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How To Assemble Mercedes In Russia - Report From The Factory

2024

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Video: How To Assemble Mercedes In Russia - Report From The Factory

Video: How To Assemble Mercedes In Russia - Report From The Factory
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How To Assemble Mercedes In Russia - Report From The Factory
How To Assemble Mercedes In Russia - Report From The Factory
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- Guys, how much do you earn?

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“We can't talk about this …”

- And what operations are you doing at this post?

- Assembling the engine. More precisely, we mount attachments. Yes, pour oil too. Where? Well, in the motor, in the gearbox … Ah, no, there is no front gear here, you are right … This is a rear-wheel drive E class …

- Quiet you, do not give out all the secrets!

I smiled at a young picker who hissed at her colleague. Start of production, visit of the president, journalists … Stress. Like the night before the exam.

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First person

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Putin opened the Russian Mercedes-Benz plant

Vladimir Putin flew to Esipovo by helicopter. Aavus cavalcade was already waiting on an improvised airfield. Reseeding in the long-armored Senate, the president drove right into the giant assembly line workshop, as if hinting: even in Russia they love Mercedes, but their shirt is closer to the body.

Having walked along the conveyor, Putin did not regret kind words to the Daimler company, which was represented by the head of Dieter Zetsche. Keynote: Russia is pleased with serious investors, new jobs and competencies.

There are similar plants in many countries: Mercedes is assembled in South Africa, Mexico, Malaysia, Thailand, Vietnam … And the Germans did not bring any special know-how. But for us, the project is extremely important: this is a great opportunity to demonstrate that Russia is still attractive to large investors - even being sanctioned on all sides.

Ordnung über alles

Having conceived his own production in Russia, Daimler acted very Russian. In the sense that I harnessed for a long time. The sites were considered different - in Kazan, Vladimir, Kaluga, St. Petersburg. There was even the option of locating the enterprise on the territory of the former ZIL - but the capital unexpectedly turned in the direction of development projects, which for the city is more environmentally friendly and more profitable.

Considerable investments (about 19 billion rubles, or over 250 million euros) had to be linked with an understanding of what the business conditions would be like at the time the plant was opened. As a result, the choice fell on the Esipovo industrial zone, which is 40 kilometers from Moscow along the Leningradskoye Shosse. Nothing other than proximity to major customers, including government agencies at different levels, this choice cannot be explained. Near Moscow there are no manufacturers of the necessary components for machines of this level (in our country, consider them not at all). And from a logistic point of view there are questions: I did not see, for example, a railway line. Will all the components be hauled by wagons along the St. Petersburg tract, which is clogged all year round?

Самая впечатляющая и ответственная часть сборочного процесса - так называемая свадьба. Смонтированные на подъемных столах силовой агрегат, трансмиссию и подвеску поднимают к подвешенному на конвейере кузову и стыкуют. После этого «пациент» становится похожим на автомобиль - не хватает лишь бамперов, дверей и колес
Самая впечатляющая и ответственная часть сборочного процесса - так называемая свадьба. Смонтированные на подъемных столах силовой агрегат, трансмиссию и подвеску поднимают к подвешенному на конвейере кузову и стыкуют. После этого «пациент» становится похожим на автомобиль - не хватает лишь бамперов, дверей и колес

The most impressive and crucial part of the assembly process is the so-called wedding. The power unit mounted on the lifting tables, the transmission and the suspension are lifted to the body suspended on the conveyor and joined. After that, the “patient” becomes like a car - all that is needed is bumpers, doors and wheels. The most impressive and crucial part of the assembly process is the so-called wedding. The power unit mounted on the lifting tables, the transmission and the suspension are lifted to the body suspended on the conveyor and joined. After that, the “patient” becomes like a car - all that is needed is bumpers, doors and wheels.

Немцы не хотят делиться информацией. Когда на конвейер встанут кроссоверы GLC, GLE и новый GLS? Тайна! Между тем в разных закоулках я насчитал несколько сваренных кузовов GLC, включая этот, обозначенный как мастер-модель: по нему будут сверять все последующие кузова
Немцы не хотят делиться информацией. Когда на конвейер встанут кроссоверы GLC, GLE и новый GLS? Тайна! Между тем в разных закоулках я насчитал несколько сваренных кузовов GLC, включая этот, обозначенный как мастер-модель: по нему будут сверять все последующие кузова

The Germans do not want to share information. When will the GLC, GLE and the new GLS crossovers get on the conveyor? Secret! Meanwhile, in different corners, I counted several welded GLC bodies, including this one, designated as a master model: all subsequent bodies will be checked against it. The Germans do not want to share information. When will the GLC, GLE and the new GLS crossovers get on the conveyor? Secret! Meanwhile, in different corners, I counted several welded GLC bodies, including this one, designated as a master model: all subsequent bodies will be checked against it. Why in the present turbulent time did the Germans need a plant in Russia? Having signed a special investment contract (SPIC) for nine years in 2017, Daimler received tax benefits and regained access to government orders - our dear officials will finally get a chance to legally purchase personal cars with a star. For example, instead of Camry. This means that in relation to BMW and Audi, which also lost access to the Gostenders (screwdriver assembly machines do not participate in them), Mercedes-Benz will clearly be in a winning position.

When there is a big game, all secrets are kept behind seven seals. The Germans know how. How much do workers get? What is the degree of localization? When will crossovers get on the conveyor? There is no specific answer. Well, let's figure it out for yourself.

Welding and Wrenches

Once there was a military town. Now, after cutting down part of the forest, an industrial park has arisen, the basis of which will be the Mercedes plant. 85 hectares of land were taken under it.

The initial production capacity is 25 thousand cars per year. In terms of working days - about a hundred Mercedes daily. Now they are collecting three or four cars a day (according to the information boards on the conveyor), but they will gradually increase the pace. This year should collect about 5, 000 cars.

Задний модуль - собранные на подрамнике подвеска, редуктор и приводы - поставляется из Германии
Задний модуль - собранные на подрамнике подвеска, редуктор и приводы - поставляется из Германии

The rear module - the suspension, gearbox and drives assembled on a subframe - comes from Germany. The rear module - the suspension, gearbox and drives assembled on a subframe - comes from Germany.

Двигатели приходят в сборе. Их расконсервируют, «женят» с коробкой передач, заливают эксплуатационные жидкости - и отправляют на сборочный конвейер
Двигатели приходят в сборе. Их расконсервируют, «женят» с коробкой передач, заливают эксплуатационные жидкости - и отправляют на сборочный конвейер

Engines come complete. They are being re-opened, “married” with the gearbox, operating fluids are poured - and sent to the assembly line. Engines come complete. They are being re-opened, “married” with the gearbox, operating fluids are poured - and sent to the assembly line. Related Materials

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Additional areas will allow, if necessary, to expand production, but already existing lines in the limit allow to produce 35 thousand cars annually. Why so much if last year in Russia they sold only 38 thousand Mercedes? There will be guestders - there will be demand. That is why they start with the assembly of E classes (I saw on the conveyor of the machine only two colors - black and white). Later they will be joined by crossovers GLC, GLE and the new GLS, the next generation.

Degree of localization? Mercedes remained silent, but the director of KAMAZ, who was present at the opening, Sergey Kogogin told on the sidelines that localization would be 30–35%. Despite the fact that the localization of components is zero: all parts and assemblies come straight from Germany and the USA. But the degree of localization of production, expressed in money, includes energy costs, consumables, workers' labor, and everything else, without which the plant cannot exist. With welding and painting of bodies just about 30% runs in.

Один из кондукторов сварки кузова Е класса. Штампового производства на заводе нет, все кузовные панели, а их 330 штук,  - импортные. Точечная сварка осуществляется ручными клещами - при скромных объемах производства нет смысла раскошеливаться на роботов, которые львиную долю времени будут простаивать. Операторы сварочных клещей проходят семинедельное обучение за границей - на аналогичном оборудовании
Один из кондукторов сварки кузова Е класса. Штампового производства на заводе нет, все кузовные панели, а их 330 штук,  - импортные. Точечная сварка осуществляется ручными клещами - при скромных объемах производства нет смысла раскошеливаться на роботов, которые львиную долю времени будут простаивать. Операторы сварочных клещей проходят семинедельное обучение за границей - на аналогичном оборудовании

One of the conductors for welding the E-class body. There is no stamp production at the plant, all body panels, and their 330 pieces, are imported. Spot welding is carried out with manual pincers - with modest production volumes there is no point in shelling out robots that will stand idle for the lion's share of the time. Welding pliers operators undergo seven-week training abroad using similar equipment. One of the conductors for welding the E-class body. There is no stamp production at the plant, all body panels, and their 330 pieces, are imported. Spot welding is carried out with manual pincers - with modest production volumes there is no point in shelling out robots that will stand idle for the lion's share of the time. Welding pliers operators undergo seven-week training abroad using similar equipment.

Роботам доверена только самая ответственная операция, которая требует прецизионной точности,  - сварка воедино крыши, боковин и пола кузова
Роботам доверена только самая ответственная операция, которая требует прецизионной точности,  - сварка воедино крыши, боковин и пола кузова

Robots are entrusted with only the most critical operation, which requires precision accuracy - welding together the roof, sidewalls and floor of the body. Robots are entrusted with only the most critical operation, which requires precision accuracy - welding together the roof, sidewalls and floor of the body.

Все увиденные мною на конвейере «ешки» - с простыми аналоговыми приборами. Похоже, это самые доступные версии, их должны расхватывать корпоративные парки и чиновники средней руки. Осталось установить руль, постелить покрытие на пол, установить с помощью манипуляторов сиденья и привязать блоки управления всей электроникой, включая замок зажигания
Все увиденные мною на конвейере «ешки» - с простыми аналоговыми приборами. Похоже, это самые доступные версии, их должны расхватывать корпоративные парки и чиновники средней руки. Осталось установить руль, постелить покрытие на пол, установить с помощью манипуляторов сиденья и привязать блоки управления всей электроникой, включая замок зажигания

All the “esh” I saw on the conveyor are with simple analog devices. It seems that these are the most accessible versions, corporate parks and middle-ranking officials should grab them. It remains to install the steering wheel, lay the cover on the floor, install with the help of the manipulators the seats and attach the control units to all the electronics, including the ignition switch. All the “esh” I saw on the conveyor are with simple analog devices. It seems that these are the most accessible versions, corporate parks and middle-ranking officials should grab them. It remains to install the steering wheel, lay the cover on the floor, install with the help of the manipulators the seats and attach the control units to all the electronics, including the ignition switch.

Assembly lines are also sharpened to a small scale. Welding - with manual pincers, with the exception of the most critical stage, in which the floor, side walls and roof are connected together: this operation was entrusted to Kuka robots.

In principle, you can assemble a car from accessories and large subassemblies in a well-equipped garage. The body is the hardest part. And its "geometry" is set by ultra-modern conductors - on this the Germans ate the dog. Engines, gearboxes, complete suspension assemblies - everything comes ready now, just screw it on.

Everywhere sterile clean, you can eat from the floor. Workers are all youth. They don’t give out secrets, so they value work. By the way they pick up parts not too confidently and how they hold electric wrenches, it’s clear that they taught them all this just yesterday. So, if electronics turn off, it is necessary to scold the German workers, but the oil that is not spilled into the engine or poorly glued glass is on our conscience.

But all this is a growth disease that will surely be overcome in the shortest possible time. And perhaps I would dare to buy even a car from the first parties - if I were an official and did not spend my own.

Специальный робот аккуратно наносит полосу клея на заднее стекло. Операция совершенно безобидная, но согласно технике безопасности строгие немцы обнесли установку стеклянным ограждением. Панорамная крыша, если таковая есть, вклеивается на более раннем этапе
Специальный робот аккуратно наносит полосу клея на заднее стекло. Операция совершенно безобидная, но согласно технике безопасности строгие немцы обнесли установку стеклянным ограждением. Панорамная крыша, если таковая есть, вклеивается на более раннем этапе

A special robot gently puts a strip of glue on the rear window. The operation is completely harmless, but according to safety measures, strict Germans surrounded the installation with a glass fence. The panoramic roof, if any, is glued at an earlier stage. A special robot gently puts a strip of glue on the rear window. The operation is completely harmless, but according to safety measures, strict Germans surrounded the installation with a glass fence. The panoramic roof, if any, is glued at an earlier stage.

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