PDF Guide to engine and transmission plants in Europe

Guide to engine and transmission plants in Europe

September 6, 2004

Engine plants consolidate across Europe

WIM OUDE WEERNINK AUTOMOTIVE NEWS EUROPE

European automakers are consolidating their once-specialized powertrain plants, as reflected in Fiat Auto's decision this month to halt engine production at its headquarters plant in Mirafiori outside Turin.

The aging Fiat 1.6-liter Torque gasoline engine family will be replaced by the latest General Motors-based Ecotec engine. The engines are made at joint-venture Fiat-GM Powertrain plants in Bochum, Germany, and Szentgotthard, Hungary. Fiat will transfer its Torque engine production to Argentina, where emission standards are less strict.

Fiat's move illustrates that economies of scale play an increasing role in reorganizing European engine and transmission production. Labor unions and Fiat-GM Powertrain want to save jobs at Mirafiori. Fiat-GM Powertrain plans to boost transmission production at the site.

"High labor costs in western Europe are driving automakers to establish powertrain plants in eastern Europe," says Vik Barodia, head of global powertrain research at Global Insight in London.

"It is easier to shift a single activity from a west European production base to the east, preferably to a new dedicated plant," he says. "Closing an entire plant in the west is more difficult because of industrial relations."

Automakers typically see engines and transmissions as core manufacturing operations. So with a few transmission system exceptions, carmakers keep r&d and production of powertrains in-house. But most automakers operate separate locations to manufacture these key car systems, at varying distances from their main car assembly plants.

"Engines and transmissions remain a core activity for carmakers since these systems are essential for an individual car's character, together with car design," Barodia says.

Joint production

But in the future, automakers will increasingly use powertrain plants

for joint-production vehicle programs or as centers for specific engine

concepts, such as diesels.

(story continues next page)

IRELAND

5 8 12

7 7

ESTONIA

DENMARK

LATVIA

LITHUANIA 2

5 6 U. K. 1 21

1 21

4

NETH.

49

3

1

1

3

POLAND

FRANCE 1

BELGIUM

1 3

6

34

10 6 4

5

GERMANY

3 11

1

3 LUX.

2 13 3

8 233

361

4

4

1 8

2 5

SWITZERLAND 1

1

6

42 5

CZECH

SLOVAKIA

3

21

AUSTRIA

2

14

4 HUNGARY

SLOVENIA

16 1 ITALY

9

1

2 10

CROATIA

BOSNIA

BELARUS

UKRAINE MOLDOVA

ROMANIA 7

1 PORTUGAL

9 SPAIN

9

ANDORRA

15 4 72

15 12

10

YUGOSLAVIA

BULGARIA

MACEDONIA

ALBANIA GREECE

52 6

TURKEY

8

For example, later this year Toyota will start producing 250,000 1.0-liter gasoline engines and 300,000 transmissions annually in Walbrzych, Poland, to supply its joint-vehicle program with PSA/Peugeot-Citroen in Kolin, Czech Republic.

Mitsubishi and DaimlerChrysler started joint production of a gasoline engine earlier this year in K?lleda, Germany. The engine is used in both the Mitsubishi Colt and Smart ForFour.

BMW and PSA are working on a common program for small-capacity gasoline engines for their vehicles plus the next-generation Mini.

"But while PSA and BMW will contribute with production of specific engine components, it has not yet been decided how engine assembly will be arranged," says BMW spokesman Jochen M?ller.

Some powertrain joint ventures are decades old. Francaise de Mechanique, in Douvrin, France, is owned equally by PSA and Renault. Francaise de Mechanique even has had its own aluminum foundry to make engine blocks for 30 years. Most other engine producers source castings from specialist suppliers.

Volkswagen group benefits from modular engine concepts by producing a complete range of larger engines at its Salzgitter, Germany, plant and at its Audi plant in Gyor, Hungary. But some model-specific VW engines are produced at ? or near ? local assembly plants such as Seat's plant in Martorell, Spain, and Skoda's complex in Mlada Boleslav, Czech Republic.

Economies of scale

Older powertrain plants are gaining economies of scale from the combined corporate know-how and increased volume following recent mergers, reorganizations or new joint ventures.

Since forming their alliance in 2000, Fiat and GM have benefited from supplying each other with engines and transmissions.

"While Fiat has benefited from GM Europe's experience with gasoline engines, Opel, Vauxhall and Saab enjoyed Fiat's know-how of direct injection diesel engines, which makes Fiat GM Powertrain so beneficial for all parties," a GME spokesman says.

Fiat-GM Powertrain is a separate company, and supplies systems to GM affiliates around the world.

Because of the merging of all GM and Fiat engine and transmission plants in Europe into Fiat-GM Powertrain, both carmakers can source engines and transmissions from 16 different plants, the highest number of any carmaker in Europe. But Fiat-GM thinks there is no overcapacity.

"We currently need all capacity in our engine and transmission plants," says Johanna Lomp-Knetsche, spokeswoman at Opel Powertrain in R?sselsheim, Germany. Opel Powertrain is a division of Fiat-GM Powertrain, which supplies GM-designed and produced engines and transmissions to Fiat and Opel/Vauxhall.

Centralizing powertrain production sometimes increases shipping distances and can complicate logistics. But the economies of scale ? higher production volume and shared development costs ? make up for the disadvantages, the GM spokesman said.

PSA has stepped up its engine production in Tremey, France, because of its joint venture with Ford on diesel engines.

Powertrain plants are typically separate legal entities from parent automakers or auto groups because this independence permits them to supply to other automakers outside the group.

For example, Francaise de Mechanique, the Renault/PSA joint venture, also makes diesel engines for Suzuki and Ford (with which partner PSA also has a joint venture for small-capacity diesel engines).

But investments in specific powertrain plants are substantially higher than for simple assembly plants. More tooling is needed to produce engines and transmissions.

In addition, powertrain systems, especially engines, have higher r&d costs and longer lifecycles than the vehicles that use them.

BMW GROUP 11 Hams Hall, UK ? (engine) ? 1.6-liter 4-cylinder gasoline engines, 1.8 4-cylinder

gasoline engines, 2.0-liter 4-cylinder gasoline engines 22 Munich, Germany ? (engine) ? 6-, 8- and 12-cylinder gasoline engines, high-

performance engines for BMW cars, 8-cylinder diesel engines, 12-cylinder diesel engines 33 Steyr, Austria ? (engine) ? 4- and 6-cylinder diesel and 6-cylinder gasoline engines

DAIMLERCHRYSLER 11 Berlin-Marienfelde, Germany ? (engine) ? 12-cylinder gasoline engines, 8-cylinder

diesel engines (Mercedes-Benz); gasoline and diesel engines (Smart) 22 Mannheim, Germany ? (engine) ? commercial vehicle engines 33 Rastatt, Germany ? (transmission) ? passenger cars transmissions 44 Stuttgart Untert?rkheim, Germany ? (engine) ? engines (Mercedes-Benz) 44 Stuttgart Untert?rkheim, Germany ? (transmission) ? transmissions (Mercedes-Benz) 55 Barcelona, Spain ? (transmission) ? (Mercedes-Benz V class, Vito and Viano) 66 Gaggenau, Germany ? (transmission)

FIAT-GM POWERTRAIN 11 Arese, Italy ? (engine) ? 2.5-, 3.0- and 3.2-liter V-6 gasoline engines (Alfa Romeo

156, 166, GTV, Spider, GT and Lancia Thesis) 22 Aspern, Austria ? (engine) ? 3- and 4-cylinder, 1.0- , 1.2- and 1.4-liter gasoline

engines (Opel/Vauxhall) 22 Aspern, Austria ? (transmission) ? manual and AMT 5-speed transmissions; manual

6-speed transmissions 33 Bielsko, Poland ? (engine) ? SDE 1.3-liter common-rail diesel engines (Fiat, Lancia,

Opel-Vauxhall mini and supermini cars) 44 Bochum, Germany ? (engine) ? 1.4-, 1.6-, 1.8-liter 4-cylinder gasoline ECOTEC

engines (Opel/Vauxhall) 44 Bochum, Germany ? (transmission) ? manual and AMT transmissions 55 Bursa, Turkey ? (transmission) ? 5-speed manual transmissions 66 Ellesmere Port, UK* ? (engine) ? 3.0-liter V-6 gasoline engines (Saturn L series, Saab

9-5), 3.2-liter V-6 gasoline engines (Cadillac CTS, Opel/Vauxhall Vectra Signum and Vectra Wagon, Saab) 77 Gothenburg, Sweden ? (transmission) ? 5-speed manual transmissions 88 Kaiserlautern, Germany ? (engine) ? 2.2 normal asp/2.0-liter I-4 supercharged gasoline engines (Saturn Ion Red Line), 2.2-liter I-4 gasoline engines (Chevrolet

Cavalier, Malibu and Malibu Classic; Oldsmobile Alero; Pontiac Grand Am and

Sunfire; Saturn L series, Ion and Vue; Opel /Vauxhall; Saab), 2.0- and 2.2-liter direct

injection diesel engines (Opel/Vauxhal and Saab)

99 Mirafiori, Italy** ? (engine) ? 1.6-liter gasoline torque engines (Fiat and Lancia)

99 Mirafiori, Italy ? (transmission) ? C514: 5- and 6-speed manual transmissions;

5-speed MTA

100 Pratola Serra, Italy ? (engine) ? 4- and 5-cylinder: 1.6-, 1.8-, 2.0- and 2.4-liter

gasoline engines; 1.9- and 2.4-liter diesel engines (Alfa Romeo, Fiat and Lancia)

111 R?sselsheim, Germany ? (transmission) ? 6-speed manual transmissions

122 Sodertalje, Sweden ? (engine) ? 2.0- and 2.3-liter 4-cylinder gasoline engines

(Saab), L850: 2.0 turbocharged gasoline engines (Saab)

133 Strasbourg, France ? (transmission) ? automatic transmissions

1144 Szentgotthard, Hungary ? (engine) ? 1.4-,1.6- and 1.8-liter 4-cylinder gasoline

ECOTEC engines (Opel/Vauxhall)

144 Szentgotthard, Hungary ? (transmission) ? CVT and Allison transmissions

1155 Termoli, Italy ? (engine) ? 1.1-, 1.2- and 1.4-liter FIRE gasoline engines (Fiat Punto,

Seicento, new Panda, Idea, Stilo, Doblo; Lancia Ypsilon)

15 Termoli, Italy ? (transmission) ? C510 5-speed manual and AMT transmissions;

C513 5-speed manual transmissions

16 Verrone, Italy ? (transmission) ? C530 5- and 6-speed manual and AMT

transmissions

FIAT GROUP

1 Foggia, Italy ? (engine) ? engines (Fiat and Iveco)

22 Maranello, Italy ? (engine) ? engines (Ferrari and Maserati)

FORD MOTOR CO.

11 Blanquefort, France ? (transmission) ? RWD hydraulic automatic transmissions (Ford

Transit), RWD electronic automatic transmissions (Ford Ranger, Explorer), RWD

electronic automatic transmissions (Ford Ranger)

22 Bridgend, South Wales, UK ? (engine) ? 1.4-liter 4-cylinder gasoline Zetec engines,

1.6-liter 4-cylinder gasoline Zetec engines, 1.8-liter 4-cylinder gasoline Zetec engines

(Ford Focus and Mondeo), 2.0-liter 4-cylinder gasoline Zetec engines (Ford Focus),

1.6-liter, 4-cylinder gasoline Zetec-SE engines (Ford Focus and Fiesta Sport), 3.2-liter

V-8 gasoline engines (Jaguar XJ8), 4.0-liter V-8 gasoline enignes (Jaguar XJ8, XK8

and S-type)

33 Cologne, Germany ? (engine) ? 4.0-liter V-6 gasoline SOHC engines (Ford Aerostar,

Explorer, Mondeo and Ranger)

33 Cologne, Germany ? (transmission) ? MTX-75 transmissions (Ford Focus, Mondeo, Transit Connect, Toumeo Connnect; Jaguar X-type), VXT-75 transmissions (Ford Galaxy and Transit)

44 Dagenham, Essex, UK ? (engine) ? 1.8-liter 4-cylinder IDI ? (Ford Ikon, pickup), 1.8-liter 4-cylinder TDCi and 1.8-liter TDDi (Focus Transit Connect), 2.0-liter 4-cylinder TDDi ? (Ford Transit, Mondeo), 2.0-liter 4-cylinder TDCi ? (Ford Mondeo, Transit; Jaguar X-type), 2.4-liter 4-cylinder TDCi and TDDi ? (Ford Transit), 2.0-liter 4-cylinder Gas DOHC engines ? (Ford Galaxy), 2.3-liter 4-cylinder Gas DOHC engines- (Ford Galaxy, Transit), 2.7-liter V6 Diesel ? (Jaguar S-type)

55 Halewood, Liverpool, UK ? (engine) ? transmissions (Ford Transit and LDV), transaxles (Ford Escort, Fiesta and Ka)

66 In?nu, Turkey ? (Ford Otosan Engine ? Ford 41%, Koc Holding 41%, Public 18%) ? (engine) ? 6.0-liter 6-cylinder gasoline engines (Ford Cargo), 6.2-liter 6-cylinder gasoline engines (Ford Cargo), 2.5-liter 4-cylinder DI diesel engines (Ford Transit Duratorq)

66 Inonu, Turkey ? (Ford Otosan Engine ? Ford 41%, Koc Holding 41%, Public 18%) ? (transmission) ? 5-speed transmissions (Ford Transit)

77 Skovde, Sweden ? (engine) ? 4-, 5- and 6-cylinder inline engines (Volvo) 88 Koping, Sweden ? (transmission) ? (Volvo) 99 Valencia, Spain ? 1.8 and 2.2 Duratec HE gasoline engines (Ford Focus, C-Max,

Mondeo) GETRAG

11 Ludwigsburg, Germany ? (transmission) ? manual transmissions (BMW, DaimlerChrysler, Ford, Jaguar, Mitsubishi, Mini and Smart); gear sets (Audi, GM and Porsche)

22 Modugno, Italy ? (transmission) ? manual transmissions (Fiat, GM, Land Rover, MG Rover, Opel and Saturn)

33 Neuenstein, Germany ? (transmission) ? manual transmissions (Audi, BMW, General Motors, Nissan, Porsche, Skoda, Toyota and Volkswagen); automated manual transmissions (BMW and Smart)

44 Rosenberg, Germany ? (transmission) ? manual transmissions (BMW and DaimlerChrysler)

55 Koping, Sweden ? (transmission) ? manual transmissions (Volvo and Ford)

GETRAG FORD

11 Blanquefort, France ? (Bordeaux plant) ? (transmission) ? manual transmissions for

Ford and MG Rover

22 Halewood, Liverpool, UK ? (transmission) ? manual transmissions (Ford Fiesta,

Fusion, Focus, Ka and Transit)

33 Cologne, Germany ? (transmission) ? manual transmissions (Ford Escort, Focus,

Galaxy, Mondeo and Transit; Jaguar X-type)

HONDA

11 Swindon, UK ? (engine) ? gasoline engines (Honda Accord, Civic and CR-V)

ISUZU

11 Polska, Poland ? GM and Isuzu joint venture ? (engine) ? 1.7-liter 4-cylinder direct

injection diesel engines (Opel Astra and Corsa), 1.7-liter 4-cylinder DOHC diesel

engines (Honda Civic)

LOMBARDINI S.R.L.

11 Reggio Emilia, Italy ? (engine) ? 1-cylinder liquid cooled diesel engines, 2-, 3-, 4-

cylinder liquid cooled diesel engines, 3-, 4-cylinder liquid cooled diesel engines;

1-cylinder air-cooled gasoline engines; 2-cylinder liquid-cooled gasoline engines

MDC POWER

11 K?lleda, Germany (engine) ? (Mitsubishi 50%, DaimlerChrysler 50%) ? 1.1-, 1.3- and

1.5-liter 3- and 4-cylinder gasoline engine (Smart Forfour and Mitsubishi Colt)

NISSAN

11 Barcelona, Spain ? (engine) ? 2.2-liter 4-cylinder turbodiesel, 2.2-liter 4-cylinder

turbodiesel, 1.8-liter 4-cylinder gasoline (Almera Tino)

22 Sunderland, UK ? (engine) ? 1.5-liter 4-cylinder gasoline; 1.8-liter 4-cylinder gasoline;

2.2-liter 4-cylinder diesel; 2.2-liter 4-cylinder diesel (Almera); 1.0, 1.2, 1.4-liter

4-cylinder; 1.5-liter 4-cylinder turbodiesel DCI (Micra); 1.6, 1.8, 2.0-liter 4-cylinder;

1.9, 2.2--liter 4-cylinder turbodiesel (Primera)

PORSCHE

11 Zuffenhausen, Germany ? (engine) ? V-8 (Cayenne), V-10 (Carrera GT), Flat 6

(Boxster, 911)

POWERTRAIN LTD

11 Longbridge, UK ? (engine) ? gasoline and diesel engines (MG Rover, Land Rover,

Caterham, Lotus and others)

11 Longbridge, UK ? (transmission) ? (MG Rover and others)

PSA

11 Douvrin, France ? (Fran?aise de Mecanique ? PSA 50%, Renault 50%) ? (engine) ?

engines (PSA Peugeot/Citroen, Ford and Renault)

22 Metz, France ? (transmission) ? (Peugeot and Citroen) 33 Tremery, France ? (engine) ? 4-cylinder gasoline and diesel

engines, HDI diesel engines, 16-valve gasoline engines, HDI 1.4-liter diesel engines (PSA/Peugoet-Citroen and Ford) 44 Valenciennes, France ? (transmission) ? Automatic and manual transmissions (Peugeot, Citroen and Fiat)

RENAULT 11 Cacia, Portugal ? (transmission) ? 5-speed manual transmissions (Clio, Kangoo,

Laguna, Megane, Scenic, Twingo), 6-speed manual transmissions (Megane) 22 Bursa, Turkey ? (engine) ? 1.4-liter 4-cylinder gasoline engines, (Clio, Kangoo,

Megane I and II); 1.6-liter 4-cylinder gasoline engines (Clio, Kangoo, Laguna, Megane I and II, Scenic) 22 Bursa, Turkey ? (transmission) ? 5-speed manual transmissions (Clio, Kangoo, Megane, Scenic, Twingo) 33 Choisey, France ? (engine) ? Mahindra engines (based on Renault's 2.0-liter 4-cylinder gasoline engine) 44 Cleon, France ? (engine) ? 1.8-liter 4-cylinder gasoline engines F4P (Megane I and II, Laguna), 2.0-liter 4-cylinder gasoline engines (Megane I and II, Scenic, Laguna), 1.9-liter 4-cylinder turbodiesel engines (Clio, Espace IV, Laguna, Master, Megane I and II, Scenic, Traffic), 2.2-liter diesel engines (Avantime, Espace IV, Laguna, Master, Vel Ssatis), 2.2-liter diesel engines (Master) 55 Ruitz, France ? (Societe de Transmission Automatique, Renault 80%, PSA 20%) ? (transmission) ? Automatic transmissions 66 Douvrin, France ? (Fran?aise de Mecanique ? PSA 50%, Renault 50%) ? (engine) ? engines (Citroen, Peugeot and Renault) 77 Pitesti, Romania ? (engine) ? 1.4-liter 4-cylinder engines, 1.9-liter 4-cylinder engines (Dacia) 77 Pitesti, Romania ? (transmission) ? NG and JH transmissions (Dacia) 88 Seville, Spain ? (transmission) ? 5-speed manual transmissions (Clio, Kangoo, Megane, Scenic, Twingo), JH automatic and manual transmissions 99 Valladolid, Spain ? (engine) ? 1.4-liter 4-cylinder gasoline engines (Clio, Megane I and II, Scenic), 1.6-liter 4-cylinder gasoline engines (Clio, Kangoo, Laguna, Megane I and II, Scenic), 1.5-liter 4-cylinder diesel engines 101 Viry-Chatillon, France ? (engine) ? Formula 1 naturally aspirated 3.0-liter V-10 engines

TOYOTA

11 Deeside, North Wales, UK ? (engine) ? 1.4-, 1.6- and 1.8-liter gasoline engines,

2.0-liter diesel engines (Toyota Avensis, Corolla)

22 Jelcz-Laskowice, Poland ? (engine) ? 2.0-liter diesel engines (production to begin in 2005)

33 Valenciennes, France ? (engine) ? 1.0- and 1.3-liter gasoline engines, 1.4-liter diesel engines (Toyota Yaris)

44 Walbrzych, Poland ? (engine) ? 1.0-liter gasoline engines

44 Walbrzych, Poland ? (transmission) ? manual transmissions VOLKSWAGEN

11 Bratislava, Slovakia ? (transmission)

22 Gyor, Hungary ? (engine)

33 Kassel, Germany ? (transmission)

44 Martorell, Spain ? (engine) ? (Seat)

55 Mlada Boleslav, Czech Republic ? (engine) ? (Skoda)

55 Mlada Boleslav, Czech Republic ? (transmission) ? (Skoda)

6 Polkowice, Poland ? (engine) ? diesel engines

7 Prat, Spain ? (transmission) ? (Seat)

8 Sachsen, Germany ? (Chemnitz factory) ? (engine) ? 3- and 4-cylinder gasoline engines

99 Salzgitter, Germany ? (engine) ? gasoline and diesel engines

100 Sant'Agata Bolognese, Italy ? (engine) ? 5.0-liter V-10 gasoline engines

(Lamborghini Gallardo), 6.2-liter V-12 gasoline engines (Lamborghini Murcielago)

ZF FRIEDRICHSHAFEN

11 Bouth?on, France ? (transmission) ? manual and automatic transmissions

(commercial vehicles)

22 Barcelona, Spain ? (transmission) ? manual and automatic transmissions

(commercial vehicles)

33 Brandenburg, Germany ? (transmission) ? manual, automatic and CVT transmissions

(passenger cars)

44 Eger, Hungary ? (transmission) ? manual and automatic transmissions (commercial vehicles)

55 Friedrichshafen, Germany ? (transmission) ? automatic and manual transmissions

(commercial vehicles)

66 Sint-Truiden, Belgium ? (transmission) ? manual, automatic and CVT transmissions

(passenger cars)

*Production stopped in July **Production stopped in September

Source: Automotive News Europe

 ................
................

In order to avoid copyright disputes, this page is only a partial summary.

Google Online Preview   Download