Manufacturing technologies and performance

GAZ commercial vehicles.
The world`s best practices in technology and manufacturing, work and environmental management has been introduced.

Gorky Automobile Plant (GAZ) today is a state-of-the-art hi-tech plant with a high automation level. There are over 20 production facilities at GAZ, including automotive part production, metal production, casting and press shops, forging and toppling shops, cabin and body welding shops, a few paint shops and assembly lines.

PROGRESS OVER THE LAST YEARS

The plant, its premises, machinery and equipment are regularly revamped, renovated and upgraded. There have been the following manufacturing lines launched for NEXT generation vehicles:

  • independent front suspension for LCVs
  • automated stamping of A-class exterior panels
  • advanced-tech paint shop
  • new cabin and body welding lines with a 85% level of automation

GAZ Production System. Four Basic Principles

  • Think about your customer

    A customer is not just an end-user but also an internal customer (a section or a shop where the product moves to for further operations or even an operator who works with the product next). For a supplier it means that they must make products in full compliance with the technical and quality requirements.

  • People are our most valuable asset

    Investment made to develop your people are the best in performance as while developing a person influences the manufacturing factors around them: methods, technology, equipment, materials. All employees should feel sure that that the company needs them and they will be well paid for if they work honestly and make positive contributions to develop the company.

  • Kaizen

    Manufacturing processes should continuously improve. Work standards (workplace arrangements, quality, sequence, etc) are the foundation for improvements as they define the manufacturing process and are continuously improved. The main idea of continuous improvements (kaizen) is that you should never stop once you have made an achievement, the process of changes should be ongoing daily work.

  • Decisions should be made on the factory floor

    Production decisions should not be made in the offices - they should be made on the factory floor (gemba) where the problem is or where an improvement is required. The efforts of the management and the auxiliary services focus on where most work is done and where products are made, i.e. on the factory floor. It is there where problems are solved and improvements are made.

Revamped production facilities for GAZ commercial vehicles

Stage 1 Stamping

Stage 2 Welding

Stage 3 Painting

Stage 4 Assembly line

Stage 5 Quality Management System

STAMPING

The automated class A stamping line is equipped with the latest generation six-axis multifunctional KUKA robots and LG presses with dies. The line is used to make large parts, including external side panels, underbodies, sliding and swing doors. With the new state-of-the-art equipment high accuracy and good production performance are delivered.

7

HIGH-PERFORMANCE PRESSES WITH A FORCE UP TO 800 TONS.

6-8 parts/min.

Capacity

9,900 tons

the total weight of dies used in the Next gen manufacturing process.

WELDING

Bodies and cabs of the Next gen vehicles are welded on state-of-the-art automatic welding lines. The new welding line was installed by Russian and Korean engineers from LG. The intelligent control system monitors all parameters of the production process. With the feedback mechanism the system can automatically adjust the welding parameters if necessary.

98

Fanuc Japanese robots at the GAZelle NEXT van body welding line

100

KUKA German robots are installed in the cab welding line

85 %

of welding operations are performed automatically

6000

welding points in the GAZelle Next van body

<0.2 mm

maximum allowed deviation for each spot

700 kg

carrying capacity of the highest-powered robot

The smart control system with a feedback mechanism.

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MATERIALS

The vehicle body is made from galvanized steel with high corrosion resistance. That is why we offer over 8 years of corrosion warranty.

EISENMANN PAINT SHOP

The state-of-the-art paint shop delivers high quality of surface treatment, priming and painting. A positive air pressure is built up inside the working zone, which pushes even the tiniest dust particles from the spray booths.

13 STAGES

OF SURFACE CLEANING, PREPARATION AND PRIMING

22

AIR CONDITIONING SYSTEMS

1 MICRON

AIR CLEANLINESS CLASS

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MATERIALS

Any paint or lacquer is released for application following a range of lab and production tests. After testing, they are applied to several bodies in order to fine-tune robot software and to measure their resistance to external impact and chipping. Such process pre-inspection helps us choose the process materials delivering high paint quality and durability. Tests in the salt-spray booth (simulating operation under real conditions over 16 years) showed no corrosion of the NEXT Gen vehicle bodies.

ASSEMBLY LINE

The vehicles are placed onto the assembly line based on the heijunka principle. Experienced process engineers determine the sequence for alternating more labor-intensive and less labor-intensive models to ensure best balance of the main assembly line operations during a month. The assembly line features a high level of mechanization.

520

commercial vehicles per shift - capacity of the largest assembly line

4

assembly lines for drop side vehicles, chassis, vans, mini buses and light duty trucks

220 min

the average time to assemble a GAZelle NEXT

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QUALITY MANAGEMENT SYSTEM

Core Standard Procedures:

fact
Training
fact
Analysis and control processes
fact
Eliminating cause

WHAT DOES THE QUALITY ASSURANCE SYSTEM START WITH?

  • STAGE: GET ACCURATE STATISTICS ON QUALITY (GET COMPLETE INFORMATION ON DEFECTS FROM CUSTOMERS AND DEALERS, SET UP AN AUTOMATED ONLINE SYSTEM FOR WARRANTY CLAIM MANAGEMENT).

  • STAGE: SET UP A SUPPLIER NOMINATION AND APPROVAL SYSTEM FOCUSED TO SELECT SUPPLIERS ABLE TO DELIVER SMOOTH PRODUCTION PROCESSES AND GOOD QUALITY OF THE PRODUCTS.

  • STAGE: INCORPORATE QUALITY CONTROL INTO THE MANUFACTURING PROCESS.

VECTOR NEXT Length: 7645 mm Max. Passenger capacity: 53
VECTOR 8.8 Length: 8800 mm Max. Passenger capacity: 64
PAZ-320412 Length: 8560 mm Max. Passenger capacity: 70
PAZ-3204 Length: 7500 mm Max. Passenger capacity: 53
PAZ-3203 Length: 7100 mm Max. Passenger capacity: 43
PAZ-4234 Length: 8165 mm
PAZ-32053/54 Length: 7000 mm
KAVZ-4235 AURORA Length: 8410 mm
LiAZ-4292 Length: 9500 mm Max. Passenger capacity: 82
LiAZ-5292 restyling Length: 12410 mm Max. Passenger capacity: 114
LiAZ-6213 Length: 18040 mm Max. Passenger capacity: 153
LiAZ-5256 city Length: 11400 mm
LiAZ-5256 suburban Length: 11400 mm
LiAZ-5293 Length: 11400 mm
KAVZ-4270 Length: 10200 mm Max. Passenger capacity: 84
CRUISE Length: 12060 mm Max. Passenger capacity: 49
VOYAGE Length: 12500 mm Max. Passenger capacity: 60
VOYAGE L Length: 14950 mm Max. Passenger capacity: 100
VECTOR 8.8 m intercity Length: 8800 mm Max. Passenger capacity: 50
LiAZ-5256 intercity Length: 11400 mm Max. Passenger capacity: 66
KAVZ-4238 Length: 10030 mm
VECTOR NEXT school Length: 7645 mm
PAZ-3203/04-70 school Length: 7100 mm
PAZ-32053-70 school Length: 7000 mm
KAVZ-4235/4238 school Length: 8410 mm
PAZ-3206 Length: 7000 mm
Electrobus Length: 12420 mm
Dump truck
Semi-truck
Dumper 4x4, 6x6 GVW 13...22.5t
Crew bus 4x4, 6x6 GVW 13...22.5t
Dropside truck 4x4, 6x6 GVW 13...22.5t
Tractor unit 4x4, 6x6 GVW 13...22.5t
Special vehicles
Tractor 4x4, 6x6 GVW 13...22t
Tipper 4x4, 6x6 GVW 13...22t
Rotational bus 4x4, 6x6 GVW 13...22t
Onboard 4x4, 6x6 GVW 13...22t
Special vehicles
Tipper 6x6 GVW 34t
Tractor 6x6 GVW 34t
Special vehicles
Dropside truck 4x4, 6x6, 8x8 GVW 13...26.1t
Crew bus 4x4, 6x6, 8x8 GVW 13...26.1t
Dumper 4x4, 6x6, 8x8 GVW 13...26.1t
Tractor unit 8x8 GVW 13...26.1t
Tractor unit 6x6 GVW 13...26.1t
Special vehicles
GAZelle NEXT DROP-SIDE TRUCK
GAZelle NEXT VAN
GAZelle NEXT MINIBUS
GAZelle NEXT FRAME BUS
Special vehicles
GAZelle CITY LOW-FLOOR FRAME BUS
GAZon NEXT DROP-SIDE TRUCK
Special vehicles
Sadko Next DROP-SIDE TRUCK
Sobol business 4WD DROP-SIDE TRUCK
Sobol business 4WD VAN
Sobol business 4WD MINIBUS
GAZelle business DROP-SIDE TRUCK
GAZelle business VAN
GAZelle business MINIBUS
Special vehicles