Opel Quality offensive in full swing

• All-time high: Launch quality improved by 25 per cent in just one year
• Ambitious goal: Number 1 in quality among volume automakers
• Analysis results: New methods introduced to prevent faults
• Currently: Top scores for Opel models in ADAC breakdown statistics and TÜV Report

Opel Corsa 

Opel quality for passenger cars and light commercial vehicles (LCV) is at an all-time high. Within the past twelve months, for example, launch quality of new cars has been increased by 25 per cent. This value results from the manufacturer's internally defined production standards as well as from customer feedback within the first year after purchase. Most recently launched Opel Corsa and Opel Mokka models demonstrate first-class production quality right from the start – regardless of whether they are efficient combustion engines or battery-electric vehicles.

Opel Corsa-e

There are good reasons for this quality improvement: Opel has set itself the goal of zero faults. To achieve this, the Rüsselsheim automaker has also introduced new analysis methods that have a predictive effect in production. Such forecasting systems recognise when parameters change in such a way that they could lead to possible errors in production and intervene preventively. Result: no faulty parts are produced in the first place, production continues undisturbed, and quality is consistently high.

Opel Mokka GS Line

“At Opel and throughout Stellantis Group, we have set ourselves ambitious quality targets. We want to become the number 1 among volume manufacturers. Everywhere where faults are eliminated, we increase quality, increase customer satisfaction and at the same time also reduce our costs,” says Opel CEO.

Opel Mokka-e

At the German sites in Rüsselsheim and Eisenach, the switch to the latest Group's platform has also led to further improvements. Uniform platform strategy and the reduction of unnecessary complexity are important factors for the high quality and reliability of the vehicles. At Opel's headquarters, series production of the all-new Astra generation has just begun. Here, the five-door Opel Astra and soon also Opel Astra Sports Tourer estate will roll off the production line with German precision. 

All-New Opel Astra: Assembly in Rüsselsheim 

All versions of the Opel Grandland are manufactured in Eisenach to the highest quality standards. This is also confirmed by the latest TÜV report, in which Opel's SUV flagship was ranked an excellent 11th overall out of all 128 models inspected. In addition, according to the 2022 ADAC breakdown statistics, Opel models in various market segments, from Grandland and Crossland to ADAM, stand out as reliable used cars.

All versions of the Opel Grandland are manufactured in Eisenach

Opel engineers are also focused on further improving long-term quality. To this end, cooperation with suppliers has been intensified. Engineers speak of “robustness” here when defining running times and standards for parts and components. In addition to the well-known customer satisfaction studies, the quality guardians from Rüsselsheim also evaluate reviews and suggestions in forums and other social media channels. Furthermore, Opel dealers are involved as early as possible to learn from them, from the customer's point of view, where further improvements are possible. All feedback is taken seriously and seen as an opportunity to improve quality.

TÜV Report 2021: Opel Insignia and Opel ADAM are best in class

• Opel Insignia flagship takes strong second place overall
• Opel claims two of six possible class victories for cars between two and three years old
• Results from 8.8 million major inspections

Opel Insignia 

Opel ADAM and the flagship Insignia have fewer errors than other cars in their classes. As last year, in the new TÜV Report the Opel ADAM continues to dominate the segment for mini cars aged two to three years, with an average significant error rating of only 3.7 per cent. TÜV has even fewer concerns with Opel’s flagship. Opel Insignia is not only at the top of its class, it also takes the silver medal in the overall classification. With a rating of 2.2 percent, Opel Insignia is only just behind the Mercedes GLC (1.7 percent).

Opel ADAM

“With the Opel Insignia, we are pleased to see that a midsize model from a volume manufacturer has made it to the podium”, said Joachim Bühler, Managing Director of the TÜV Association.

Opel Insignia ST

“The new TÜV Report is confirmation of our high level of quality, from flagship to small cars”, said Andreas Marx, the head of Opel in Germany. “Of course, we always aim to increase customer satisfaction in all areas. Our decades-old advertising claim – Opel the reliable – applies to our cars more than ever.”

 Opel Insignia GSi

When it comes to the technical condition of vehicles in Germany, the TÜV Report has been a reliable source since 1972. The strengths and weaknesses of individual cars are listed in classes according to their age. Around 8.8 million major inspections were analysed for the TÜV Report 2021. Two hundred and twenty-eight different models were inspected between July 2019 and June 2020.

Opel Insignia GSi ST

Opel Corsa-e Rally: Safety First !

• Opel and DMSB develop new safety concept for the ADAC Opel e-Rally Cup
• Pioneer in the development of safety standards for electric rally cars
• Concept includes the use of vehicles as well as training of teams and rally marshals

 Opel e-Rally

As the first car manufacturer worldwide, Opel is currently developing a fully electric rally car for use in a national championship. One of the key areas of focus of the ADAC Opel e-Rally Cup is safety. The development of the Corsa-e Rally is a trailblazing achievement. As no one has ever held an electric rally one-make cup before, the corresponding rules and regulations must be developed in parallel with the competition car. Opel and the ADAC, as the series operator, are working closely together with the Deutscher Motor Sport Bund – DMSB (German Motor Sport Federation) in this process.

“Safety always comes first at Opel,” emphasises Opel Managing Director Engineering Marcus Lott. “On the one hand, our engineers strive for the greatest possible driving dynamics and driving fun for our customers – on the road as well as on the rally stages. On the other hand, total focus is on operational safety. So also in this respect, customers, organisers and fans can rely on us in the ADAC Opel e-Rally Cup. We are all looking forward to exciting and safe rallies in the coming season.”

Opel Corsa-e Rally is based on the production model. This makes the Opel Motorsport engineers’ challenging work much easier. After all, the Corsa-e already meets the very high European standards for approval of type-approved vehicles. Additional racing-specific regulations stipulated by the FIA and the DMSB serve to further improve safety.

In the underbody of the Opel Corsa-e Rally, high-strength steel protects the 18 battery modules, which in turn are installed in a battery casing. In addition, the car has a two-piece protective plate made of five-millimetre thick aluminium.

Furthermore the Corsa-e Rally, like its series production counterpart, complies with regulation UN ECE R100.02. This defines the conditions for the approval of vehicles with regard to the special requirements for the electric powertrain of road vehicles and their batteries. This includes, for example, the minimum insulation resistance of high-voltage components and lines as well as fire protection. The drive batteries (REESS, Rechargeable Energy Storage Systems) must also fully comply with this regulation in terms of mechanical integrity, vibration, thermal shock, mechanical impact, fire resistance, overcharge protection, over-discharge protection, over-heating protection and external short circuit protection.

Fire extinguishing system required is Lifeline Zero 360. It works with an electrically insulating extinguishing agent, whereby the fire risk in an electrically powered car with no fuel on board is generally much lower than in a conventional vehicle with a combustion engine.

Meticulous monitoring of the high-voltage system

Permanent monitoring of the high-voltage system is also important for the safe operation of an electric rally car. Different faults call for different measures. In the event of an insulation fault, a sophisticated sensor system ensures that the displays of the Master Alarm Indicator System immediately report a fault in the HV system, which is operated at up to 434 volts. System can then be switched off manually inside and outside the cockpit. Irrespective of this, the HV system is completely switched off within less than one second in the event of a severe delay, such as an accident. Master Alarm Indicator constantly provides information on the current status of the high-voltage system by means of light signals.

Comprehensive training for safety personnel

Deutscher Motor Sport Bund is responsible for ensuring that the strict safety regulations can be adhered to at all times during an event. On the one hand, this concerns the technical specification of the car, the key data of which are regulated in Appendix J of the International Sporting Code. However, since these formulations are very comprehensive and highly specific, the DMSB is currently developing a safety concept in cooperation with Opel and TÜV Thuringia that meets the needs of both experts and users in practice.

One of the most important tasks for the DMSB is the training of the rally marshals, from the marshals on the special stages to the Service Park personnel. For all persons who have to perform certain tasks on or with an electric competition car, different safety certifications are required, which are categorized according to the colours blue-green-yellow-orange-red. Only those who are certified in the red category are allowed to carry out work on the high-voltage system of the Opel Corsa-e Rally or any other electric rally car.

Newly developed safety concept for the ADAC Opel e-Rally Cup covers all relevant areas for the use of electric rally vehicles. It encompasses the technical specifications, the training of teams and rally marshals as well as information for spectators on the special stages and in the Service Park.

“DMSB is responsible for careful monitoring of compliance with technical and sporting regulations, which include safety guidelines,” says DMSB Sports Director Michael Günther. “Our task is to develop a concept for electrically powered rallying in order to guarantee the safety of all participants and to make exciting rallying possible. In the first step, this also includes identification and elimination of possible knowledge gaps among all participants.”

!NEW! Germany’s Best: Opel Meriva MPV Wins TÜV Gold Certificate

• TÜV general inspections prove: No other passenger car has fewer defects
• Good results: Opel Astra, Agila and Insignia also convince TÜV inspectors

Opel Meriva MPV

This Opel means a lot of space and very few defects. When Meriva drivers take their Opel to a TÜV (German Technical Inspection Agency) general inspection, then they can count on their car. No doubt about it. Because the Meriva will pass the inspection with flying colors. This is confirmed in the new TÜV Report 2014, which also announces that its experts have named the Opel Meriva MPV the car with the lowest defect rate (‘defects dwarf’) and awarded it the TÜV Gold Certificate.

Opel Meriva MPV - FlexDoors

With publication of the TÜV Report in tomorrow’s Auto Bild, the trade magazine applauds, “Opel is back. And how ! The Hessians have a real winner with the Meriva MPV.”

With a mini defect rate of 4.2 percent, the compact van is winner in the two to three-year-old cars category, beating strong rivals from Mazda (4.6 percent), Toyota (4.8), Porsche (5.2) and BMW (5.5) tied with Audi (places two to five). This excellent result is not achieved by any other vehicle in the entire TÜV Report and gives the Meriva the overall victory among all inspected passenger cars in Germany.

“The Meriva is a typical Opel. With its extremely flexible and ergonomically perfectly designed interior, it is a real winner. This year it already won in its class in the J.D. Power Customer Satisfaction Survey, and now it adds the TÜV Gold Certificate to its accolades. Our well-known slogan ‘Opel the Reliable’ is once again right on the mark here,” says Thomas Simon, Vice President Quality at Opel, adding, “In January our new Meriva will be available with the economical whisper diesel engine, modern infotainment and lots of chic chrome. Our small van is going to make sure we have many happy and satisfied customers.”

In addition to the Meriva, three more Opel models were named “defects dwarf” and made it into the top 50 of the two and three-year-old cars category: Astra, Agila and Insignia all landed in the top sector of the TÜV evaluation.

Opel Astra five-door hatchback

Ranked 16, the Opel Astra even came in seven places ahead of its arch-rival, the VW Golf (23).

TÜV inspected a total of nearly eight million vehicles within one year.

Opel Zaragoza plant celebrates 30 Years and 11 million cars

• Anniversary ceremony held at the plant
• Plant currently makes popular Opel Corsa and Meriva
• Celebrations are part of 150^th anniversary of Opel brand

The Opel/Vauxhall plant in Zaragoza, Spain, has just celebrated its 30^th anniversary, having produced more than eleven million cars. The plant in the region of Aragon currently manufactures the five door Corsa variant and the Meriva. In 1982, the first Corsa rolled off the assembly line. This marked the beginning of the plant’s extraordinary success story that saw the production of six different Opel vehicle labels over the years.

Spanish King inaugurates production Opel Corsa A (1982)

At a ceremony attended by senior government representatives, Managing Director Antonio Cobo, praised the dedication of the employees and their “Passion for Quality” philosophy. Several reports of independent organizations guarantee GM España´s quality products. For instance, the Opel Meriva achieved the lowest defect rate in a TÜV report 2007 and the Opel Corsa is “The Most Reliable vehicle” according to a DEKRA report 2010. 

Opel Corsa A (1982)

Around 6,000 employees work at the plant with more than 4.1 billion euro invested there in total. Since Zaragoza’s opening, 9,161,725 Corsa, 1,331,966 Meriva, 213,369 Combo, 250,728 Tigra, 153,908 Kadett and 52,731 Astra have been produced.

Opel Kadett E (1986)

Opel Astra F range (1991)

Opel Tigra (1994)

 History of Plant Zaragoza

• 1979 Ground breaking
• 1982 Start of production, 1^st Opel Corsa generation
• 1983 Implementation of the second shift
• 1986 Start of production Opel Kadett
• 1988 Implementation of the third shift (First one in the World)
• 1993 Launch of the 2 ^nd Opel Corsa generation
• 1994 Start of production Opel Tigra
• 2000 Launch of the 3 ^rd Opel Corsa generation
• 2003 First Opel Meriva produced in January
• 2006 Assignment of 2^nd Opel Meriva generation
  Launch of the 4^th Opel Corsa generation
• 2007 Start of production Opel Combo
  Corsa 8,000,000 in August and 25^th Anniversary
  Yearly Historical Production Record with 485,857 units
• 2008 World’s largest rooftop solar power station installed
• 2009 Unit  10,000,000 / Opel Corsa ecoFLEX in April
  One-millionth Meriva produced in July
  First Auto Company Certified in Quality Advanced Management
• 2010 New Opel Meriva start of production in April
• 2011 100,000 Opel Meriva B just in 10 months

The Zaragoza celebration comes in the middle of Opel’s 150^th anniversary year. In 1862, the company started out as a sewing machine factory in Rüsselsheim, Germany, then switched to bicycle production and started making cars in 1899.