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IZHEVSK AUTOMOBILE PLANT

Company profile
Izhevsk, December 22, 2009

CONTENT
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IZHEVSK AUTOMOBILE PLANT


Company profile
Izhevsk, December 22, 2009

LOCATION ADVANTAGES & LOGISTICS

LOCATION AREA DETAILS

13

POTENTIALS FOR TRANSPORT LOGISTICS

14

POTENTIALS FOR STOCKING LOGISTICS

PRODUCTION CAPACITIES & TECHNOLOGY


16

HISTORY OF PRODUCTION BUILDUP

18

SPECIFICATION OF CURRENT LINEUP

22

PRODUCTION SITE

23

BASIC PRODUCTION

32

COMPONENTS PRODUCTION

36

ENGINEERING INFRASTRUCTURE

46

INFORMATION TECHNOLOGIES (IT)

50

ENGINEERING SUPPORT & DEVELOPMENTS

DEALERS NETWORK
52

DEALERS NETWORK DATA

QUALITY SYSTEM
54

QUALITY SYSTEM DETAILS

57

QUALITY SYSTEM BENCHMARKS

HUMAN RESOURCES
The additional information on technical and economic indicators "JSC
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: ksi@izhavto.ru

58
59

LABOR STAFF SELECTION & ADAPTATION


FLEXIBLE SYSTEM OF STAFF SELECTION

SUMMARY

LOCATION ADVANTAGES & LOGISTICS


Location area details
LOCATION OF MINING AREAS & INDUSTRIAL SITES OVER RUSSIA.

S.-Petersburg agglomeration

Moscow agglomeration
Nizhny Novgorod
agglomeration
Rostov
agglomeration

Kazan agglomeration
Izhevsk,

Samara-Togliatti
agglomeration

Udmurt Republic,

IzhAvto

Ekaterinburg agglomeration
Chelyabinsk agglomeration

Krasnoyarsk
agglomeration

Mining operations
Manufacturing activities

Mining operations

Vladivostok agglomeration

Manufacturing activities

Volga Federal
17% District (PFD)

83%

Khabarovsk
agglomeration

Irkutsk
agglomeration

1. Urals Federal District = 45%


2. Volga Federal District = 17%
3. Central Federal District = 11%

23%

Volga Federal
District (PFD)

77%
1. Central Federal District = 31%
2. Volga Federal District =23%
3. North-West Federal District = 12%

Good geographic & economic position of


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.

LOCATION ADVANTAGES & LOGISTICS


Location area details
Location of major CAR ASSEMBLY PLANTS IN RUSSIA (passenger cars & LCV).
AVTOTOR (KIA,Chevrolet, BMW)
170,000 units per year

Available
production capacities
in Russia amount to

GM Manufacturing Rus (Chevrolet, Opel)


90,000 units per year

St. Petersburg
Vsevolozhsk

Kaliningrad

NISSAN Motor Manufacturing Rus


50,000 units per year
Ford Motor Manufacturing Rus
150,000 units per year

Volkswagen Group Rus (VW, Skoda, Audi),


150,000 units per year

Moscow

200
0

TagAZ (Hyundai)
150
0
180,000 units
per 1year

500

Ulyanovsk

GAZ
65,000+200,000 units per year
IzhAvto (KIA)
220,000(360,000) units per year

N. Novgorod

000

Taganrog

Izhevsk

Elabuga
500
Nab. Chelny

Togliatti

100
0
150
0

UAZ
110,000 units per year

200
0

Sollers (Fiat, SsangYong)


80,000 units per year

GM-AVTOVAZ
102,000 units per year

units per year

Toyota Motor Manufacturing Rus


200,000 units per year

AVTOFRAMOS (Renault)
160,000 units per year
Kaluga

92% 2,880,000

8%

Production capacities of
IzhAvto plant
(220,000 units per year
with potential buildup
to 360,000 units per year)

Sollers (Fiat)
75,000 units per year

Sollers
50,000 units per year

Sollers (Isuzu)
25,000 units per year
AVTOVAZ
950,000 units per year

Vladivostok

LOCATION ADVANTAGES & LOGISTICS


Location area details
COMPONENTS PRODUCTION SITES IN RUSSIA.
Kaluga region: electric
equipment, components

Leningrad region: compressors, batteries, wheel tires, plastics,


brake systems, filters, paints and sealants, tools

Tver region:
compressors, electric
equipment

Vologda region: steel sheets,


steel band, section steel

Yaroslavl region: brake systems, plastics,


motors, paints and sealants

Ryazan region.:
units

Vladimir region: lighting


equipment, components, electric
equipment

Moscow region: electric equipment, units,


components, metal roll, paints, materials, tools

Perm area: rubber technical goods, units,


fuels & lubricants, tools
200
0

Sverdlovsk region: rubber technical goods,


tools, paper goods, catalytic converters, pipes

Kirov region: paints, chemicals

150
0
100
0
500

500

Udmurt Republic: plastic goods, foam polyurethane products, metal roll,


fuels & lubricants, components, materials, automotive wiring harnesses

100
0

Chelyabinsk region: units,


plastic products, steel sheet, steel band

150
0
200
0

Bashkortostan republic: materials,


components, fixtures, technical chemistry,
chemicals, automotive glass

Orenburg
region: units

Republic of Tatarstan: automobile tires, electric equipment, components, fuels &


lubricants, tools, foam polyurethane products, materials, technical chemistry,
chemicals

Samara region: climate control units, electric equipment, units, plastic goods,
components, hot lead-coated sheet steel, materials, tools, wiring harnesses,
plastic goods

Nizhny Novgorod region: components,


materials, fuels & lubricants, technical
chemistry, automotive glass

Saratov region: rubber


technical goods

Ulyanovsk region: units,


components, materials, electric
equipment

LOCATION ADVANTAGES & LOGISTICS


Location area details
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.

IzhAvto

Industry. The basic sectors of industry in


Udmurtia 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
MAJOR REGIONAL INDUSTRIAL PLANTS IN UDMURTIA.
Glazov UPP VOS, Glazov Motor vehicle and motorcycle wiring
harnesses.
OAO CHEPETSKY MECHANICAL PLANT, Glazov Products from zirconium alloy,
calcium metal and its compounds.
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.
Sarapul Electric Generator Plant, Sarapul Electric emplifiers, alternators.
Sarapul Radio Plant Holding, Sarapul Radio, music complexes, aerials,
speakers.
ELECOND, Sarapul Blow molded general rubber goods from
thermoplastic rubber-reinforced polymers.

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 shaped
section, 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 powdered
metals.
5. Structural stock from nonferrous metals and difficult-to- form
alloys.
6. Ingots of induction, vacuum-induction, electroflux, plasma-arc remelting.
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 and
nonferrous 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 customers drawings (sleeves,
liners, wheels, plates, parts and spares for press-forging equipment,
parts and spares for welding equipment).

LOCATION ADVANTAGES & LOGISTICS


Location area details
LABOR COST (BASED NOMINAL WAGE LEVEL IN RUSSIAN REGIONS)

below 11,000 rubles


between 11,000 & 13,000 rubles
between 13,001 & 20,000 rubles
over 20,000 rubles

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.

LOCATION ADVANTAGES & LOGISTICS


Location area details
DISTRIBUTION OF EMPLOYEES IN TERMS OF WAGE SIZE AMONG SOME CONSTITUENT ENTITIES OF THE RUSSIAN FEDERATION
in % to the total number of employees.
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

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.

between 30,000 and 50,000 rubles per month


over 50,000 rubles per month

10

LOCATION ADVANTAGES & LOGISTICS


Location area details
ECONOMIC ACTIVITY OF POPULATION AGED 15 TO 72 YEARS AMONG SOME CONSTITUENT ENTITIES OF THE RUSSIAN FEDERATION.

Economically
active population,
thousand people

including
employed
unemployed
people

Portion of economically
active population,%

in thousand people

Employment Unemployment
rate,%
rate,%

74 844,9

67 761,3

7 083,6

66,9

60,5

9,5

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

911,4

829,3

82,1

69,5

63,2

9,0

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

683,2

622,3

60,9

65,2

59,4

8,9

Russian Federation
Kaluga region

Leninigrad region
Saint-Petersburg city

Ulianovsk region

The Udmurt Republic has considerable human resources, including substantial portion of idle population.
11

LOCATION ADVANTAGES & LOGISTICS


Location area details
EDUCATION LEVEL.
Institutions of basic vocational education
Number of
educational
institutions,
units
Russian Federation
Kaluga region
Moscow region
Moscow city
Leninigrad region
Saint-Petersburg city
Kaliningrad region
Udmurt Republic
Republic of Tatarstan
Nizhny Novgorod region
Samara region
Ulianovsk region

2 963
26
105
58
27
62
15
40
80
83
54
31

Number of graduates
per annum,
thousand people

493,3
2,3
15,5
16,3
4,0
14,1
3,1
6,5
17,5
10,2
8,6
4,2

Institutions of intermediate vocational


education
Number of
institutions and
branches,
units

3 287
26
130
206
32
63
16
38
85
93
80
41

Number of graduates
per annum,
thousand people

631,7
4,2
18,8
29,8
2,2
19,6
2,7
8,9
15,2
16,0
15,2
9,3

Institutions of highest vocational education


Number of
institutions and
branches, units
(major\branches)

1134\1663
5\22
33\96
276\3
3\36
90\11
8\22
7\17
33\53
6\32
29\34
6\11

Number of graduates
per annum,
thousand people

1 125,3
4,8
23,0
168,0
2,0
73,6
5,5
13,2
30,4
33,4
26,6
9,1

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


Potentials for transport logistics
TRANSPORT CORRIDORS OF EURASIA

1 000 km

-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 of
various 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 in
Russia 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.

13

LOCATION ADVANTAGES & LOGISTICS


Potentials for stocking logistics
STORAGE FACILITIES OF IZHAVTO.
Bonded warehouse
for parts in
Petrol storage (dormant)
containers and on
pallets
Bonded warehouse for
DKD parts in containers

Storage of
unmarketable
materials
Petrol
storage

Storage of
painted plastic
parts
Storage of KD parts for
assembly

Storage of general
purpose materials

Bonded warehouse for DKD


parts
CKD parts storage
and repacking
warehouse

Fixture
storage (1)

Base depot
of metals

Storage of KD parts
for welding

Fixture Storage of
storage (2) materials for
repair and
maintenance

Storage of KD parts
for welding

Solvent storage
Storage of noxious
substances

Bonded
warehouse
of paints
Spares and
accessories
storage

14

LOCATION ADVANTAGES & LOGISTICS


Potentials for stocking logistics
IZHAVTO INBOUND LOGISTICS PERFORMANCE.

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 plants 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.
15

PRODUCTION CAPACITIES AND TECHNOLOGY


History of production buildup
HISTORY OF PRODUCTION BUILDUP
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-2715
WAGON 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 assembly
2007 March launch of KIA Sorento DKD assembly
2008 June launch of KIA Sorento full-scale production
HISTORY OF LINE-UP DEVELOPMENT

16

PRODUCTION CAPACITIES AND TECHNOLOGY


History of production buildup
HISTORY OF VEHICLE PRODUCTION BUILDUP AT IZHEVSK AUTOMOBILE PLANT.
Vehicle
throughput,
thousand units per year

max.

200

188,7 units

1988 year

100

64,2 units
2008 year

min.

8,0 units

1997 year

10,9 units
2009 year

1966
year

1970
year

1980
year

1990
year

2000
year

2009
year

17

PRODUCTION CAPACITIES AND TECHNOLOGY


Production line-up specifications
IZH-27175 vehicle GENERAL DATA.

IZH-27175 vehicle specification:


Body type commercial vehicle

IZH-27175 model is a commercial version of IZH-2717 car on the basis of


VAZ-2104 car components.

Driving model 42, rear-wheel drive


Dimensions, mm 430016601810
Wheel 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)

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.

Engine capacity, cu.cm 1 568


Max.power, kW/ rpm (HP) 54.5/5000 (74)
Fuel tank, litre 50
Gearbox manual, 5-speed
conventional, spring-type with hydraulic shock-absorbers
Rear suspension
(commonized with IZH 2717 vehicle)
independent, wishbone arms, coil springs, telescopic
Front suspension hydraulic shock-absorber, anti-roll bar (commonized with
VAZ 2104 vehicle)
Fuel consumption, l/100 km
6.7 / 8.7 / 11
at 90 km/h /120 km/h / urban driving
Max.speed, km/h 120

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 a
rear liftgate and drop backboard.

Price segment of IZH-27175 vehicle (brand / price in thousand rubles)


27175 /195
Lada /240
Citroen Berlingo /274
Lada 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
Basic specification price, thousand rubles

100

200

300

400

500

600

700

800

18

PRODUCTION CAPACITIES AND TECHNOLOGY


Production line-up specifications
VAZ-2104 CAR GENERAL DATA

VAZ-2104 car specification:


Body type station wagon
Driving model 42, rear-wheel drive
Dimensions, mm 411516201443

VAZ-21041 estate car is a really convenient and comfortable vehicle. It


answers 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.

Wheel 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

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.

Max.power, kW/ rpm (HP) 54.5 / 5000 (74)


Fuel tank, litre 42
Gearbox manual, 5-speed
conventional, rigid beam joined to bodyshell via one
Rear suspension Panhard rod and four trailing arms; coil springs;
telescopic shock-absorbers
independent; wishbone arms, coil springs, telescopic
Front suspension
hydraulic shock-absorbers, anti-roll bar
Fuel consumption, l/100 km
7.3 / 9.6 / 9.8
at 90 km/h /120 km/h / urban driving
Max.speed, km/h 143

Price segment of VAZ-2104 vehicle (brand / price in thousand rubles)

Acceleration , 0-100 km/h, sec. 17

Basic specification price, thousand rubles

19

PRODUCTION CAPACITIES AND TECHNOLOGY


Production line-up specifications
KIA Spectra GENERAL DATA

Spectra car is designed for those who equally values style, comfort, calmness and
safety.

KIA Spectra specification:


Body type sedan
Driving model 42, front wheel drive
Engine capacity, cu.cm 1 594
Max.power, hp 102
Fuel tank, litre 50
Gearbox manual 5-speed

automatic 4-speed

Dimensions, mm 451017201415
Stowable luggage, litre 440
Kerbweight, kg 1169-1245

1200-1276

Type of engine 1.6 l DOHC, petrol, port injection system


Front / rear suspension independent, spring-type, MacPherson, anti-roll bar
Fuel consumption
5.9 / 7.6 / 10.2
at 90 km/h /120 km/h / urban driving
Max.speed, km/h 180
Acceleration, 0-100 km/h, sec. 13

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. The
reinforced 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.

6.2 / 7.9 / 11.2


170

Price segment of KIA Spectra car (brand / price in thousand rubles)

16

Basic specification price, thousand rubles

20

PRODUCTION CAPACITIES AND TECHNOLOGY


Production line-up specifications
KIA Sorento GENERAL DATA

Technical specification of Kia Sorento vehicle:


station wagon

Body type

44

Driving model

2.5 CRDi / 3.3 V6

Engine
Capacity

2497 / 3342

Power, hp

170 / 241

Gearbox

manual 5-speed

Dimensions, mm
Stowable luggage
withfolded-up seats,l
Front suspension

automatic 5-speed

459018651725
895/1900
independent, spring-type, telescopic shock-absorbers, anti-roll bar

conventional, lever-type, springs, telescopic shock-absorbers, anti-roll


Rear suspension
bar
Max.speed, km/h
182/190
Acceleration, 0-100 km/h, sec.
Fuel consumption,
Diesel
city \country \ mixed cycle
Petrol
Fuel tank, litre

New generation of frame 4WD vehicles from KIA Motors


An elegant and challenging design, harmonious interior trim, every part of interior
manifests a great care about drivers and passengers comfort. Due to re-oriented backs
of front seats, rear passengers can enjoy much more space. A more powerful 2.5 l
diesel engine (170 hp) and 3.3 l gasoline engine (241 hp) encompass the latest design
innovations. Combined with electronic constant 4 WD system, all this makes the
vehicle as an undisputed leader in extreme off-road conditions or modern megacity
constraints.
A special care is given to passengers safety: the vehicle features ABS with electronic
brake force distribution (EBD), electronic stability program (ESP), front and side
airbags, safety curtains and active headrests. Real lovers of comfort will highly
appreciate its dual-zone climate control.

37 511
10 \ 6.7 \ 7.9

11 \ 7.3 \ 8.6

-\-\-

14.2 \ 8.9 \ 10.8

Price segment of KIA Sorento vehicle (brand / price in thousand rubles)

80

Basic specification price, thousand rubles

21

PRODUCTION CAPACITIES AND TECHNOLOGY


Production area
GENERAL LAYOUT OF IZHEVSK CAR PLANT.

Building 3

Building 18

Building 16

Building 14

Assembly complex

Building 64
Welding Complex

Welding
Complex

Storage facilities

Building 2

Building 16

Stamping Complex

Paint Complex

Building 85

Building 65

Complex for new platform vehicle assembly

Building 83

Total area of the plant is 1,680,000 sq.m, where


774,000 sq.m is total area of buildings;
232,000 sq.m is active production area;
542,000 sq.m* is reserved area*
(*including within the active production sites)

Building 90

22

PRODUCTION CAPACITIES AND TECHNOLOGY


Basic production
.

Type of production
Stapmping
Welding
Paint
Plastic paint
Assembly
TOTAL

Current capacities,
thousand units per year

350
280
220
50
315
350

Potential (additional)
capacities*, thousand units per
year

+10
+80
+140
+310
+45

* 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

PRODUCTION CAPACITIES AND TECHNOLOGY


Basic production
LAYOUT OF basement AREA AT (-7.20) m LEVEL.

NON-OCCUPIED AREAS

NON-OCCUPIED AREAS

NON-OCCUPIED AREAS

NON-OCCUPIED AREAS

NON-OCCUPIED AREAS

24

PRODUCTION CAPACITIES AND TECHNOLOGY


Basic 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 of
manufacture - 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 1996

25

PRODUCTION CAPACITIES AND TECHNOLOGY


Basic production
WELDING SHOP

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.
26

PRODUCTION CAPACITIES AND TECHNOLOGY


Basic production
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 year
Automatic 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.

27

PRODUCTION CAPACITIES AND TECHNOLOGY


Basic production
PAINT SHOP.

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.
28
9. Coating repair line (for coarse defects) 1 unit.

PRODUCTION CAPACITIES AND TECHNOLOGY


Basic 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.

29

PRODUCTION CAPACITIES AND TECHNOLOGY


Basic production
ASSEMBLY SHOP.

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, DONG ROFA CO. LTD, Korea;
- chassis line (power and free conveyor), 2005, DONG ROFA CO. LTD, Korea;
- final line (floor-type double slat conveyor), 2005, DONG ROFA CO. LTD, Korea;
- test line, 2005, HANKOOK . , 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)
30

PRODUCTION CAPACITIES AND TECHNOLOGY


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.

31

PRODUCTION CAPACITIES AND TECHNOLOGY


Parts production
PARTS PRODUCTION.

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, -1610 type and portable guns of MTP1111 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 PDG312 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 production
Area 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.

32

PRODUCTION CAPACITIES AND TECHNOLOGY


Parts production
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 m
Capacity 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
33
polymers, polyamide, polycarbonate, thermoplastic elastomer.

PRODUCTION CAPACITIES AND TECHNOLOGY


Parts production

Technical data of plastic parts production equipment:


Automatic molding machines (Germany).

Type

Number, units

Closing force, kN

ErgoTECH 110-310H/80V
ErgoTECH 420/1450
ErgoTECH 500/2300
ErgoTECH 500/3300
ErgoTECH 650/3300
ErgoTECH 800/5200
ErgoTECH 1000/5200
ErgoTECH 1000/8000
ErgoTECH 1300/12000
ErgoTECH 2200/12900
ErgoTECH 2700/12900

1
3
3
4
5
1
4
3
2
1
2

Shot volume, cu.m


1100
168/42
4200
763
5000
1212
5000
1779
6500
1779
8000
2835
10000
2835
10000
4375
13000
6730
21150
6500
27000 Izhevsk Plastic Plant

All automatic molding machines are equipped with compact automatic feeders as well as thermostats for mold temperature control.

Extrusion blow molding equipment (Krupp-Kauteks).

Type

Number

Application

10.01.-60.01

2 To make air ducts and seervice fluid tanks

Izhevsk Plastic Plant

Equipment (Galino) for manufacturing foam parts.

Type

Number

Application

6818012; 682338
532503

Type

Max.sheet size, mm

2 To make headrest & seat cushion fillers

Izhevsk Plastic Plant

1 To make instrument panels and sunvisors

ERGON, Izhevsk

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
1300

Sheet thickness, mm
900 0,4 4,0

Max.output, kg/h
400 34

PRODUCTION CAPACITIES AND TECHNOLOGY


Parts production

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
JOB
OPERATOR
PARTS

STATION #157

RESPOT JIG
1

STATION #155
PRE-BUCK JIG

STATION #154

RESPOT JIG

2 (2)

JIG & ACCESSORIES 1

STATION #153

PRE-BUCK JIG

STATION # 151

22

PRE-BUCK JIG
2

20

12

JIG & ACCESSORIES 1

JIG & ACCESSORIES 1

JIG & ACCESSORIES 1

JIG & ACCESSORIES 1

JIG & ACCESSORIES 1

CO2 WELDER (REPAIR)


CO2 WELDER 2
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 ASSEMBLY

SIDE MEMBER ASSY


LH/RH

BRACKET-BODY
SUPPORT

BRACKET ASSY,
DIFFERENTIAL MOUNT,
LH/RH

PILLAR ASSY, FR, LH/RH

CROSS-MEMBER ASSY.FR SUSPENSION

PILLAR ASSY, RR, LH/RH

BRACKET, RR SHOCKABSORBER, LH/RH

BRACKET ASSY, FR,


TOP ARM #1, LH/RH

CROSS-MEMBER ASSYGEARBOX

RADIATOR BRACKET
ASSY, TOP, LH/RH

BRACKET ASSY, FR
BUFFER, LH/RH

BRACKET ASSY, FR,


TOP ARM #2, LH/RH

CROSS-MEMBER ASSYFUEL TANK

RADIATOR BRACKET,
BOTTOM, LH/RH

HOOK ASSY, FR.

BRACKET ASSY, FUEL


TANK, #1

CROSS-MEMBER ASSY-SPARE WHEEL

PARTS LOADING

BRACKET ASSY, ENGINE SPARE WHEEL


MOUNT, LH/RH, etc.
BRACKET, etc.

WELD SEAM LENGTH

STATION #152
PRE-BUCK JIG

2 (2)
20

INSPECTION & REPAIR


FACILITIES 1

MACHINES &
EQUIPMENT

STATION #156

INSPECTION & REPAIR

8822 mm

7506 mm

451 mm

SILENCER SUSPENSION CROSS-MEMBER ASSYRING #3, etc..


RR SUSPENSION, etc.
4805 mm

1679 mm

3530 mm

35

PRODUCTION CAPACITIES AND TECHNOLOGY


Engineering infrastructure
POWER FACILITIES.

Maximum throughput efficiency of IzhAvto engineering/utility systems.

2008

The prices
in 2009,
2009 ,

without
the VAT

The
electric
power

Natural gas

Thousand
in kw hour
102139,164 .
*

1334,80 /.
*
Rbl. /Thousand
in kw hour

85768,80 Thousand
. 3 in cubic m.

2097,26,Rbl.
/.
3in cubic m.
/Thousand

Water

1957515 3
cubic m.

9,72 /
3 m.
Rbl. /cubic

Oxygen

72359 3
cubic m.

28,34 Rbl.
/3
/cubic m.

Acetylene

2461,5 kg.

144,0 /
Rbl. /kg.

Carbonic acid

86798
kg.

7,00 Rbl.
/
/kg.

Power resource

1
2

Consumption in 2008

Energy production of IzhAvto can provide utilities enough for annual output of 360,000 vehicles.
36

PRODUCTION CAPACITIES AND TECHNOLOGY


Engineering infrastructure

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 250-61-5 (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 compressors
instead 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 VA
Electrical 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.
37

PRODUCTION CAPACITIES AND TECHNOLOGY


Engineering infrastructure

Gas facilities and GasEnergy.


Acetylene and carbonic acid are provided by GasEbergy, daughter company of IzhAvto.
The acetylene station of 120 cu.m/hour is intended to produce acetylene gas and dissolved acetylene
via carbide-to-water method.
Carbonic acid gas and liquefied carbon dioxide are produced from stack gases of IzhAvto boiler plant.
The design capacity is12 ton of 2 per day (3,000 ton per year).
Gas to IzhAvto plant is delivered through main gas pipeline of medium pressure (max.3 kgf/sq.m)
with annual consumption of up to 100 million cubic meters.
Oxygen is bought by IzhAvto from the local BumMash plant.
Heating and ventilation.
Heat supply network includes intra-site and extra-site heating systems.
The length of main heating system is:
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.
The total pipeline is 15,946 m long.
The factorys heating is ensured by means of supply-and-exhaust systems.
The exhaust technological ventilation is fitted with gas-and-dust collectors, SovPlim-type systems and
incinerators of hazardous discharges.
Communication.
Communication is supported by digital automatic telephone exchange station Coral Flexi Com 5,000.
There are in total about 4,200 dial telephone sets and about 2,000 wire-radio outlets at the plant.
Automated metering of utilities.
An automated metering system combines electric power meters, heat power meters, gas meters, water
meters, effluents meters, compressed air meters. The system is capable to run real-time monitoring of
energy consumption using over 200 meters of commercial and technical records and supervise all
IzhAvto energy networks.
38

PRODUCTION CAPACITIES AND TECHNOLOGY


Engineering infrastructure

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 their
environmental 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.
39

PRODUCTION CAPACITIES AND TECHNOLOGY


Engineering infrastructure

OAO IzhAvto achievements in the area of energy and environmental safety.

40

PRODUCTION CAPACITIES AND TECHNOLOGY


Engineering infrastructure

Location of IzhAvto transformer substation

Transformer substation
Distributive point 10 of kw

41

PRODUCTION CAPACITIES AND TECHNOLOGY


Engineering infrastructure

IzhAvto heat supply network

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.
In 2007 IzhAvto sold heating power to different Izhevsk factories to the total amount of 88,560,000 rubles.

42

PRODUCTION CAPACITIES AND TECHNOLOGY


Engineering infrastructure

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

43

PRODUCTION CAPACITIES AND TECHNOLOGY


Engineering infrastructure

IzhAvto compressed air network

High pressure air


Low pressure air

44

PRODUCTION CAPACITIES AND TECHNOLOGY


Engineering infrastructure

IzhAvto process gas network

Carbonic gas
Acetylene
Oxygen
Natural gas

45

PRODUCTION CAPACITIES AND TECHNOLOGY


Information Technologies (IT)
Information Technologies (IT).

IzhAvto corporate network capacities

entralized antivirus program

There are about


3,000 ports for
terminal network
equipment.

1,600 PCs

700 printers

20
Software for data
backup

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.
46

PRODUCTION CAPACITIES AND TECHNOLOGY


Information Technologies (IT)

IT system general design concept.


Production chain, data flow in information system (IS):

PROCESSES:
Production, Logistics

MES | CCR

Cognos

Axapta

1 platform

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.

47

PRODUCTION CAPACITIES AND TECHNOLOGY


Information Technologies (IT)

IT system general design concept.


MES/CCR functional
Basic MES functions (MES=Manufacturing Executive System):
vehicle monthly production schedule processing;
generation of days 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)

48

PRODUCTION CAPACITIES AND TECHNOLOGY


Information Technologies (IT)

IT system general design concept.


IS briefly

Basic functional

Central base

Capital assets
Transport means
monitoring

materials, finished products, non-material assets,


cash desk, bank, securities (shares, notes, BC),
loans, settlements with accountable persons,
capital assets, etc.
records on capital assets availability, flow and leasing, precious metals in capital assets,
depreciation calculation, tax accounting.
inspection of consignment notes at the plant exits
(double entry and data comparison by security staff)
Total user number: over 200

Platform / Client
Cognos
Lotus Notes
Web-technologies

Budgeting system.
e-mail;
BOSS-Referent automated system of document flow and records;
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

PRODUCTION CAPACITIES AND TECHNOLOGY


Technological support and developments
DESIGN & ENGINEERING.

Production
engineering
department

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.

Vehicle
engineering
department

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.

Localization
department

Laboratories
Center

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.

Multichannel atomic emission


spectrograph

Two-axis measuring
device

Design and engineering support


facilities and systems 50


Technological support and developments

CHIEF
DESIGNER
DEPARTMENT

Thermal pressure
chamber

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 (Users 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.

Hydraulic
pulsator

Ergonomics

Prototyping

3D scanning and modeling

Engineering

51

DEALERS NETWORK
Dealers network performance
DEALERS NETWORK OF IZH-VAZ VEHICLES.

98 outlets in 59 cities

Number of
outlets

Number of
cities

Northwestern Federal District

11

Southern Federal District

Central Federal District

27

15

Volga Federal District

25

15

Ural Federal District

11

Siberian Federal District

15

10

52

DEALERS NETWORK
Dealers network performance
DEALERS NETWORK OF KIA VEHICLES.

155 outlets in 76 cities

Number of
outlets

Number of
cities

Northwestern Federal District

21

Southern Federal District

19

11

Central Federal District

44

16

Volga Federal District

40

21

Ural Federal District

19

Siberian Federal District

12

11

53

QUALITY SYSTEM
Quality system performance
COMPLIANCE OF QUALITY MANAGEMENT SYSTEM (QMS) WITH INTERNATIONAL STANDARDS.

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 ISO
9001:2000 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).

54

QUALITY SYSTEM
Quality system performance
QUALITY MANAGEMENT SYSTEM.

- 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 customers requirements.
Control and improvement processes
System control
Documentation control
Internal auditing
Analyses from the management side
Preventive and corrective actions

Basic production processes


Pre-production activities
Product quality control

Meeting
customers
demands

Service

Product shipment

Finished
vehicles
(customers)
audit

Vehicle
production
process

Receiving
inspection

Purchasing

Production
scheduling

Designing and
development

Inadequate products management

Supportive processes
Parts & material handling
Equipment maintenance and repair
Control over facilities for monitoring & measuring
Staff management

55

QUALITY SYSTEM
Quality system performance
PRODUCTION SYSTEM OF BUILT-IN QUALITY.

Definition: methods for building the


quality into the production process in a
way to prohibit defects or earlier identify
them with simultaneous actions against
potential defect recurrence

Elements of built-in quality:


quality standards;
process flow charts;
job element sheets;
feedback over the process chain.

Objective: fully exclude the risk of defect


at the customers.

RECEIVING
INSPECTION

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.

QUALITY
ASSURANCE IN
PRODUCTION

Operators 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.

FIELD WARRANTY
QUALITY
CONTROL

System of earlier defect detection (EDD).


Warranty data analyses.
Weekly quality meetings.

56

QUALITY SYSTEM
Quality system performance benchmarks
QUALITY SYSTEM BENCHMARKS.

The application of visual and automatic control systems of defect prevention (Andon, Poka-yoke) significantly improved the product quality
score.
QUALITY WELDING KIA Spectra.

QUALITY PAINT KIA Spectra.

QUALITY ASSEMBLY KIA Spectra.

2005

2006

2007

2008

2005

2006

2007

2008

2005

2006

2007

2008

year

year

year

year

year

year

year

year

year

year

year

year

Customer audit KIA Spectra


93,1

body

water leak

Four benchmarks are used by IzhAvto for product quality


assessment:

paintwork

driving

Direct yield percentage of products accepted by inspector


from the 1st or 2nd time, after minor rectification at the
relevant conveyor line.

plastic

KD

trim

target

32,6

25
20

16

15

14,8

14,0

10

12,6

First pass yield percentage of products passed the


inspection post with no remarks.
Defect rate number of defects per vehicle.

chassis

0
2005
2005
year

2006
2006
year

2007
year

2008
year

2009
year

Customer audit number of defects per finished vehicle.


electric system

57

HUMAN RESOURCES
Staff recruitment and adaptation
HR MANAGEMENT SYSTEM.
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.

PERSONNEL DIVISION
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.

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.

LABOR ORGANIZATION AND PAYROLL DEPARTMENT


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.

58

HUMAN RESOURCES
Flexible system of staff recruitment
SOURCES OF STAFF RECRUITING FOR AVAILABLE VACANCIES.

DATA BASE OF FORMER


IZHAVTO EMPLOYEES

About 3,000 people


were laid off on
mutual agreement
of the parties within
2008-2009.
About 5,000 people
were laid off on
voluntary discharge
(unsolicited
dismissal) within
2004-2009.

GRADUATES OF
VOCATIONAL SCHOOLS,
TECHNICAL COLLEGES,
HIGHER EDUCATIONAL
INSTITUTIONS

Vocational school
graduates 6,500
students per year

EMPLOYEES OF OTHER
ORGANIZATIONS

Employed
population of
Udmurtia 771,300
people

UNEMPLOYEED

Unemployed
population of
Udmurtia 88,100
people

Vocational technical
colleges 8,900
students per year
Vocational Higher
educational
institutions 13,200
student per year

59

SUMMARIES
OAO IzhAvto can boast ...

1.1. Favorable geographic and economic location.


1.2. Vicinity of metal, material, plastics, components suppliers.
1.3. Available regional labor market with qualified and low-priced labor force;
1.4. Good access to the country freight traffic flows;

2.1. Production capacities for building 360,000 vehicles per year.


2.2. High-tech technologies in welding, paint, assembly;
2.3. State-of-the art systems of production, logistics and finance management;
2.4. In-house design & engineering unit to run production supervision;
2.5. Capabilities to setup a Design & Engineering Centre (available infrastructure, skilled
candidates pool, experience in development, state support for R&D through tax benefits;
2.6. Available infrastructure (buildings, equipment, utilities and communications) with relevant
functional units for maintenance and repair;
2.7. Power generation to support the production of 360,000 vehicles per year;

3.1. Available qualified personnel;


3.2. Efficient and operating system of staff selecting and training, that makes possible to recruit
good new personnel for extended production volumes at short time.
60