Zaporizhia Automobile Building Plant

CJSC «ZAZ» is the sole enterprise in Ukraine having full-scale cycle of passenger cars production, including stamping, welding, painting, body trim and car assembly. New modern high-technology production process, meeting requirements of International Standard ISO 9001:2000, has been created and is constantly improved at the plant. ZAZ makes considerable contribution to the development of national economy

Official site: http://www.avtozaz.com/

 

Dynamics of ZAZ development, which priorities include constant striving for improvement of own products, activities on implementation of new ideas and widening of car models range, shows the progress in creation of national car.

 

QUALITY MANAGEMENT SYSTEM AND POLICY

In general the Quality policy of the company is aimed at meeting customer demands and expectations, as well as improvement of quality management system. Production corresponds to the requirements of the International Standard ISO 9001:2000 and the requirements set forth by the partners of JSC "ZAZ", it:

 

ensures manufacturing of high quality products and their continuous improvements;
increases the customers' satisfaction;
determines functions, authorities and responsibility of all personnel, improves the interaction and mutual understanding among the personnel;
increases efficiency of taken decisions;
continuously improves the processes of engineering, production, control and management;
increases efficiency of company's operation in whole through the methods of prevention that prevail over the methods of eliminating defects;
increases the competitiveness and profitability of the company.

 

 

 

WELDING PRODUCTION

Automation of production, which has practically fully excluded the manpower, especially at the stage of body welding, increased the speed and improved the quality of performed operations. Body welding is carried out on the lines furnished with unique equipment, having no analogs in Ukraine. The operations are performed by robot-technological systems.
22

Maximum mechanization and automation of welding production enables, with low labor costs, not only to ensure the quality in compliance with the most strict requirements, but also to control it with modern diagnostic facilities.
Welding production comprises flexible automatic lines "FANUC", "СОМАU", "КUKA" and control systems "Texas-500", "Alen-Bredley", "Simatik-110".

The quality level of welded bodies is evaluated in body measuring laboratory, using modern equipment which corresponds to the world standards. Coordinate measuring machine PRO Compact, which is installed in the laboratory, is multifunction; it performs measuring functions, scans the surfaces and, using the software, transforms them into three-dimensional image surfaces. The quality of welded joints is controlled by tear-down and non-destructive methods. The quality of outer surface and compliance of gaps of the closure parts is controlled on 100% of manufactured bodies.

Production capacity makes up 22 bodies per hour.

PAINTING PRODUCTION

Painting process consists of two constituents: body painting anf plastic parts painting.
Before delivering the parts to painting booths, they pass degreasing, washing, blowing and drying in the surface pretreatment machine. After gas-flame treatment and blowing with ionized air, the parts are delivered to priming and painting booths. All processes are carried out by means of robots.

Body surface pretreatment at the stage of degreasing and phosphating is carried out by the method of sinking into cataphoresis tank and spraying, using the phosphating and cathodic electrophoresis. Using painting materials, manufactured by BASF and KCC companies, and modern painting technology provide the warranty against rust-through corrosion of the body for 10 years.

11

After sealers' application stage there is tricyclic painting process. Spraying gun head of each "SAMES" robot is turning with the speed of 30 thousand revolutions per minute, painting of one body takes 1 minute and 25 seconds.
The lines ensure using both "pastel" and "metallic" paints. Painting shop is equipped with nine modern robots, five of them are intended for application of paint, four - for application of clear coat. Capacity of Painting shop - conveyer with a speed of 3.75 m/min, where the bodies are painted in 12 colors: 8 - metallic, 4 - pastel.
New robotized equipment can be easily reprogrammed, performing the painting fast and with high quality. Two automatic lines with the total conveyer length of 4 100 m are operating in production.

Painting conveyers ensure the capacity of 32 bodies per hour.

ASSEMBLY PRODUCTION

The production is arranged by the principle of running lines, using the system of overhead and slat floor conveyers. “Lanos”, “Slavuta” and “ZAZ Pick-Up” cars are assembled simultaneously with the rate of 32 cars per hour.

New conveyer line and equipment, being used for assembly, are universal ones, that allows to adapt easily the shop for assembly of new car models.

Zaporizhia Automobile Building Plant manufactures 5 models of passenger cars under ZAZ brand by fullscale production method.

ASSEMBLY PRODUCTION

The production is arranged by the principle of running lines, using the system of overhead and slat floor conveyers. 44

The production is arranged by the principle of running lines, using the system of overhead and slat floor conveyers.

“Lanos”, “Slavuta” and “ZAZ Pick-Up” cars are assembled simultaneously with the rate of 32 cars per hour.

New conveyer line and equipment, being used for assembly, are universal ones, that allows to adapt easily the shop for assembly of new car models.

Zaporizhia Automobile Building Plant manufactures 5 models of passenger cars under ZAZ brand by fullscale production method.

TESTING

Characteristics of the car are checked at roller bench, brake test bench, wheel alignment and headlamp adjustment benches, installed in the Assembly Shop.
The test track consists of different types of pavement - speed bumps, plates for checking asymmetric loads, ropes for checking symmetric loads and different kinds of road pavement. Test experts check the car for compliance with noise, vibration and rigidity requirements, perform additional visual inspection of all parts and units of test car on a ramp with uphill/downhill sections.
Each car passes final treatment, which includes the following operations:

 

washing after driving test;
leak-proofness inspection;
elimination of defects found after driving test;
inspection of outer surfaces;
installation of extra options.

 

LOGISTICS

After the tests and final treatment the batch of cars is delivered to the stockyard for finished cars, to car logistics department. The stockyard capacity is more than 1300 new cars, which are every day ready for shipment to the sales network of Ukraine and abroad.

Streamlined ZAZ's logistics system is being developed constantly, ensuring on-the-fly efficiency and quality of works related both to just-in-time deliveries of component parts to the plant's conveyers and timely deliveries of finished cars to sales network upon a request of its future owner. Logistics Center (area: 12 thsd.m²), located at the plant's territory, operates uninterruptedly, allowing to receive hundred thousands of cargoes, being necessary for the production process, and to conduct their efficient handling and delivery to any point of designation at the production lines. Nowadays logistics system also includes two yards for storage and shipment of finished products with the total area of 51,289 m², where more than 1,300 new cars ready for everyday dispatch to wherever you want in Ukraine can be stored.

JSC "ZAZ" is actively implementing the export policy, strengthening the achieved positions on the export markets and developing the new directions. The company exports the cars, KD kits and components to Russia, Kazakhstan, Azerbaijan, Georgia, Armenia, Belarus, Syria, Jordan, Iraq and Egypt.

UkrAVTO Corporation    Presentation


UkrAVTO in your city