New Opel plant in Rüsselsheim - Compact, Flexible Body Shop

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The new Rüsselsheim plant has a planned annual capacity of around 270,000 cars, manufactured on a joint production line in three shifts. The facility, which is being built along the lines of the Opel production plant in Eisenach, is one of the biggest projects in the company's DM 9 billion investment program in Germany.

Old Ruesselsheim

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Opel AG: The New Ruesselsheim Plant 2002 (4)

Compact, Flexible Body Shop:

The body shop, with an area of more than 54,000 square meters, will start up at the same time as the assembly area. 600 robots have been programmed for welding, bonding and handling operations to ensure consistently high quality. Several operations will be performed by laser welding. One main characteristic of the particularly compact production process is its high flexibility, with up to four different models running largely on one combined line.

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All the add-on parts like the hoods and doors are made in production cells in the immediate vicinity of their assembly position on the main line. This avoids long transport distances and warehousing and also allows fast feedback on matters of quality.

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The compact structure of this manufacturing unit also guarantees a high level of availability. Another bonus is that the pilot production for new models can be carried out on the original equipment.

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all photos: Adam Opel AG

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