concentration of defense plants in Russia. The republic has
ample oil reserves, though there is no oil refining.
Industry. The basic sectors of industry inUdmurtia include machine building, metal working, ferrous
metallurgy and woodworking industry.
Energy industry is represented by a complex of heat power
plants (in cities Izhevsk, Sarapul, Votkinsk, Glazov) and
Votkinsk hydraulic power station. Metallurgy is concentrated in
Izhevsk, foundry – in Izhevsk and Votkinsk.
There can be singled out the production of bearings, equipment
for oil fields, hunting and sporting guns,
chemical processing equipment, machine tool building.
A significant portion of Udmurtian plants is related to the
military-industrial complex of Russia.
An automotive components sector holds a special place and is
focused on Russian car makers within the Volga Federal
District of RF.
Basic social and economic indices of the Udmurt
Republic:
Economically active population in Udmurtia is 859,500
people
Industrial production in Udmurtia is 225,500 billion rub.Average pay (industry) in Udmurtia is12,400 rub.
Basic social and economic indices of Izhevsk city:
Economically active population of Izhevsk is 395,700
people
Industrial production of Izhevsk is 90,6 billion rub.
Average pay (industry) in Izhevsk is 15,000 rubles
LOCATION ADVANTAGES & LOGISTICS
Location area details
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7
MAJOR REGIONAL INDUSTRIAL PLANTS IN UDMURTIA.
LOCATION ADVANTAGES & LOGISTICS
Location area details
ООО Glazov UPP VOS, Glazov Motor vehicle and motorcycle wiring
harnesses.
OAO CHEPETSKY MECHANICAL PLANT, Glazov Products from zirconium alloy,
calcium metal and its compounds.
ОАО Izhevsk Plastic Plant, Izhevsk Blow molded products, large-size molded
products, foamed polyurethane packings , thermal insulation materials.
NITI PROGRESS, Izhevsk Machinery for electron-beam welding, non-standard
welding facilities, tire industry equipment.
OAO BUMMASH PLANT, Izhevsk Forgings, machined forgings and shafts, dies
and special-purpose tools , pipes.
OOO ERGON, Izhevsk Foamed polyurethane products, sound deadeners.
OAO IZHEVSK TOOL PLANT Cutting and auxiliary tools, gages , fixtures,
casting and forging tooling.
OAO IZHEVSK RADIO PLANT, Izhevsk On-board telemetric and radio
engineering complexes, chip assemblies on ceramics, low noise amplifiers,
sealed lead-ins, etc., safety and automatics systems , navigation equipment
for navigation systems GLONASS/GPS, FM wirelesses, PCBs, nylon
(polyamide) ribbon cables (daisy chain), surface mounting products , tooling:
molds , dies , gages, measuring and cutting tools (design , manufacturing and
delivery), casting and molding, manufacturing of cross-equipment.
OAO AKSION CONCERN, Izhevsk Electric and electronic components – light
equipment control modules, communication hardware, LED- based light
devices.
FGUP IZHEVSK MECHANICAL PLANT, Izhevsk Castings, propeller shafts,
compressors, electric tools.
OOO IZHEVSK UPP SPUTNIK VOS, Izhevsk Cables, links, rods and small-size
stampings.
ZAO LUTCH, Izhevsk Plastics molding.
ОАО Sarapul Electric Generator Plant, Sarapul Electric emplifiers, alternators.
ОАО Sarapul Radio Plant Holding, Sarapul Radio, music complexes, aerials,
speakers.
ОАО ELECOND, Sarapul Blow molded general rubber goods from
thermoplastic rubber-reinforced polymers.
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8
LOCATION ADVANTAGES & LOGISTICS
Location area details
MAJOR REGIONAL INDUSTRIAL PLANTS IN UDMURTIA.
OAO IZHSTEEL, Izhevsk Metal products from structural carbon and
alloyed steel, tool carbon & alloyed steel, high-speed, stainless steel
– rolled & sized section, steel with special surface finishing, various
purpose wires, cold rolled & flat-rolled band, high precision shapedsection, stampings and forgings.
NIIMT – RESEARCH INSTITUTE OF METALLURGICAL TECHNLOGIES,
Izhevsk
Major products:
1. Forgings from tool & high alloyed steels.
2. Thin-walled precision pipes with submicron finished surfaces from
stainless nano-modified nitrogen-containing steels with enhanced
corrosion resistance and strength properties.
3. High-strength hot rolled seamless tubes from various steels and
alloys, including stainless steel of improved properties, titanium and
special alloys.
4. Complicated high-loaded parts from high-strength powderedmetals.
5. Structural stock from nonferrous metals and difficult-to- form
alloys.
6. Ingots of induction, vacuum-induction, electroflux, plasma-arc re-
melting.
7. Volumetric nitriding of ingots during electroflux re-melting.
8. Nitrided ferroalloys with high nitrogen content.
9. Nano-size alloy materials.
10. Shafts of multi-layer materials made of tool & structural steels.
11. Superlight armor.
12. Centrifugal casting process to manufacture sleeves, inserts, liners,
bands, rollers, roller jackets, brake drums, oven rolls, shells, bi-metal
bushes and tubes, couplings from synthetic iron, steel andnonferrous metals.
ZAO Izhevsk EXPERIMENTAL MECHANICAL PLANT, Izhevsk Production
of bars with special surface finishing for front suspension springs.
OOO - MEGALIT, Izhevsk Production of tailor-made pre-machined
casting blanks and parts with minimum allowance vs drawing-set
sizes. Parts machining according to customer’s drawings (sleeves,
liners, wheels, plates, parts and spares for press-forging equipment,
parts and spares for welding equipment).
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LABOR COST (BASED NOMINAL WAGE LEVEL IN RUSSIAN REGIONS)
IzhAvto,Izhevsk, Udmurtia
An average wage level in Udmurtia (industry) is 12,400 rubles, being 2,000 to 20,000 rubles below the wages in some other industrial centers, such
as Moscow region and Moscow, Leningrad region and Saint-Petersburg, Nizhny Novgorod region, Samara region, Republic of Tatarstan.
Eventually, this helps reduce production costs when comparing with other RF regions.
9
below 11,000 rubles
between 11,000 & 13,000 rubles
between 13,001 & 20,000 rubles
over 20,000 rubles
LOCATION ADVANTAGES & LOGISTICS
Location area details
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DISTRIBUTION OF EMPLOYEES IN TERMS OF WAGE SIZE AMONG SOME CONSTITUENT ENTITIES OF THE RUSSIAN FEDERATION
in % to the total number of employees.
As it can be seen from the above labor
market research, in regions with operating
car plants, the Udmurt Republic is the least
expensive in terms of manpower recruiting.
Ulyanovsk region
Samara region
Nizhny Novgorod region
Republic of Tatarstan
Udmurt Republic
Kaliningrad region
Saint-Petersburg
Leningrad region
Moscow
Moscow region
Kaluga region
Russian Federation
below 5000 rubles per month
between 5000 and 10,000 rubles per month
between 10,000 and 15,000 rubles per month
between 15,000 and 20,000 rubles per month
between 20,000 and 30,000 rubles per month
between 30,000 and 50,000 rubles per month
over 50,000 rubles per month 10
LOCATION ADVANTAGES & LOGISTICS
Location area details
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ECONOMIC ACTIVITY OF POPULATION AGED 15 TO 72 YEARS AMONG SOME CONSTITUENT ENTITIES OF THE RUSSIAN FEDERATION.
in thousand people
The Udmurt Republic has considerable human resources, including substantial portion of idle population.
11
LOCATION ADVANTAGES & LOGISTICS
Location area details
employed
peopleunemployed
Russian Federation 74 844,9 67 761,3 7 083,6 66,9 60,5 9,5
Kaluga region 576,8 530,3 46,5 72,6 66,7 8,1
Moscow region 3 672,4 3 502,6 169,8 68,8 65,6 4,6
Moscow city 6 144,1 5 915,5 228,6 72,3 69,6 3,7
Leninigrad region 911,4 829,3 82,1 69,5 63,2 9,0
Saint-Petersburg city 2 734,0 2 630,2 103,8 74,4 71,5 3,8
Kaliningrad region 501,9 445,8 56,1 66,7 59,2 11,2
Udmurt Republic 859,5 771,3 88,1 71,6 64,3 10,3
Republic of Tatarstan 1 962,3 1 763,5 198,8 67,0 60,2 10,1
Nizhny Novgorod region 1 801,0 1 667,7 133,3 68,1 63,1 7,4
Samara region 1 683,0 1 591,0 92,0 66,3 62,6 5,5
Ulianovsk region 683,2 622,3 60,9 65,2 59,4 8,9
Portion of economically
active population,%
Employment
rate,%
Unemployment
rate,%
includingEconomically
active population,
thousand people
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EDUCATION LEVEL.
At present, the state educational institutions of Udmurtia total over 68,000 students at higher educational institutions, 40,000 students in specialized
secondary schools (over 50 engineering professions) and 17,800 students in vocational (trade) schools (150 trade programs).
Over 6500 qualified workers leave annually basic vocational colleges and schools in Izhevsk.Basic schools for automotive industry encompass Izhevsk automechanical college, polytechnic school, vocational schools which train on such trades as car
repair man, electric and gas welder, maintenance man, etc.
Among specialized secondary education institutions, the basic ones for automotive industry include Izhevsk industrial technical college and Izhevsk
polytechnic school which train on “manufacturing engineering“, "specialized machine tools and equipment", "metal cutting/machining" (according to
sector of industry), "technical maintenance & repair of motor transport",
"logistics & transport management (according to mode of transport), etc.
The major institution for automotive industry in the sphere of higher education is Izhevsk State Technical University founded in 1952 on the basis of
Moscow Technical University named after Bauman, evacuated from Moscow during the Great Patriotic War (World War II, 1941-1945).12
LOCATION ADVANTAGES & LOGISTICS
Location area details
Number of
educationalinstitutions,
units
Number of graduates
per annum,
thousand people
Number of
institutions andbranches,
units
Number of graduates
per annum,
thousand people
Number of
institutions andbranches, units
(major\branches)
Number of graduates
per annum,
thousand people
Russian Federation 2 963 493,3 3 287 631,7 1134\1663 1 125,3
Kaluga region 26 2,3 26 4,2 5\22 4,8
Moscow region 105 15,5 130 18,8 33\96 23,0
Moscow city 58 16,3 206 29,8 276\3 168,0
Leninigrad region 27 4,0 32 2,2 3\36 2,0
Saint-Petersburg city 62 14,1 63 19,6 90\11 73,6
Kaliningrad region 15 3,1 16 2,7 8\22 5,5
Udmurt Republic 40 6,5 38 8,9 7\17 13,2
Republic of Tatarstan 80 17,5 85 15,2 33\53 30,4
Nizhny Novgorod region 83 10,2 93 16,0 6\32 33,4
Samara region 54 8,6 80 15,2 29\34 26,6
Ulianovsk region 31 4,2 41 9,3 6\11 9,1
Institutions of intermediate vocational
educationInstitutions of highest vocational educationInstitutions of basic vocational education
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LOCATION ADVANTAGES & LOGISTICSPotentials for transport logistics
TRANSPORT CORRIDORS OF EURASIA
1 000 km
Ирак
-Centers of automobile industry
of Europe & Asia
The vicinity of Eurasian transport corridor, passing
through the territory of Udmurt Republic, provides
certain benefits for transport logistics. This is especially
important for deploying the state strategy to further
develop the transport system of the RF. Elimination ofvarious bottlenecks and enhanced throughput efficiency
of transport network will enable a faster freight
turnover, while infrastructure development will improve
the quality of transport & logistics services in the RF.
The key strategic objectives in Russian transport system
development are:
- 2 to 4-times increase in RF transport systems
performance;
- higher commercial speed of main commodity flows:
1st phase: to reach 800 - 1000 km/day (in developed
countries it is 1400 km/day) by 2020;
2nd phase: to reach 1400 km/day by 2030;
- en-route time (hours per day): at least 20;
- urgent and in-time deliveries to reduce the stock for
guaranteed commercial production:
1st phase: to be 6-8 days by 2020,
2nd phase: to be 3-6 days by 2030 (level of developed
countries);
It will eventually cut the unit transport costs in the price
of finished product:
1st phase: to go down to 15% (the current level inRussia is 35%) by 2020,
2nd phase: to go down to 13% (level of developed
countries) by 2030; power intensity to go down by 20%
vs 2007; yield of capital investments to go up 30% vs
2007.
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LOCATION ADVANTAGES & LOGISTICSPotentials for stocking logistics
STORAGE FACILITIES OF IZHAVTO.
14
Bonded
warehouse
of paints
Petrol storage dormant)
Bonded warehouse for
DKD parts in containers
Bonded warehouse
for parts in
containers and on
pallets
Bonded warehouse for DKD
parts
CKD parts storage
and repacking
warehouse
Storage of general
purpose materials
Base depot
of metals
Solvent storage
Storage of noxious
substances
Storage of
unmarketable
materials
Petrol
storage
Storage of
painted plastic
parts
Storage of KD parts for
assembly
Fixture
storage 1)
Fixture
storage 2)
Storage of
materials for
repair and
maintenance
Storage of KD parts
for welding
Storage of KD parts
for welding
Spares and
accessories
storage
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IZHAVTO INBOUND LOGISTICS PERFORMANCE.
15
Storage facilities.
The storage facilities of Izhevsk car plant include a complex of commodity-oriented stores which meet specific
requirements to keeping and processing different material resources.
Storage facilities are one of the links in IzhAvto logistics chain and cover both indoors and separate outdoors depots.
The total storage area is 64,520 sq.m, including 17,230 sq.m of bonded warehouses. In addition, IzhAvto has available
an extensive system of rooms at -7.2 m level, which total 85,680 sq.m, where only 35,560 sq.m are currently used for
production purposes.
In terms of organization and structure, the storages belong to the production procurement shop, finished product
shipping shop, production and auxiliary shops.Direct and indirect auxiliary materials, components are all delivered to the plant by trucks and railroad.
The plant has a ramified system of railways. The total length of railroad within the plant is12.6 km. The number of
dead sidings is 16, where 8 sidings go inside the buildings and to the open-air storage of finished product shop.
Freight turnover.
The plant‟s design (for the annual output of 220,000 vehicles) allows to take to the plant 63,700 ton of goods by
trucks and 364,200 ton of goods by railroad. It also allows to take from the plant 112,000 ton of goods by truck and
200,000 ton by railroad. In view of available free space, IzhAvto can increase its freight turnover to cover the potential annual output of 360,000 vehicles.
In-plant transport operations and material handling are in charge of storage & retrieval department through the use of
motor vehicles, motor and electric fork lift trucks, transport trolleys and shuttles. The overall length of motor roads
within the plant is 16 km.
LOCATION ADVANTAGES & LOGISTICSPotentials for stocking logistics
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PRODUCTION CAPACITIES AND TECHNOLOGYHistory of production buildup
HISTORY OF LINE-UP DEVELOPMENT
HISTORY OF PRODUCTION BUILDUP
16
1965 – START OF AUTOMOBILE PLANT CONSTRUCTION
1966 – IN DECEMBER, ROLLING OF THE FIRST IZHEVSK PRODUCTION MOSKVICH-408 VEHICLE OFF THE ASSEMBLY LINE
1967 – IN DECEMBER, LAUNCH OF PRODUCTION OF IMPROVED MODEL - MOSKVICH-412
1971 – LAUNCH OF PRODUCTION OF IZH MODELS ON THE BASIS OF MOSKVICH-412 VEHICLE, i.e. IZH-2125 COMBI, IZH-2715WAGON TRUCK, IZH-27151 COMMERCIAL VEHICLE AND IZH-27156 ESTATE CAR
1988 – RECORD PRODUCTION TURNOUT – ALMOST AS MANY AS 190,000 CARS
1991 – LARGE-SCALE PRODUCTION OF IZH-2126 VEHICLE
2000 – IN MARCH, AFFILIATION OF THE PLANT GETTING UNDER SOK GROUP CONTROL. END OF 90-TH YEARS PRODUCTION
FALLING-OFF PERIOD
2000 – GRAND-PRIX OF ZA RULEM MAGAZINE IN CATEGORY „YEAR BREAKTHROUGH‟
2001 – LAUNCH OF VAZ-2106 VEHICLE PRODUCTION
2002 – LAUNCH OF VAZ-2104 VEHICLE PRODUCTION
2003 – FEB 6TH, ROLLING OF 4-MILLIONTH VEHICLE OFF OAO IzhAvto ASSEMBLY LINE
2004 – LARGE-SCALE PRODUCTION OF FABULA VEHICLE
March 2004 – SKD ASSEMBLY OF THE FIRST KIA Spectra CAR LOT, PREPARATIONS FOR THE VEHICLE FULL-SCALE PRODUCTION
2005
Aug. 22 – LAUNCH OF KIA Spectra CAR PRODUCTION AT IZHEVSK AUTOMOBILE PLANT;
Oct. 21 – CELEBRATION OF THE PLANT 40-YEAR ANNIVERSARY
Oct. 28 – START OF KIA Spectra CAR SHIPPING TO DEALERS INTO ALL THE REGIONS
Dec. – LARGE-SCALE PRODUCTION OF THE TRUCK ON THE BASIS OF VAZ-2104 VEHICLE
2006
Apr. 27 – ROLLING OF 10-THOUSANDTH KIA Spectra CAR OFF OAO IzhAvto ASSEMBLY LINE
Dec. 22 – launch of KIA Rio DKD assembly2007 March – launch of KIA Sorento DKD assembly
2008 June – launch of KIA Sorento full-scale production
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PRODUCTION CAPACITIES AND TECHNOLOGY
History of production buildup
HISTORY OF VEHICLE PRODUCTION BUILDUP AT IZHEVSK AUTOMOBILE PLANT.
100
200
1966
year
Vehicle
throughput,
thousand units per year
1970
year
1980
year
1990
year
2000
year
2009
year
max. 188,7 units1988 year
min. 8,0 units1997 year
64,2 units2008 year
10,9 units2009 year
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PRODUCTION CAPACITIES AND TECHNOLOGYProduction line-up specifications
IZH-27175 vehicle GENERAL DATA.
IZH-27175 vehicle specification: IZH-27175 model is a commercial version of IZH-2717 car on the basis ofVAZ-2104 car components.
A new IZH-27175 commercial vehicle is not only as good as its predecessor, but can
also boast a number of more attractive consumer properties.
A large percentage of parts, unified with VAZ vehicle components, has added much to
car technological effectiveness and resulted in a more reliable car, easy to maintain and
cheaper in the field.
IZH-27175 vehicles are built within the main processing chain of OAO IzhAvto,
therefore retrofitted welding facilities are used for their production. IZH-27175 body is
painted together with Kia Spectra and VAZ-2104 cars in the same paint line which
features new modern equipment and ED process. For 27175 body painting mainly
domestic manufacturers‟ paints are used. IZH-27175 vehicle is built in a version with arear liftgate and drop backboard.
Price segment of IZH-27175 vehicle (brand / price in thousand rubles)
200
Basic specification price, thousand rubles
300 400 500 600 700 800
ВИС Lada /240
Citroen Berlingo /274
Lada на базе Renault Logan /310
FIAT Doblo /399
Opel Combo Van /423 Peugeot Partner /426
Renault Kangoo /451
Ford Tourneo /483
Ford Transit /503
Skoda Praktik /539
Volkswagen Caddy /561
100
ИЖ 27175 /195
18
Body type commercial vehicle
Driving model 4х2, rear-wheel drive
Dimensions, mm 4300х1660х1810Wheel base, mm 2 700
Carrying capacity, kg 605
Stowable luggage, cu.m 4
Type of engine VAZ-21067
Fuel system port injection system (Euro 2)
Engine capacity, cu.cm 1 568
Max.power, kW/ rpm (HP) 54.5/5000 (74)
Fuel tank, litre 50
Gearbox manual, 5-speed
Rear suspensionconventional, spring-type with hydraulic shock -absorbers
(commonized with IZH 2717 vehicle)
Front suspensionindependent, wishbone arms, coil springs, telescopichydraulic shock-absorber, anti-roll bar (commonized with
VAZ 2104 vehicle)
Fuel consumption, l/100 km
at 90 km/h / 120 km/h / urban driving6.7 / 8.7 / 11
Max.speed, km/h 120
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PRODUCTION CAPACITIES AND TECHNOLOGYProduction line-up specifications
VAZ-2104 CAR GENERAL DATA
VAZ-2104 car specification: VAZ-21041 estate car is a really convenient and comfortable vehicle. Itanswers both purposes - passenger carriage and various loads transportation, either it is
long-distance or in-city trips. It is also a good choice for carrying goods to smaller sales
outlets or for transporting whatever crop you have grown in your garden.
VAZ-21041 car features a roomy passenger compartment, its tailgate floor split line
makes goods handling much easier. When necessary, the rear seat can be folded. The
car is low-maintenance and reliable in operation.
Price segment of VAZ-2104 vehicle (brand / price in thousand rubles)
19
Basic specification price, thousand rubles
Body type station wagon
Driving model 4х2, rear-wheel drive
Dimensions, mm 4115х1620х1443Wheel base, mm 2 424
Stowable luggage, cu.m 0.63 /1.23
Type of engine VAZ-21067
Fuel system port inject system (Euro 2)
Engine capacity, cu.cm 1 568
Max.power, kW/ rpm (HP) 54.5 / 5000 (74)
Fuel tank, litre 42
Gearbox manual, 5-speed
Rear suspension
conventional, ri gid beam joined to bodyshell via one
Panhard rod and four trailing arms; coil springs;
telescopic shock-absorbers
Front suspension independent; wishbone arms, coil springs, telescopichydraulic shock-absorbers, anti-roll bar
Fuel consumption, l/100 km
at 90 km/ h /120 km/h / urban driving7.3 / 9.6 / 9.8
Max.speed, km/h 143
Accelerati on , 0-100 km/h, sec. 17
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PRODUCTION CAPACITIES AND TECHNOLOGYProduction line-up specifications
KIA Spectra GENERAL DATA
KIA Spectra specification:Spectra car is designed for those who equally values style, comfort, calmness and
safety.
The vehicle is fitted with 1.6 liter gasoline engine, 101.5 hp. The built-in front
suspension compression control valve dampens vibration on rough roads. Thereinforced brake pads help evenly distribute loads, while their larger area enhances the
braking effectiveness. The stabilizer bars add to better road behavior and steerability. A
longer front end and good aerodynamic body shape create the impression of fast but
smooth movement. The passenger compartment of this notchback is convenient both to
its driver and passengers. The heater and air conditioner are operated by handy control
knobs. All seats have proven proportions and convenient side support. The optimum
distance between front and rear seats allows passengers to feel comfortable even during
long-miles trips.
Price segment of KIA Spectra car (brand / price in thousand rubles)
20Basic specification price, thousand rubles
Body type
Driving model
Engine capacity, cu.cmMax.power, hp
Fuel tank, litre
Gearbox manual 5-speed automatic 4-speed
Dimensions, mm
Stowable luggage, litre
Kerbweight, kg 1169-1245 1200-1276
Type of engine
Front / rear suspension
Fuel consumption
at 90 km/h /120 km/h / urban driving5.9 / 7.6 / 10.2 6.2 / 7.9 / 11.2
Max.speed, km/h 180 170
Acceleration, 0-100 km/h, sec. 13 16
440
1.6 l DOHC, petrol, port injection system
independent, s pring-type, MacPherson, anti-roll bar
sedan
4х2, front wheel drive
1 594102
50
4510х1720х1415
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PRODUCTION CAPACITIES AND TECHNOLOGYBasic production
ПРОИЗВОДСТВЕННЫЕ МОЩНОСТИ ИЖЕВСКОГО АВТОМОБИЛЬНОГО ЗАВОДА.
* The available free production area and extended infrastructure allow to increase IzhAvto capacities
(subject to additional investments) to 360,000 units per year at 2-shift operation.
The available area can also be used for setting up the production of power plants (engine and
transmission) up to 300,000 units.23
Type of production Current capacities,thousand units per year
Potential (additional)
capacities*, thousand units peryear
Stapmping 350 +10
Welding 280 +80
Paint 220 +140Plastic paint 50 +310
Assembly 315 +45
TOTAL 350
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PRODUCTION CAPACITIES AND TECHNOLOGYBasic production
LAYOUT OF basement AREA AT (-7.20) m LEVEL.
24
NON-OCCUPIED AREAS NON-OCCUPIED AREAS
NON-OCCUPIED AREAS
NON-OCCUPIED AREAS
NON-OCCUPIED AREAS
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PRODUCTION CAPACITIES AND TECHNOLOGYBasic production
STAMPING SHOP The stamping shop launches the basic production flow. It covers metal cutting, processing and parts
stamping.
Blanking area: production cycle starts with blanking area with facilities for automatic slitting, shaped
blank cutting (KOMATSU, Japan), shearing equipment.
Production area – 35,000 sq.m
Large-size parts stamping:
Area – 42,000 sq.m
Production capacity – 350,000 kits.
List of equipment:
- 5 lines of 400 ton force, including main presses of 800 ton force (year of manufacture - 1971,
Renault, France) – to stamp parts of fuel tank, bulkhead, wing shield, front struts);
- 1 line of extra-large presses of 1200 ton force, including main press of 2000 ton (year ofmanufacture - 1971, Renault, France) – to stamp roof, floor, etc.;
- 24 lines of 250 to 800 ton force to make outside panels and car body stampings, ERFURT, Germany
(year of manufacture 1970 -1996);
- automatic line L8T3200 of 3200 ton force, KOMATSU, Japan, year of manufacture - 1996, to stamp
outside parts (door panels, hood, wings).
Middle-sized and small parts stamping:
Area – 26,756 sq.m.
Production capacity – 350,000 kits.List of equipment:
- power presses of 16 to 400 ton force, made in Russia;
- automated machinery complexes – presses of 40 to 200 ton force with automatic band feeding;
- ERFURT automatic presses of 100 ton force - 4 units;
- automatic gripped-feed lines 150 AD of 100 ton force, made in Russia – 6 units;
- ERFURT fine blanking press of LEINHAAS system, 450 ton force, year of manufacture – 199625
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PRODUCTION CAPACITIES AND TECHNOLOGYBasic production
WELDING SHOP
26
The welding complex and manufacturing process of Izhevsk Automobile Plant ensure the welding
quality and body geometry on a conceptually new level: body is checked by CMM, with over 800
critical points on body & separate units being daily monitored to prove the parameters set by
engineering documentation.
Total production area - 99,500 sq.m.
Total capacity of welding facilities – up to 360,000 units per year.
Welding production of VAZ 2104, IZH 27175 vehicles
Area – 47,600 sq.m
Design capacity of current lines: VAZ 2104 – 70,000 vehicles per year, IZH 27175 – 30,000
vehicles per year
List of equipment:
- VAZ 21043 body welding main buck (manufactured by OOO NITI Progress, Russia);
- IZH 27175 body welding main buck (manufactured by OAO IzhAvto, Russia);
- VAZ 21043 and IZH 27175 floor welding line (manufactured by FIAT, Italy);- VAZ 21043, IZH 271752 finish line, Russia;
- front RH/LH pillar welding line (manufactured by OAO AVTOVAZ, Russia)
- multispot welders (manufactured by OAO AVTOVAZ, Russia)
- welding stations OOO NITI Progress, OAO IzhAvto (manufactured by OAO AVTOVAZ, Russia)
KIA Spectra welding production
Total area of the building with KIA Body Shop is 13,000 sq.m, including:
- occupied area – 7,000 sq.m.
- free area – 6,000 sq.m.
Capacity – 45,000 bodies per year
List of equipment:
- welding station for body sides and body side units with manual respot;
- welding line of wing shield, front end, base plate with manual respot;
- line of body build and welding;
- body welding in a jig system by robots (6 units) with further manual respot;
- finish line.
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PRODUCTION CAPACITIES AND TECHNOLOGYBasic production
27
KIA Sorento Body Shop
Process area: 2,000 sq.m.
Production capacity: 15,000 bodies per year
Body welding process encompasses 8 welding lines:
- front floor welding line;
- central floor welding line;- rear floor welding line;
- complete floor line;
- RH body side welding line;
- LH body side welding line;
- body build line;
- finish line.
Equipment supplier: METIA, Korea
Welding Shop (IZH – Oda family)
Production capacity: 165(180),000 bodies per yearAutomatic welding lines:
- 2 lines – wing shield (wheel apron),
- 2 lines – engine compartment,
- 3 lines – floor,
- 4 lines – body sides,
- 1 line – body,
- 2 lines – doors,
- 1 line – hood,
- 2 lines – body respot welding
List of equipment:
- KUKA welding robots – KRC 50/50 – 157 units,
- BOSCH weld controllers (PSS2081.50) – 186 units,
- DEMAG frequency converters DRU.
Currently, the equipment is removed from operation and is preserved in good condition. Other models can be
welded, following the relevant equipment change-over.
Control system (CS): local CS are made on the basis of SIEMENS controllers. In the buffer storages the
original CS is installed.
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PAINT SHOP.
28
PRODUCTION CAPACITIES AND TECHNOLOGYBasic production
Production area: 55,000 sq.m
Total capacity of body paint complex: 220,000 units per year
Body paint production capacities can be increased up to 360,000 units per year through
available free areas or additional work shifts.
A new paint line can potentially use modern paint materials for body pretreatment and top coating,
allowing both solid and metallic paints. The main supplier of paint materials is Kumgang Korea
Chemical Co. (KCC).
The paint complex includes several process lines:
PT and ED lines (with 2-component primer),
sealing and UBS lines,
adhesive primer line, base and clear coat application lines.
There are 12 robots in paint process to apply secondary primer, first and second layers of top coat
and clear coat.
List of PT & primer lines equipment:
1. PT plant – methods and materials of Henkel company (10 rinse stages: 1 – hot water; 2-3 -
degreasing; 4-5 – water; 6 – activating; 7 – phosphating; 8-10 – water and DI water) – 1 unit.
2. ED plant – two-component ED paint of 4th generation (6 application stages: 1 – ED coating; 2-4
– UF rinsing; 5-6 – DI water rinsing) – 1 unit.3. ED oven tunnel – 1 unit.
4. ED coating repair line, sealing and UBS (underbody sealing) line – 2 units.
5. Sealing oven tunnel – 1 unit.
6. Coagulation system (system of separation paint and return water) – 2 units.
7. Sealing and UBS preparation units – 2 units.
8. DI water plant – 1 set.
9. Coating repair line (for coarse defects) – 1 unit.
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29
PRO UCTION CAPACITI S AN T CHNO OGYBasic production
List of equipment for solid and metallic coating:
1. Primer line – 3 robots (Bell system - electrostatics).
2. Mini-paint mix plant for color primers (4 systems) – 1 set.
3. Secondary primer dry-off tunnel – 1 unit
4. Line for primer defect rectification – 2 units
5. Spray line for two-coat base (acrylic paints) –
3 robots for 1st base coat (Bell system - electrostatics),
3 robots for 2nd base coat (system of air atomizers),3 robots for clear coat (Bell spray – electrostatics)
(4 systems + 3 mini systems).
6. Base dry-off tunnel – 2 units
7. Line for minor defect rectification and paint quality inspection – 2 units.
8. Paint mix room (new) – 1 set.
9. Technological air conditioners (modernized) – 6 units
Control System (CS):
- centralized industrial control system, including process monitoring, production planning, body flow tracking, material usage. There is a
control room (paint shop synoptics);
- central and local control systems are based on SIEMENS controllers;
- control system allows to concurrently paint bodies in 7 colors;
- DURR robots in primer and base coat booths.
The remarkable fact is that equipment and technology, supplied by DURR (Korea) and refined by IzhAvto and IzhEnergoservis, render
possible to run PT and paint processes in one chain, including KIA Sorento frame and IZH-27175 canopy, in any sequence, using
simultaneously 7 different colors.
Application of state-of-the-art paint technologies helped extend the perforation corrosion warranty for domestic models from 3 to 6 years.
Plastic Parts Paint Shop
Production area: 3800 sq.m.
Total capacity of plastic parts paint complex: 50,000 kits per year.
Manufacturing process includes flaming activation of part surface by the in-line robot to enhance material adhesion properties and is done
on a floor-type monorail conveyor.
List of equipment:
plastic part pretreatment line, transport system, flaming station, base and clear coats spray line
Equipment supplier: DURR (France, Korea).
The safety aspect of the paint shop can be proved by the fact that in 2008 Izhevsk Automobile Plant was ranked 23rd among “green”
Russian Federation factories of the Russian Greenpeace branch. Among Udmurt Republic “green” factories IzhAvto took the 1st rating
position.
Equipment supplier: DURR (France, Korea). The equipment installed provides a complete close-loop cycle. The production totally
eliminated any harmful releases into atmosphere and discharges to sewage collection system.
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ASSEMBLY SHOP.
30
Basic production
Total capacity of Assembly Shop: 315,000 units per year. There is a potential to build the
capacity up to 360,000 vehicles per year through available free areas and equipment.
IzhAvto has universal assembly equipment for making passenger cars of practically any class
and complexity.
KIA Spectra Assembly Shop
Area – 13,600 sq.m
Capacity – 80,000 units per year
List of equipment:
- trim line (floor-type single-track slat conveyor), 2005, DONGНЕЕ ROFA CO. LTD, Korea;
- chassis line (power and free conveyor), 2005, DONGНЕЕ ROFA CO. LTD, Korea;
- final line (floor-type double slat conveyor), 2005, DONGНЕЕ ROFA CO. LTD, Korea;
- test line, 2005, HANKOOK ВЕР. СО, Korea
VAZ, IZH car Assembly Shop
Area – 33,000 sq.m
Design capacity – 220,000 units per year
List of equipment:
- trim line,1970, RENAULT, France, BOSH, Germany, OAO IzhAvto, Russia, HOFMANN,
Germany:
- interior trim line (2 parallel lines of P&F conveyor);
- assembly line (2 parallel lines of P&F conveyor converging to floor-type slat conveyors);- road test line (tests, finishing).
- circular floor-type conveyor to mount power plant and suspension, 1970, SIETAM, France;
- power plant subassembly slat conveyor 4P-17A, 1970, Russia,
- rear axle subassembly slat conveyor 4P-18A, 1970, Russia
- wheel assembly line, 1970, HOFMANN, Germany (share participation of OAO IzhAvto,
Russia)
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31
Basic production
KIA Sorento Assembly Shop
Production areas: 3500 sq.m
Production capacity: 15,000 units per year
Body assembly manufacturing process involves 4 lines:
- trim line;- slat line;
- frame assembly line;
- test line.
Equipment supplier: DONGHEE, Korea
VAZ-2104 and KIA Spectra assembly conveyors are housed in the same building and
run parallel. KIA Sorento vehicles are assembled on a separate line, while IZH-27175
and VAZ-2104 vehicles are assembled on the same line.
Assembly process covers trim line, chassis line and final line, including areas for engine,
suspension, instrument panel and other units sub-assembly
After additional quality inspection by quality control specialists, vehicles go to test line
for front and rear wheel alignment, roller dynamic test,
electric system test, KIA airbags activation,
interior leak test in shower booth and others.
Before going to finished product warehouse, final inspection of some spec parameters is
done, including paint quality and anticorrosion treatment of body & motor bay recess
areas.
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Parts production
PARTS PRODUCTION.
32
Wheels production.
Area – 1,368 sq.m
Capacity – 900,000 units per year
List of equipment:
- ERFURT automatic press of 3350 ton-force for wheel disk production, year of manufacture - 1996;
- KizErling tire rim forming line, year of manufacture – 1972;
- Sciaki wheel spot welding line, year of manufacture – 1972.
Fuel tank production
Area – 864 sq.m
Capacity – 220,000 kits
List of equipment:
- Projection, spot welding machines of MP 4020, МТ-1610 type and portable guns of MTP – 1111 type,
made in Russia;
- Seam welder for fuel tank semi-housings of MSH-3207 type – 2 pcs. , made in Russia, year of
manufacture - 1989;
- Seam welder for fuel tank semi-housings, ARO 72500, made in France, year of manufacture –
2007;
- Gas and arc welding stations of PDG – 312 type, made in Russia;
- Fuel tank leak tester (in water bath, at compressed air pressure for prohibiting tank swelling).
KIA Spectra fuel tanks production is arranged under the localization program: production sites are
prepared, equipment and tooling are purchased. Design capacity of the production is 45,000 units per
year.
Exhaust system productionArea – 2,160 sq.m
Capacity – 220,000 units
List of equipment:
- IUNG pipe-cutting machine;
- DESKAM pipe-bending NC machine,CHR-2A;
- EAGLE pipe end flaring and notching machines - 8 units;
- DESKAM silencer assembly and inner units expansion machine, MC-0822 - 1 unit;
- DESKAM MCL 96 automatic line for silencer production.
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Parts production
33
KD parts production
KIA Spectra exhaust system production was set up within the localization framework:
production sites are duly arranged, equipment and tooling are purchased. Design capacity of the production is
45,000 kits per year.
Rear axle production
Area – 11,232 m²Capacity – 220,000 kits per year, 2-shift operation
List of equipment:
- KROSS (UK) automatic line for differential machining – 1 unit;
- KROSS (UK) automatic line for axle housing machining – 1 unit;
- TAEDA SOMQ (Japan) automatic line for differential case polishing – 1 unit;
- MAUSER (Germany) automatic line for gear unit machining – 1 unit;
- KROSS (UK) automatic line for gear unit assembly – 1 unit.
- Gleason gear broaching semi-automatic machine, USA – 4 units;
- Gleason high-speed machine, USA – 6 units;
- Gleason gear lapping semi-automatic machine, USA – 5 units;- Gleason gear generator, USA – 9 units;
- Gleason sharpener, USA – 2 units;
Seats production
Site area – 9,720 sq.m
Design capacity – 220,000 kits per year at 2-shift operation.
Current capacities: VAZ 21043 vehicle - 40,000 units per year, one-shift operation; 13,000 units per year of
KD kits, one-shift operation; IZH 2717 vehicle – 15,000 units per year, one-shift operation; KIA Spectra
vehicle – 45,000 units per year, two-shift operation
Total manpower – 130 people
Includes seat frame welding areas, seat cover fabrication and final assembly.
Plastic parts production
Plastic parts production is one of the youngest divisions in the plant.
Production area: 14,300 sq.m
Production is equipped with 29 modern automatic molding machine (DEMAG, Germany,1997), and relevant
auxiliary equipment for wide range of interior and exterior plastic parts.
The following materials are used: polypropylene, polyethylene, polystyrene, ABS, ABS - PC, PVC, formaldehyde
polymers, polyamide, polycarbonate, thermoplastic elastomer.
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Parts production
Technical data of plastic parts production equipment:
Automatic molding machines (Germany).
All automatic molding machines are equipped with compact automatic feeders as well as thermostats for mold temperature control.
Extrusion blow molding equipment (Krupp-Kauteks).
Equipment (Galino) for manufacturing foam parts.
34
Type Number, units Closing force, kN Shot volume, cu.mErgoTECH 110-310H/80V 1 1100 168/42
ErgoTECH 420/1450 3 4200 763
ErgoTECH 500/2300 3 5000 1212ErgoTECH 500/3300 4 5000 1779
ErgoTECH 650/3300 5 6500 1779
ErgoTECH 800/5200 1 8000 2835
ErgoTECH 1000/5200 4 10000 2835
ErgoTECH 1000/8000 3 10000 4375
ErgoTECH 1300/12000 2 13000 6730
ErgoTECH 2200/12900 1 21150 6500
ErgoTECH 2700/12900 2 27000 Izhevsk Plastic Plant
Type Number Application
КЕБ 10.01.-60.01 2 To make air ducts and seervice fluid tanks Izhevsk Plastic Plant
Type Number Application
6818012; 682338 2 To make headrest & seat cushion fillers Izhevsk Plastic Plant
532503 1 To make instrument panels and sunvisors ООО ERGON, Izhevsk
Type Max.sheet size, mm Max.molding area, mm
Max.molding height,
mm Sheet thickness, mm
KF-4/160x45 1600 x 800 1 520 x 720 450 positive 40331
VFP-2000-II 2000 x 1000 1900 x 900 450 positive /500 negative 40453
Max.width, mm Min.width, mm Sheet thickness, mm Max.output, kg/h
1300 900 0,4 – 4,0 400
PRODUCTION CAPACITIES AND TECHNOLOGYP t d ti
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Parts production
35
Frame welding
Project designer and equipment supplier: Jaeil Laboratories, Inc. (Korea)
Design capacity: 10,000 units per year
Number of shifts: 2
Manpower: 17 persons, where 15 are direct workers
STATION STATION #157 STATION #156 STATION #155 STATION #154 STATION #153 STATION #152 STATION # 151JOB INSPECTION & REPAIR RESPOT JIG PRE-BUCK JIG PRE-BUCK JIG RESPOT JIG PRE-BUCK JIG PRE-BUCK JIG
OPERATOR 1 2 (2) 2 (2) 2 2
PARTS 20 22 20 12
INSPECTION & REPAIR
FACILITIES 1J IG & ACCESSORIES 1 J IG & ACCESSORIES 1 J IG & ACCESSORIES 1 J IG & ACCESSORIES 1 J IG & ACCESSORIES 1 J IG & ACCESSORIES 1
CO2 WELDER (REPAIR)
2CO2 WELDER 2 CO2 WELDER 2 CO2 WELDER 2 CO2 WELDER 4 CO2 WELDER 2 CO2 WELDER 2
HOIST 1 HOIST 1 HOIST 1 HOIST 1 HOIST 1 HOIST 1 HOIST 3
#156 ASSEMBLY #155 ASSEMBLY #154 ASSEMBLY #153 ASSEMBLY #152 ASSEMBLY #151 ASSEMBLYSIDE MEMBER ASSY
LH/RH
BRACKET-BODY
SUPPORT
BRACKET ASSY,
DIFFERENTIAL MOUNT,
LH/RH
PILLAR ASSY, FR, LH/RHCROSS-MEMBER ASSY.-
FR SUSPENSION
PILLAR ASSY, RR, LH/RH BRACKET, RR SHOCK-ABSORBER, LH/RH
BRACKET ASSY, FR,TOP ARM #1, LH/RH
CROSS-MEMBER ASSY-GEARBOX
RADIATOR BRACKET
ASSY, TOP, LH/RH
BRACKET ASSY, FR
BUFFER, LH/RH
BRACKET ASSY, FR,
TOP ARM #2, LH/RH
CROSS-MEMBER ASSY-
FUEL TANK
RADIATOR BRACKET,
BOTTOM, LH/RHHOOK ASSY, FR.
BRACKET ASSY, FUEL
TANK, #1
CROSS-MEMBER ASSY--
SPARE WHEEL
BRACKET ASSY, ENGINE
MOUNT, LH/RH, etc .
SPARE WHEEL
BRACKET, etc.
SILENCER SUSPENSION
RING #3, etc..
CROSS-MEMBER ASSY-
RR SUSPENSION, etc.
WELD SEAM LENGTH 8822 mm 7506 mm 451 mm 4805 mm 1679 mm 3530 mm
PARTS LOADING
MACHINES &
EQUIPMENT
PRODUCTION CAPACITIES AND TECHNOLOGYEngineeringinfrastructure
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Engineering infrastructure
POWER FACILITIES.
№
Энергоресурс
Потребление в 2008 году
Цены энергоресурса
в 2009 году, без НДС
1 Электроэнергия 102139,164 тыс. кВт*ч 1334,80 руб/тыс. кВт*ч
2 Газ природный 85768,80 тыс. м3 2097,26, руб/тыс. м3
3 Вода
1957515 м3 9,72 руб/ м3
4 Кислород 72359 м3 28,34 р/м3
5 Ацетилен 2461,5 кг 144,0 руб/кг
6 Углекислота 86798 кг 7,00 руб/кг
36
Maximum throughput efficiency of IzhAvto engineering/utility systems.
Energy production of IzhAvto can provide utilities enough for annual output of 360,000 vehicles.
Carbonic acid
Power resourceConsumption in 2008
The prices энегоресурса in 2009,
without the VAT
The electric
power
Natural gas
Water
Oxygen
Acetylene
Thousand in kw hour
Thousand in cubic m.
cubic m.
cubic m.
kg.
kg.
Rbl. /Thousand in kw hour
Rbl. /Thousand in cubic m.
Rbl. /cubic m.
Rbl. /cubic m.
Rbl. /kg.
Rbl. /kg.
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Engineering infrastructure
37
Heat power plant.
The heat power plant is intended to satisfy IzhAvto needs in steam and heat, as well
as to supply heat to nearby industrial and residential customers. The heat power plant
runs gas-fired boilers, with black oil (mazut) as a backup fuel.
The total installed capacity is 620 Gcal/hour. A project is currently underway to
retrofit the heat power plant for generating its own electric energy as much as 42.0
million kWh per year.
Compressor plant.
The compressor plant and five turbine compressors К250-61-5 (each 250 cu.m/min,
1,600 kW capacity) provide the car production with compressed air of high and low
pressure.
For the purpose of power saving, IzhAvto opted for installing local compressorsinstead of centralized compressed air supply. Today there are 27 operating
compressors which fully cover the demand of shopfloors, involved in production of
modern vehicles.
Electric power supply.
IzhAvto is powered via 10 kW buses of Avtozavod substation of 110/10 kW. The
plant installed power is187.6 МVAElectrical power is distributed throughout the plant by 9 distribution centers which
power 91 step-down transforming substations of 10/0.4 kW.
OAO IzhAvto is the only industrial enterprise in Udmurtia to buy electric energy and
power at wholesale market from 2003. Accordingly, IzhAvto features the cheapest
electric energy among machine building plants of the Udmurt Republic.
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Engineering infrastructure
39
Water supply:
Drinking water supply system includes:
- 2-stage (relift) pumping plant with two clean water reservoirs, each 6,000 cu.m,
- clean water reservoir in the engineering building.
The total water supply network is 13,242 m long.Re-circulating water supply is supported by three stations of the following flow
rates:
1st – 2,000 m/hour, 2nd – 2,000 m/hour, 3rd – 1,440 m/hour.
Waste water discharge:
The sewage system consists of:
1) household waste (fecal) ductwork,
2) industrial storm water drainage,3) industrial sewage facilities.
Waste water treatment plants:
The factory waste treatment plants (effluents neutralization station) are housed in
a detached building #49. The design throughput is 800 cu.m per hour.
The paint shop features on-site local treatment facilities. Coolants are cleaned in
a centralized station in building #3.
In 2005-2006 all technological processes were improved to minimize theirenvironmental hazard.
OAO IzhAvto was ranked 4th among the industrial plants of Russia &
Kazakhstan and 1st among the Udmurtian plants in the 2008 estimate carried out
by an independent agency NERA.
PRODUCTION CAPACITIES AND TECHNOLOGYEngineering infrastructure
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g g
40
OAO IzhAvto achievements in the area of energy and environmental safety.
PRODUCTION CAPACITIES AND TECHNOLOGYEngineering infrastructure
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41
Location of IzhAvto transformer substation
Transformer substation
Distributive point 10 of kw
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42
IzhAvto heat supply network
In 2007 IzhAvto sold heating power to different Izhevsk factories to the total amount of 88,560,000 rubles.
1st industrial line – 1,473 m;
2nd industrial line – 1,690 m;
3rd industrial line (ul.Voroshilova) – 4,820 m;
4th industrial line – 743 m;
5th city line (Starki settlement)) – 7,420 m.
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43
IzhAvto water supply network
Economic-drinking and fire-prevention waterpipe
The direct pipe duct of turnaround water supply
The return pipe duct of turnaround water supply
PRODUCTION CAPACITIES AND TECHNOLOGYEngineering infrastructure
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44
IzhAvto compressed air network
High pressure air
Low pressure air
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45
IzhAvto process gas network
Carbonic gas
Acetylene
Oxygen
Natural gas
PRODUCTION CAPACITIES AND TECHNOLOGYInformation Technologies (IT)
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There are about
3,000 ports for
terminal network
equipment.
The status of IzhAvto corporate computer network (hardware) is as follows:
data transfer – Ethernet 10/100 Mbit/sec.
network core: topology – „loop‟; data transfer medium – optics, single mode 24-fibre
cable; equipment - 3 (three) Gb exchange switches.
IzhAvto corporate network capacities
20 серверов1,600 PCs 700 printers
Сentralized antivirus program
Software for data
backup
Information Technologies (IT).
46
PRODUCTION CAPACITIES AND TECHNOLOGY
Information Technologies (IT)
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MES | CCR Axapta
Cognos
PROCESSES:
Production, Logistics
47
IT system general design concept.
“Production” chain, data flow in information system (IS):
BOSS-Referent “Production” chain is basic,
Cognos software is used for budgeting,
BOSS-Referent is used for office administration and document control.
All systems are capable of report generation.
1С platform
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Information Technologies (IT)
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IT system general design concept.
48
MES/CCR functional
Basic MES functions (MES=Manufacturing Executive System):
– vehicle monthly production schedule processing;
– generation of day‟s production orders with specs & colors breakdown;
– real-time changes in body specs;
– body registration at check points throughout the production cycle, i.e. from welding area to finished product warehouse;
– generation of production orders and components supply orders according to SILS (supply in line sequence);
– defect detection, record and tracking;
– generation of various reports, including hourly status by shopfloors /sections /brands /specs and monthly summaries on
production plan fulfillment;
– data exchange with Axapta system
Basic CCR functions (CCR=Consolidated Control Room): – control of conveyors operating conditions;
– display of conveyor equipment operating status;
– display of target and actual production data on shopfloor display boards.
Key objectives of 1C system:
- product specification control, accounting for options and replacements in parts list;
- record of empties and in-process package flow;
- metal working;
- stock taking functionality development (add-in controllers as to stock category, property status); – inventory scheduling and work-in-process inventory;
– inbound logistics (stock monitoring);
– components & materials sales;
– analytical production & logistics WEB-reporting;
– active WEB-reporting;
– generation of company operations factors for 1000 users (max.300 users simultaneously)
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Information Technologies (IT)
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IS briefly
Central base
Capital assets records on capital assets availability, flow and leasing, precious metals in capital assets,
depreciation calculation, tax accounting.
Transport means
monitoring
inspection of consignment notes at the plant exits
(double entry and data comparison by security staff)
Total user number: over 200
Basic functional
materials, finished products, non-material assets,
cash desk, bank, securities (shares, notes, BC),
loans, settlements with accountable persons, capital assets, etc.
Platform / ClientCognos Budgeting system.
Lotus Notes e-mail;
BOSS-Referent – automated system of document flow and records;
Web-technologies system of performance indicators;
proposals on improvements;
Internet portals/
OLAP reports related to human resources; reports related to production planning.
Other futomated system of spare parts management;
maintenance of regulatory & reference documentation pertinent to technical production setup;
tools for defining, analyzing and evaluating organization processes, etc.
Total number of registered users: over 500. 49
IT system general design concept.
PRODUCTION CAPACITIES AND TECHNOLOGYTechnological support and developments
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DESIGN & ENGINEERING.
Vehicle manufacturing supervision; improvements in current processes for better product quality and lower production
costs; investigation of rejects/defects causes; claim settlement; action plan for product quality upgrade; research and
experimental activity to deploy advanced car build processes.
Vehicle
engineering
department
Production
engineering
department
Localization
department
Components analyses to identify parts for localization; search, deployment of system to select and audit potential
local suppliers of parts, monitoring of component production setup activities; supervision of localization process
until the part is validated by the plant.
Incoming inspection at laboratories, including metal products, polymer products, general rubber goods, adhesives,
sealants, artificial films and leathers, oils, antifreezes, brake fluids, coolants, detergents; arrangement of arbitrary
routine lab inspection of materials and parts; instrumentation inspection (calibration) and repair; metrological control
& supervision of control, test & measuring equipment status and application observance of metrology regulation and
rules in relevant departments.
Laboratories
Center
Work study of perspective development & localization projects; investment scheduling; manufacturing documentation
development; planning & coordination between concerned departments and affiliates at all pre-production phases;
generation of pre-production specification and consolidated production specification; production area layout planning
and shopfloor optimal use; management of changes in regulatory and manufacturing documentation.
Multichannel atomic emission
spectrograph
Two-axis measuring
device
Design and engineering support
facilities and systems 50
ПРОИЗВОДСТВЕННЫЕ МОЩНОСТИ И ТЕХНОЛОГИИ
Technological support and developments
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CHIEF
DESIGNER
DEPARTMENT
51
1. Release of technical requirements, technical assignments (RfQ), schedules of activities for vehicle/vehicle units projects;
2. Release of sketches for vehicle mockup manufacturing, orders for prototype manufacturing, technical assignments for testing; monitoring of the
above;
3. Release of basic vehicle bill of material (BOM) and specifications, assembly kit parts list;
4. Release of instruction manuals for vehicles being designed or produced (User‟s manual, Vehicle Log (Service) Book), in conformity with all relevant
certification requirements;
5. Certification activities with respect to vehicles, their units and parts, release of documents required for obtaining motor vehicle type approval;“Reports for official motor vehicle design type approval “ under EC Directives and UN ECE Rules, “Certificate of compliance” for certain features and
“Type Approval for OAO IzhAvto-made motor vehicles”;
6. Carry out certification activities (to obtain Motor Vehicle General Type Approval and relevant certificates), regular checking, acceptance, endurance
tests (including on-road & bench tests) of vehicles, vehicle parts & units, localization parts & units at outside companies, authorized laboratories and
using factory-owned test equipment.
7. Carry out fitting tests for localization parts and units.
8. Carry out attestation (calibration) of test facilities owned by the Design Department.
9. Monitoring of deadlines under the contracts, release of acceptance certificates and other documents necessary to effect payments for jobs done.
10. Design Department budget planning and monitoring.
11. Parts/units production supervision from design aspect, follow-up of localization parts/units made under the license, product improvements to better
meet market demands, versions optimization, compliance of vehicle design to technical requirements and certification system:
- development of design documentation using dedicated design software;- activities on improving parts & units quality: field supervision;
- technical audit at suppliers of localization parts;
- defect analyses, action plan for defect elimination;
- experimental development;
- production vehicle audit together with quality control department.
12. Obtaining, record and custody of patents.
13. Continuous operation of dedicated design and manufacturing engineering systems (CATIA, SolidWorks, Unigraphics, AutoCAD, Compas, Isem
Surf, Rhinoserous, ADEM, etc.), used by engineering staff within the framework of common information area and corporate computer network,
including electronic document flow of design and engineering documentation.
14. Deployment and supervision of latest special-purpose design & manufacturing engineering systems.
Thermal pressure
chamber
Hydraulic
pulsator
Ergonomics
Prototyping
3D scanning and modeling
Engineering
DEALERS NETWORKDealers network performance
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DEALERS NETWORK OF IZH-VAZ VEHICLES.
11
9
27
25
11
15
7
6
15
15
6
10 52
98 outlets in 59 cities
Northwestern Federal District
Southern Federal District
Central Federal District
Volga Federal District
Ural Federal District
Siberian Federal District
Number of
outlets
Number of
cities
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DEALERS NETWORK OF KIA VEHICLES.
21
19
44
40
19
12
8
11
16
21
9
11 53
155 outlets in 76 cities
Northwestern Federal District
Southern Federal District
Central Federal District
Volga Federal District
Ural Federal District
Siberian Federal District
Number of
outlets
Number of
cities
QUALITY SYSTEMQuality system performance
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COMPLIANCE OF QUALITY MANAGEMENT SYSTEM (QMS) WITH INTERNATIONAL STANDARDS.
54
OAO IzhAvto management system was certified from 2003 until 2009 for compliance with GOST R ISO 9001-2001 by certification
body SATR-FOND. In December 2009 the factory was re-certified as to QMS compliance with GOST R ISO 9001-2008 (ISO
9001:2008).
In October 2006 the complete manufacturing chain of Kia Spectra production at IzhAvto was certified for compliance with ISO9001:2000 by transnational certification body Det Norske Veritas (DTV), Norway. Over 2007- 2009 DNV annually carried out regular
audits to confirm the QMS integrity and compliance with the standard. In total there were identified 20 instances of "good practice" (i.e.
complex measures approved at the international level).
QUALITY SYSTEMQuality system performance
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QUALITY MANAGEMENT SYSTEM.
System control
Documentation control
Internal auditing
Analyses from the management side
Preventive and corrective actions
Control and improvement processes
Basic production processes
D e s i g n i n g a n d
d e v e l o p m e n t
Pre-production activities
P r o d u c t i o n
s c h e d u l i n g
P u r c h a s i n g
R e c e i v i n g
i n s p e c t i o n
V e h i c l e
p r o d u c t i o n
p r o c e s s
F i n i s h e d
v e h i c l e s
( c u s t o m e r ‟ s )
a u d i t
P r o d u c t s h i p m e n t
S e r v i c e
M e e t i n g
c u s t o m e r s ‟
d e m a n d s
Product quality control
Inadequate products management
Parts & material handling
Equipment maintenance and repair
Control over facilities for monitoring & measuring
Staff management
Supportive processes
- system, where quality aspect is an integral part of manufacturing process, where defects are prohibited, timely recognized and actions
are taken against their recurrence.
OBJECTIVE: fully meet customer‟s requirements.
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QUALITY SYSTEMQuality system performance
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PRODUCTION SYSTEM OF BUILT-IN QUALITY.
Definition: methods for building the
quality into the production process in a
way to prohibit defects or earlier identifythem with simultaneous actions against
potential defect recurrence
Objective: fully exclude the risk of defect
at the customer‟s.
Elements of built-in quality:
· quality standards;
· process flow charts;· job element sheets;
· feedback over the process chain.
Identification and arrest of defective products at storages, 100% operator inspection before part fitting, in finished vehicles,
random checks of most frequent problems.
Dedicated “defect tours”.
Operator’s self -control under built-in quality concept.
Process unification.
Continuous improvement.
100% product final inspection at weld shop, paint shop and assembly shop finish lines.
Body-in-white (BIW) and painted body audit.Audit of critical jobs.
Weekly quality-related meetings at the top management level.
System of earlier defect detection (EDD).
Warranty data analyses.
Weekly quality meetings.
RECEIVING
INSPECTION
QUALITY
ASSURANCE IN
PRODUCTION
FIELD WARRANTY
QUALITY
CONTROL56
QUALITY SYSTEMQuality system performance benchmarks
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QUALITY SYSTEM BENCHMARKS.
The application of visual and automatic control systems of defect prevention (Andon, Poka-yoke) significantly improved the product quality
score.
Four benchmarks are used by IzhAvto for product quality
assessment:
16
12,6
2005
год
2006
год
2007
год
2008
год
2009
год
14,014,8
93,1 32,625
20
15
10
5
0
Customer audit KIA Spectra
57
Direct yield – percentage of products accepted by inspector
from the 1st or 2nd time, after minor rectification at the
relevant conveyor line.
First pass yield – percentage of products passed the
inspection post with no remarks.
Defect rate – number of defects per vehicle.
Customer audit – number of defects per finished vehicle.
body
paintwork
plastic
trim
chassis
electric system
water leak
driving
KD
target
QUALITY WELDING KIA Spectra. QUALITY PAINT KIA Spectra. QUALITY ASSEMBLY KIA Spectra.
2005 year
2006 year
2007 year
2008 year
2005 year
2006 year
2007 year
2008 year
2005 year
2006 year
2007 year
2008 year
2005
year2006
year
2007
year
2008
year
2009
year
HUMAN RESOURCES
Staff recruitment and adaptation
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HR MANAGEMENT SYSTEM.
BASIC FUNCTIONS:
1. Search and recruitment of staff
2. Staff appraisal
3. Formation of plant skill pool.
4. Disciplinary matter management:
- investigation of production labor discipline violations,
- action plan to remedy causes of labor discipline offence,
- dismissal at initiative of administration.
5. Record maintenance of employment relationship.6. Formalization of pensions and conversion of employees’ pension rights.
7. IT supervision of HR data and personified records.
PERSONNEL DIVISION
HR DEPARTMENT
1. Identification of training needs, organization of employees training.
2. Development and deployment of actions to adapt new comers.
3. Formulation and deployment of social development plans:
- organization of professional holidays (Days in honor of certain trades), meetings of the plant core team and other corporate events;
- organization of sports events and large-scale activities at the plant;
- system of awards and incentives;
- support to the Veteran Council activities.
4. Operation of factory medical aid station, hostel, library, museum, gym, factory luggage room.
5. Operation of IzhAvto radio centre.6. Cooperation with social insurance fund and medical institutions as to medical care, health improvement and recreation of employees.
1. Development and deployment of progressive systems of employees’ labor management, work measurement, remuneration and motivation.
2. Streamlining of labor processes to improve labor efficiency and workmanship.
3. Labor performance planning and monitoring.
4. Supervision on observance of effective regulatory legal acts on labor organization, rating and remuneration.
5. Work & rest schedule monitoring, planning measures for better labor time utilization.
LABOR ORGANIZATION AND PAYROLL DEPARTMENT
LABOR ORGANIZATION AND PAYROLL DEPARTMENT OBJECTIVES:
1. Employment of competent and qualified staff.
2. Personnel development through continuous and regular training.
3. Organization and rating of labor processes, development and adjustment of labor remuneration system, use of efficient incentives and motivation to improve labor productivity, workmanship and discipline.
4. Personnel social development: - setting-up of favorable social & psychological environment for the factory team, adequate conditions for healthy lifestyle, social guarantees, more thorough & sound use of leisure
time by employees.
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HUMAN RESOURCESFlexible system of staff recruitment
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SOURCES OF STAFF RECRUITING FOR AVAILABLE VACANCIES.
About 3,000 people
were laid off on
mutual agreement
of the parties within2008-2009.
About 5,000 people
were laid off on
voluntary discharge
(unsolicited
dismissal) within2004-2009.
DATA BASE OF FORMER
IZHAVTO EMPLOYEES
Vocational school
graduates – 6,500
students per year
Vocational technical
colleges – 8,900
students per year
Vocational Higher
educational
institutions – 13,200student per year
GRADUATES OF
VOCATIONAL SCHOOLS,
TECHNICAL COLLEGES,HIGHER EDUCATIONAL
INSTITUTIONS
EMPLOYEES OF OTHER
ORGANIZATIONS UNEMPLOYEED
Employed
population of
Udmurtia – 771,300
people
Unemployed
population of
Udmurtia – 88,100
people
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