:

FSO

Production possibilities
of subsidiary production units of UkrAVTO Corporation:
CJSC ZAZ and FSO concerning supply of autocomponents

Business-scheme of UkrAVTO

Manufacturing

Distribution
6

ZAZ

FSO

With 6 distribution companies

Vehicle
Auto parts


Vehicle
production

Components
production

Vehicle
production

Components
production

Own sales network

400

With 400 dealers and service centers

Vehicle

Auto parts

Scheme of preferential treatment of supplies

From Ukraine to Russia

,


Under condition of inclusion in the
report, defining the nomenclature
and volumes of supplies

Supplies from Ukraine

,
,

50%
Under condition of conformity of production to criterion,
according which the cost of raw materials, materials and
components from the third countries does not exceed 50 %
in the price of an autocomponent

( )

Supplies from other countries

(non members of CIS)


Supplies scheme

Companies of FSO Group

Companies of ZAZ Group


Companies of ZAZ Group

( )
(possibilities of component manufacturing )

(Subsidiary production unit )

(Production)

- / AutoZAZ-Motor

/ Power train

Dipol Auto-ZAZ

/ interior and exterior elements

Bosal-ZAZ

/ Exhaust systems

Tavria-Magna

- / Engineering and
producing of press-tool

/ JSC Niktim

/ Mechanic engineering

/ JSC Lityo

/ Foundry production

- / JSC ZAZ-osnastka

, , - / Tooling, instrument, die mold

/ JSC Automashinstrument

, / Tooling, instrument

/ CJSC ZAZ:
-
Press shop

/ Stamped parts

-
Shop of plastics articles

/ Production of parts from

foamed polypropylene

-
reinforcement production

, / reinforcement,
galvanic and other works

- , ,
Welding shop, painting shop, assembly shop

, / Assembling and painting works


Press production
, ,
/ The press production of CJSC ZAZ consists of large, small and medium stamping
shops and material preparation section.

31 500 2

The total area of press production is 31 500 sq.m.

, :
Shops are equipped with modern, high-performance equipment as follows:
-, - / two-coordinate, three-coordinate automatic presses;
/ tandem robotized lines;
/ single-action presses with hydraulic and
pneumatic cushions;
/ double-action presses.

90 000 .

Total volume of the processed rolled sheets is about

90 000 ton per year
2 000 . /
The range of the produced parts includes about 2 000 parts.
./
It is possible to produce all stamped parts of car body.


Press production

Large stamping shop

/ Blanking line by AIDA :

8000 .
0,5-2,5 .
500-1800 .
2500 5000 .
1400 .
20-65 .
2009 .
Press force: 8000 kN
Coil thickness: 0.5-2.5 mm
Coil width: 500-1800 mm
Moving bolster: 25005000 mm
Die height: 1400 mm
Productivity: 20-65 strokes per minute
The line was put into operation in 2009.


Press production

Large stamping shop

G1 / Two tandem robotized lines, type G1:

( 6- )

( , 6-
7- )

The first line consists of 7 presses

(equipped with ten 6-axis robots):

,

. 10000 kN 20000
kN
Cushion drawing press made by Fagor company
(Spain), double-action by VzTMP comany and five single
action presses. Force: 10 000 - 20 000 kN

The second line consists of 5 presses

(made by AIDA company and equipped with three 6axis robots and four 7-axis robots):
,
.
8000 kN 20000 kN
Main cushion drawing press and five single-action
presses. Force: 8 000 - 20 000 kN


Press production

Large stamping shop

Samples of production

.


.
Press production has the complete list of body parts for vehicles.
Performing such works as pattern cutting of coils, also there is a possibility of
deep drawing with double-action presses and presses of simple action equipped
with hydraulic cushion.


Press production

Medium and small stamping shop

Samples of production


Manufacturing of plastic products

Shop of plastics articles

:
Products are produced by the following main technological processes:

;
- ;
;
;
;
;
;
;
;
.

structural foam molding

rubber press molding;
flat-strip-shaped products by extrusion moulding
method;
thermo moulding;
hot stamping;
thermoplast ultrasonic sealing;
heat sealing;
tampon printing;
assembling;
producing components, made of foamed
polypropylene;
vibration welding.

.
Maintenance of mechanical training of manufacture is performed by
own tool manufacturing of CJSC ZAZ


Manufacturing of plastic products

Shop of plastics articles

Samples of production

Vehicle components

Large-scale goods


Manufacturing of plastic products

Producing components, made of foamed polypropylene

,
, .
Production of energy absorbers for Lanos cars was mastered, which allowed to reduce essentially the costs for
transportation of large-size parts and to decrease their cost.

Samples of production


Front and rear
energy absorbers

Molding machine for producing components,
made of foamed polypropylene


Manufacturing of plastic products

Painting line of plastic products

,
.
,
.
The equipment of Plastic Parts Painting Shop is made by Eisenmann company.
During production the painting robots are used in order to increase line productivity and improve quality of paint coating.

120 . .
Production capacity of Plastic Parts Painting Shop is up to 120 thsd. sets per year.


Reinforcement production

Brief description

:
Reinforcement production is relative to multi-plane production and consits of:
:

, ,
;

, ;

Reinforcement shop with sections:

cold heading of metalware;

producing components, made of polyurethane;

producing seats frames, tubes, fuel tank and

assembling of vehicle suspension ;

pattern cutting, fabrication and assembling seats;

spring winding;

electrodeposited coating;

dip painting and powder painting.

-
:

;
;
-;
.

Tool and bench shop with sections :

multispindle automatic machine;

singlespindle automatic machine;
forging shop;
thermal processing.


Reinforcement production

Reinforcement shop
, .
Production includes welding lone, milling and complete process beam assembly.
96 . . (2 )
Production capacity 96 thous. vehicles per year (2 shifts)

Welding line and processing of rear axle of suspension

/ welding post

/
Milling edges machine


Reinforcement production

Reinforcement shop

Samples of production


Reinforcement production

Section of producing components, made of polyurethane

- , , ,
,
Molding of elastic and integrated polyurethane - soft elements of seats, sofas, armchairs, armrests, handles and steering
wheels

(),

( , .)
.
Automatic line by Gallino (Italy) is designed for producing items
(internal cushion of seats, steering wheels etc.) of polyurethane by
injection molding into open casting method.

.
Molded parts are carried in automated storage
(conveyor type) for final polymerization of polyurethane.


Reinforcement production

Section of pattern cutting and fabrication of upholstery

:
40 Zinger, Durkopp, Adler.
Section equipped with modern cutting tool:
40 industrial sewing machines by Zinger, Durkopp, Adler.


Reinforcement production

Section of seats assembling

Finished components entered into section of final assembling of seats.


Reinforcement production

Electrodeposited coating

Samples of production


Reinforcement production

Powder painting line

Ideal-line ()
.
Installation of parts powder painting line made by Ideal-line company (Denmark) allowed to implement new
technology at CJSC ZAZ

. .
Powder painting with special polymeric paints ensures essential cost reduction of coating compared with traditional
materials. Beside, the protective features of the coating are improved.
Capacity of the line - 700 thsd. m2/year.
- 700 . 2/.
Max. dimensions of parts to be painted (L x W x H) :
:
1300 510 1200 mm.
( x x ) 1300 510 1200 .
Max. weight of parts to be painted 80 kg.
80 .


Instrumental production
-
JSC ZAZ-osnastka

( ; , , -
; ),

- .
Instrumental production consists of:

Three shops (cutting and additional tools production shop; fine and coarse die blocks and molding die shop; large-size die blocks
and inspection tools shop),

Forge-performing shop.
- 17242 2

Total area - 17242 m2


Instrumental production
-
JSC ZAZ-osnastka

:
542 , ,
, :

Equipment:
542 units of: general-purpose equipment, metal-cutting, presses and and special-purpose equipment is used:
:
- MAGERLE
- , - 4004001400;
- REFORM
- , - 2001600.

:
AGIEcut100, (250200300);
AGIEcut200, (250250400).
S 3/30, (340320420)
S 5/40, (600500600)

:
MECOF 240/,
(200010002000);
MECOF COPY200,
(200010005350) ( ,

D/ /)

Grinder group :
creepfeed grinding machines by MAGERLE for special-purpose
equipment producing; operating space - 4004001400;
machines for grinding Spline Shafts by REFORM for specialpurpose equipment producing; operating space - 2001600.

Spark-erosion group:
wiry AGIEcut100, operating space (250200300);
wiry AGIEcut200, operating space (250250400).
piercing S 3/30, operating space (340320420)
piercing S 5/40, operating space (600500600)

Milling group:
BED TYPE MILLING by MECOF 240/, operating space
(200010002000);
BED TYPE MILLING by MECOF COPY200, operating space
(200010005350) (it has 5 DOF which are used for high-precision
milling of difficult surfaces in system D/ /)


Instrumental production
-
JSC ZAZ-osnastka

Directions of activities
:

, 20 ;
, 10 ;

, .

Die block producing:

large-size, 20 tonne and above;

mid-size, up to 10 tonne;
special small-size
cutting-out stator parts, finishing cuttingout.


Instrumental production
-
JSC ZAZ-osnastka

;
- ;
;
-;
-

, .

Molding die production

aluminum and nonferrous casing;

for powder metallurgy;
injection casting;
molding die for industrial rubber
articles;
molding die for polystyrene
materials for building baffles;


Instrumental production
-
JSC ZAZ-osnastka

:
Work tool and instrument production:


Instrumental production
-
JSC ZAZ-osnastka


Foundry production

JSC Lityo
, , .
Production consists of: gray cast iron shop, pressure-die casting shop, pattern-shop

, . / Production
capacity, tone

, . /

15 000

0,3 - 5 000

415 420, /
cast iron 415 420, cast iron with increased strength

/ under
pressure

500

0,005 - 0,5

1 / zinc alloy

/ steel

400

/up to 1 000

/ Founding

/ cast iron

1) :

/ Material

Weight, kg

/ heat-resistant steel

/ Equipment:

3-5/;
-1,5;
-0,25;
-0,25.

2) :
20-1.
3) - :
. 91285,
. 348,
. -216

4) :
. 314
. 42322

5) :
71107
-18

6) :

1) Melting group:

cupola installation with 3-5 tone per hour productivity;

electric arc furnace DSP-1,5;
induction furnace IST-0,25 type;
smelting furnace DMK-0,25.

2) Shape-generating group:
molding machine 20-1 format

3) Core sand-shooter machines:

mod. 91285,
mod. 348,
mod. -216

4) Scrubbing group:
rattle barrel continuous-running mod.314
rotoblast barrel continuous-running mod. 42322

5) Pressure-die casting machines:

71107
automatic casting machine L-18

6) Equipment for pattern production:

wood-working and metal-working machinery


Foundry production

JSC Lityo

Samples of production

foundry goods for vehicles

technologic and die block foundry
foundry by order
metallic and wooden patterns
model-core tooling

Foundry goods

Foundry goods from nonferrous casing


Joint manufacture
-
JSC Bosal-ZAZ
()
.
,
,
.
Jointly with Bosal company CJSC ZAZ arranged the production of exhaust system components.
Modern process equipment ensures good quality welding of exhaust system components, lockseaming and cap spinning
of resonator and rear silencer seams, which allows to bring down power consuming welding operations to minimum.

( 8 40 )
Machine for bending and processing of pipes
( 8 40 ) with CNC


Joint manufacture
-
JSC Bosal-ZAZ

Samples of production


Joint manufacture
-
JV "Tavria-Magna"
- ,
, -
.
1988 :
- -
.
. .
2008 :
- ( ).
, - , , , ,
, , , , -
40 .

Tavria-Magna, Ukrainian and Canadian joint venture, is specialized enterprise that is located on ZAZ joint stock venture. It has been
created for projecting and producing large and very large moulds designed for manufacturing plastic parts for automotive industry and other
branches.
In 1988 Tavria-Magna has been created by AvtoZAZ, automotive plant and Magna International Inc., Canadian large industrial enterprise.
Since 2008 Tavria-Magna have been reorganized into JSC.
Tavria-Magna is specialized in projecting and manufacturing large and very large moulds for plastic and nonferrous alloy parts for automotive and
other industry branches in CIS countries, Canada, Germany, Israel, Italy, Switzerland, Hungary, Greece etc. Wide range of goods includes production from
mid-size molding die with weight from dozens of kilogramme to bumber systems with weight to 40 tonne.


Joint Production
-
JV Tavria-Magna
-
.
Main business activity of JV production manufacturing of moulds for any plastic under pressure.

-.
The enterprise owns texturing the mould surfaces technology.

300020001500 ., 40 .
Maximum dimensions of products are 3000 x 2000 x 1500 and weight can be up to 40 t.


Joint Production
-
JV Tavria-Magna

Examples of production

Storage battery

Rear lamp

Surfacing of gearbox

Mirror box

Steering wheel

Inside interior parts

Family of Tavria and Slavuta vehicles

Rear bumper

Airline box

Front bumper


Joint Production
-
JV Tavria-Magna

Family of GAZ vehicles

Rear review mirror

Instrument panel

Front bumper

Rear bumper

Bumper covers


Joint Production
-
JV Tavria-Magna

Chrysler Siber


Joint Production
-
JV Tavria-Magna

Family of VAZ vehicles

Rear review mirror

Front lamp

Inside interior parts

Rear lamp

Wheelarch liners

Wheel cap

Wheelarch liners


Joint Production
-
JV Tavria-Magna

Lada Kalina, Lada Priora

Family of Lada Kalina, Lada Priora vehicles


Joint Production
-
JV Tavria-Magna

Niva Chevrolet
Family of Niva Chevrolet vehicles

Spare wheel cap

Radiator grill

Outside mirror of rear review

Tooling of tires production

Sills of floor


Joint Production
-
JV Tavria-Magna

Filler

Lanos
Family of Lanos vehicles

Input airline panel

Handle of trunk

Instrument panel

Door cover

Wheelarch liners

Wheelarch liners

Front bumper

Wheel cap

Rear bumper


Joint Production
-
JV Tavria-Magna

LAYKA, HYMER
Interior of LAYKA, HYMER vehicles


Joint Production
-
JV Tavria-Magna

- Peugeot, Renault, Volkswagen

Moulds for Peugeot, Renault, Volkswagen

 ()
FSO GROUP (Poland)

Enterprise of group

/ Production

DPI ZCS POLAND

, ,
welding, punching, instrument cluster, switches

HANYANG ZAS

, , , ,

Middle and small moulded composition, baffle plate steering wheels, found parts of pressing box, painting

SHINCHANG ZPZP

, , ,
Door lock, switches, shifters, door handles

ZPP AUTO

, , , , , ,
Brackets, brake pulley, cable linkage, pedals sets, pressing, welding , painting

SUNGSAN ZEM

(, , ), ,
Lighting equipment, intrusion molding, metallized coating

ZEM

Wire harness

KORAM ZZM

(, , ), ,

Large plastics components (bumpers, instrument cluster, door lining), painting assembly work, Seats cushion

ZASET

, , , , ,

Clutch, small and middle pressed parts, welding, trimmings of a body, heat treating, electrochemical facing

DONGWON

Exhaust system

UN WHA POLAND

Safety belts

ZTS POLSKA

, , ,
Seats, small and middle press-work, welding, pipe bending

Promatics Sp.Zo o.o.

Raw materials for intrusion molding production

DPIZCS

DPI ZCS POLAND - CIECHANW

, , ,
Welding, small-sized press forming, instrumental panel production

instrument cluster

fuel tank

switch panel

DAEWOO Lanos

McPherson strut

McPherson strut

CHEVROLET Aveo

steel Press production

a fuel tank

HANYANG ZAS - ELBLG

Middle and small plastic components

outside mirror

steering wheel

/plastics elements of interior trim

()
inside handle

handle a trunk

DAEWOO Lanos

outside mirror

CHEVROLET Aveo

compartment door fuel filler

()
handle outside

plastics elements of interior trim

compartment door fuel

filler

SHINCHANG ZPZP - MARKI

DAEWOO Lanos

wipers and lamp switches

doors handless

locks, keys

mirror steering panel

10 %

ZPP AUTO - SIEDLCE

pedals sets

suspension arm

gear box steering

DAEWOO Lanos

rear axle
/
press and welding parts

window lifter
(automatic and manual)

impact beam

CHEVROLET Aveo

rear axle

30 %

SUNGSAN ZEM - EK

Lighting equipment

lighting of compartment and luggage space

rear stop lamp

DAEWOO Lanos

head lamp

ext. rear lamp

fog front lamp

turn signal lamp

ZEM - EK

ZEM Ek Sp. Z o.o.

Production of wiring harness

62 %

KORAM ZZM - WARSZAWA

Large plastics components

Toolbar

Bumpers

Door trim

DAEWOO Lanos

CHEVROLET Aveo

21 %

Bumpers

Instrumental panel

Door trim

Seats cushion

ZASET - KOUCHW

pressed part

Small and middle pressed parts

stiffener of a body

frame of toolbar

suspension of boot
compartment

bonnet latch

lock of boot
compartment

Suspension elements

box- type product

stiffener of a body

control element of parking brake

40 %

DONGWON - KOUCHW

Exhaust systems

Power door bracing

DAEWOO Lanos

Exhaust system
/front, /middle, /backward deafeners

Door frames

UN WHA POLAND - PUTUSK

seat belt

Safety belts

43 %

ZTS POLSKA - GRJEC

Seats

DAEWOO Lanos

head restraint lock

seat assembly

CHEVROLET Aveo

1%

seat assembly

 !
Thank you!