Groupe PSA starts production of the Turbo PureTech Three-cylinder petrol engine at the Tychy plant

• The Tychy plant (Poland) benefited from € 250 million in investments to improve its performance and manufacture the 1.2 litreTurbo PureTech engine
• A modernized plant implementing Groupe PSA process and quality standards
• Production capacity projected up to 460,000 engines to handle increasing customer demand for petrol engines

1.2 litreTurbo PureTech engine

Groupe PSA inaugurated the new assembly line for the Turbo PureTech 3-cylinder petrol engine in Tychy at a ceremony attended by Jadwiga Emilewicz, Poland’s Minister of Entrepreneurship and Technology, Carlos Tavares, Chairman of the Managing Board of Groupe PSA, local authorities, the plant’s management and all its employees.

Jadwiga Emilewicz, Poland’s Minister of Entrepreneurship and Technology, Carlos Tavares, Chairman of the Managing Board of Groupe PSA 

With this new assembly line, the EB Turbo PureTech petrol engine – awarded International Engine of the Year four times in a row – is gradually becoming a global-scale engine for Groupe PSA. The EB Engine (Atmo and Turbo) is currently produced in France (Douvrin, Tremery) and China (Xiangyang) and, from 2019 onwards, will be produced in Hungary (Szentgotthard), Morocco (Kenitra), and from 2020 in India (Hosur).

3.8 million EB engines have been produced to date and this additional capacity corresponds to increasing market demand, supported in particular by production of new Opel/Vauxhall models on Groupe PSA platforms and technology. This highly efficient engine contributes to the reduction of the CO₂ emission with an average fuel consumption reduced by 4% compared to the previous generation.

The powertrain plant in Tychy was modernized to boost its performance in line with Groupe PSA standards: New technologies and equipment, supported by new IT systems, ensure a high quality of production with appropriate trainings provided to production teams. Performance of our industrial organisation is also enhanced, by locating component plants close to vehicle factories.

 “I would like to highlight that the Tychy teams have demonstrated their ability to improve their performance, thus allowing for investments to modernize the plant and allocate a state-of-the-art engine. The Tychy plant has a sustainable future now and will be a strong contributor to the Groupe PSA manufacturing footprint, organized to produce engines for our five brands and meeting growing customer demand for this award-winning engine,” said Carlos Tavares, Chairman of the Managing Board of Groupe PSA.

“The factory in Tychy is back in the game as a part of Groupe PSA and all the teams are committed to meeting the new challenges set for us. The plant has been thoroughly modernized with the right level of investment to ensure the best level of efficiency, among the most modern engine manufacturing sites in Europe. We are proud to contribute to the shift to low-emission PureTech petrol engines,” said Arkadiusz Suliga, Tychy plant director.

Groupe PSA’s Turbo PureTech petrol engine named International Engine of the Year for the 4th year in a row

Today, the Turbo PureTech 3-cylinder petrol engine (110 hp and 130 hp) was named International Engine of the Year in the 1-litre to 1.4-litre category, for the 4^th year in a row, by the panel of the 20^th International Engine of the Year Awards in Stuttgart.

Groupe PSA has filed 210 patents for its family of 3-cylinder petrol engines. The new‑generation PureTech engine offers improved performance, fuel consumption and efficiency, with specific benefits including:

• a 4% improvement in fuel consumption on average compared with the previous generation;
• improved engine response time thanks to an optimised turbocharger (20% faster increase in torque from 1500 rpm);
• a 75% reduction in particulate emissions through the use of a gasoline particulate filter (GPF), meeting the Real Driving Emissions (RDE) conformity factor of 1.5 set by EU regulations for 2020, three years in advance;
• a more compact structure, to adapt to the new Common Modular Platform (CMP) dedicated to small city cars, core sedans and compact SUVs.

Launched in 2017 on the new Peugeot 308, the new generation is now being deployed on Groupe PSA’s vehicles across some hundred applications in more than 70 countries. The engines comply with Euro 6d-TEMP and China 6b standards.

The PureTech 3-cylinder engine is currently manufactured in France (Française de Mécanique plants in Douvrin, Pas-de-Calais and Trémery, Moselle) and China (Xiang Yang plant). In addition to production capacity being doubled in the French plants in 2018, the plants in Tychy, Poland, and Szentgotthárd, Hungary, will also start producing the PureTech engine in 2019 and 2020, respectively.

On this occasion, Alain Raposo, Senior Vice President, Powertrain and Chassis Engineering at Groupe PSA, said: “We’re proud to receive this prestigious award for the fourth year in a row, as proof of the skills of our development teams. Most of our vehicles are now equipped with this engine, which has been highly successful among our customers. This award is a global recognition of the competitiveness and efficiency of our petrol range, and in particular our PureTech 3-cylinder engine.”

Groupe PSA optimizes its manufacturing base in Europe

• Improving performance of powertrain plants to fulfil orders for future Opel/Vauxhall models based on PSA platforms
• Preparing manufacturing facilities for the ICE energy mix transition as well as the electrification push
• Localising automatic gearbox production to meet shifting customer demand

In order to step up its development and boost its competitiveness in Europe, the Group has decided to:

• Increase the agility of its manufacturing base by producing components as close as possible to car plants,
• Adapt its output to customer expectations, taking into account technological and energy shifts.

These changes are also an opportunity to adjust production capacity for Group engines as the manufacture of Opel/Vauxhall models is gradually ramped up on Groupe PSA platforms and fitted with Groupe PSA powertrains and technologies.

In light of the above, the Group has decided to make three adjustments:

• Increase production of the 3-cylinder Turbo PureTech petrol engine – awarded “Engine of the Year” in its category for three years in a row – as close as possible to car plants. In addition to doubling production capacity in France, compared to 2016, already in progress in Douvrin and Trémery plants, the Group will be producing PureTech engines in Tychy (Poland) and Szentgotthárd (Hungary) from 2019 onwards.
• Increase production of gearboxes from 2019 with the manufacture under license of automatic gearbox in Valenciennes (France), set to reach full potential by 2020, thanks to a strategic partnership signed with AISIN AW. Until now, this component has been manufactured in Japan and China. The Group will also invest to produce additional volumes of manual ML gearboxes in Metz-Borny (France) and MB6 gearboxes in Aspern (Austria), in particular to equip its high-end and light commercial vehicles and serve growing needs driven by production of Opel/Vauxhall cars.
• Prepare the Trémery plant (France) to produce electrical motors from 2019 onwards, before acceleration from 2021 onwards, thanks to the joint venture signed with Nidec. They will support the electrification push, as 100% of the Group’s vehicle range will include e an electrified offering by 2025.

These decisions have been made based on a performance assessment of manufacturing sites and in accordance with the New Momentum for Growth commitments signed in July 2016 by five out of six trade union organisations. The new production allocations also take into account what has been presented to employee representatives as part of the Opel/Vauxhall PACE! plan.

Yann Vincent, Executive Vice- President, Manufacturing and Supply Chain, said: “What will make the difference will be our agility to prepare our manufacturing base to produce components that meet customer needs and respond to the energy shift, creating the conditions for a sustainable future through enhanced performance. Groupe PSA’s 15 component production plants in Europe, located in France, Germany, Austria, Hungary and Poland, are eager to propose the best quality and performance to our customers.”

!NEW! Official Opening of Global Business Services in Tychy

120 new employees to support Opel/Vauxhall colleagues across Europe

In the presence of Jerzy Majchrzak, Director Innovation and Industry Department in Ministry of Economy, and Ulrich Schumacher, Opel Group Vice President HR & Labor Director, the newly established Global Business Services Center was opened in Tychy today. This new center will offer support to over 20 local Opel/Vauxhall facilities in Europe providing services from serving as the first point of contact for employees in all HR related matters to data maintenance, expense reporting and training. Presently, 90 consultants out of a total of 120 have already been hired.

Jerzy Majchrzak, Director Innovation and Industry Department in Ministry of Economy, Stefan Hoffmann, Assistant Director GBS Europe, Anna Polak-Kocińska, Vice President of Polish Information and Foreign Investment Agency, Andrzej Dziuba, Mayor of Tychy and Ulrich Schumacher, Opel Group Vice President HR & Labor Director (from left to right) at the official opening of the Global Business Services Center in Tychy.

“We welcome the fact that General Motors is opening new kinds of business activities in Poland alongside the traditional automotive business. The new shared service center will create a number of new jobs for the people of the region. This is further proof of GM’s significant commitment to Poland and confirmation that, thanks to the efforts of the Ministry of Economy, a good environment for investors has been created,” said Jerzy Majchrzak at the opening ceremony.

Ulrich Schumacher, Opel Group Vice President HR & Labor Director added: “We are delighted that we have managed to bundle an important part of our service activities for Europe here in Poland. This investment is further proof of the important role that Poland plays in the international Opel/Vauxhall network.”

The newly opened General Motors Global Business Services Center is part of GM Manufacturing Poland and is located in the Tychy plant facilities. GM Manufacturing Poland currently employs a total of 3,900 people in three branches: vehicle manufacturing in Gliwice, engine manufacturing in Tychy and the newly opened Tychy GBS Center. In the second half of this year, the Gliwice plant will begin production of the new generation Opel Astra. Furthermore, a new engine family will be produced in the Tychy plant.

Opel is one of the fastest growing brands in Poland. In 2014, the brand sold more than 28,000 vehicles in the country (+41 percent) and was able to rise to number four of the total vehicle market with a market share of nearly 7.2 percent. The upward trend continued this year: In the first two months of 2015, sales increased by more than 24 percent and market share by around 2 percentage points compared to the same period last year.

!NEW! Opel/Vauxhall to Produce Second Flagship in Rüsselsheim and to Invest in New Engine and Transmission Production

• GM Chief Executive Officer Mary Barra announces production of New SUV in  Rüsselsheim
• Considerable investments in engine and transmission production in the Rüsselsheim, Kaiserslautern and Tychy plants
• Third shift at the Eisenach plant will be added next year
• Clear commitment to Opel/Vauxhall, Germany and Europe

Opel Group CEO Dr. Karl-Thomas Neumann and GM CEO Mary Barra in front of the new Corsa E.  Barra announces production of a new SUV in Rüsselsheim.

During her second visit to Germany this year, Mary Barra, Chief Executive Officer of General Motors, announced additional considerable investments. Barra confirmed that new model will be produced at Opel’s traditional headquarters in Rüsselsheim by the end of the decade. “This SUV will be the brand’s second flagship alongside the Insignia,” Barra said. As announced in March, 245 million euro will be invested in Opel’s Rüsselsheim plant to meet future requirements. Furthermore, Barra declared additional investments of more than half billion euro in the engine and transmission plants in Rüsselsheim, Kaiserslautern and Tychy (Poland), thus providing the impetus for Opel to move to the next stage of its powertrain offensive with fuel efficient engines and transmissions.

Opel Insignia - Current flagship model

“Opel/Vauxhall is of high strategic importance for GM. The product offensive with 27 new models and 17 new engines has enjoyed a very successful start. These additional investments will help the brand shine again and further strengthen our position in Europe. They are a clear sign of GM’s commitment to Opel, to Germany and to Europe,” said Barra.

Opel Group CEO Dr. Karl-Thomas Neumann and GM CEO Mary Barra 

Opel Group CEO Dr. Karl-Thomas Neumann was delighted by the clear message: “General Motors and Opel/Vauxhall are closer than ever before.” He continued to explain that Opel/Vauxhall  has General Motor’s full support. “The additional investments are further proof of the excellent cooperation.”

Both, Mary Barra and Dr. Neumann, pointed out that all necessary decisions were taken after a constructive dialog with employee representatives. They recognized the cooperation with the European employee representatives, the Industrial Metal Union (IG Metall) and Opel’s general works council, chaired by Wolfgang Schäfer-Klug.

Wolfgang Schäfer-Klug: "The package of measures is based on existing collective labor agreement commitments. The agreement is an important prerequisite for the continuation of Opel’s ride in the fast lane. It helps to continue our growth course with safe and competitive jobs."

Dr. Neumann also announced that a third shift will be established at the plant in Eisenach as of mid 2015. “This is good news for Eisenach as we are enjoying strong demand for the Opel/Vauxhall ADAM and the new Corsa  E.”

Opel ADAM 

Mary Barra expressed her delight with the new Corsa E, adding that 45,000 orders before the official market launch show that the fifth generation of the small car is well on its way to becoming a bestseller.

!NEW! GM Invests 250 Million Euros in Modern Engine Production in Tychy

• Start of production of new midsize diesel engines is scheduled for 2017
• Plant is upgraded to highest technological standards

GM Poland plant in Tychy

General Motors today announced the allocation of the new generation midsize diesel engine family to the GM Manufacturing Poland plant in Tychy.

GM Poland plant Tychy - 1.7 CDTI Engine assembly

Start of production of the all-aluminum 1.6 liter four-cylinder turbo-diesel (CDTI) Euro 6 engines  that combine high performance with top refinement and high fuel efficiency is scheduled for 2017.

Total investment in the plant, which is located in the Katowice Special Economic Zone, will amount to 250 million euros. This is the biggest investment in the history of the Tychy plant and includes additional buildings and new manufacturing technology.  The maximum annual production capacity will be 200,000 units.

GM Poland plant Tychy - 1.7 CDTI Engine assembly

The investment will enable the extension and modernization of the plant’s infrastructure. The building’s surface area will increase by 30 percent with the addition of the storage area as well as high tech production and testing lines. This expansion takes the plant’s technological competence to the next level and transforms the assembly facility into a full production plant.  Construction and installation of the new production equipment will continue until 2016.

Opel’s new 1.6 CDTI is the quietest diesel in its class

“The new midsize diesel engine family is an important part of our engine offensive. We appreciate the good quality and high efficiency of our Polish location and look forward to implementing this exciting project,” says Peter Thom, Member of the Management Board, Adam Opel AG and Vice President Manufacturing Europe.

“The automotive industry is a very important branch of our market, therefore this new investment in the GMMP Tychy plant is very good news not only for the region, but also for the whole economy,” says Janusz Piechociński, Poland Deputy Prime Minister, Minister of Economy.

“The new investment moves the GM Manufacturing Poland plant to the next development level and secures its future. With this comprehensive portfolio of modern engines and vehicles, we are committed to contributing to the Opel/Vauxhall product offensive. We would like to thank the Polish Ministry of Economy that supported the investment,” said Andrzej Korpak, Managing Director of the GM Manufacturing Poland plant.

The new engine family will meet Euro 6 emission standards while securing high power and torque density, low fuel consumption and reducing CO2 emissions. Engines will be installed in a wide range of Opel/Vauxhall models, setting the benchmark for noise, vibration and harshness.

The GM Manufacturing Poland plants in Gliwice and Tychy employ 3,500 people.  The current portfolio includes the Opel Astra, the Cascada convertible and the 1.7 liter turbo-diesel (CDTI) engine .  With today’s announcement, total GM investments in Poland will amount to over 1 billion euros.

!NEW! GM Purchases Remaining Shares in Tychy Plant

Today, General Motors Co. signed an agreement to purchase the remaining 40% shares of Isuzu Motors Polska Sp. Z o.o. (ISPOL) from Isuzu Motors. The signing ceremony took place at the ISPOL plant in Tychy, Poland. From now on, the plant where currently Circle L 1.7l diesel engines are built will operate as “GM Powertrain Poland”.

GM Tychy Plant in Poland

GM has already owned 60% interest of the engine plant since 2002. Its purchase of the remaining 40% underlines the importance of Europe for GM, as this is one of the most competitive car markets in the world with highest customer demands in terms of fuel economy and CO2 standards.

At a glance

The Tychy plant was established in 1996 and started production in 1999. Since then the plant manufactured over 2 million engines for Opel/Vauxhall. The engines are for the models Corsa, Meriva, Combo, Astra and Zafira.

The plant’s mission is “To build Europe’s best diesel engine”. Tychy is proud to have the certificates ISO 14001and ISO/ TS 16949:2009 and set a high value on safety at work.

The engines of the joint venture, thanks to low fuel consumption, operational reliability and environmental friendliness, are placed among the worldwide Diesel power train leaders.

History of the Tychy Plant:

• 1996 Foundation of the company: 100% ownership by Isuzu Motors Limited
• 1999 Start of production for Opel
• 1999 “Supplier of the year” award from General Motors
• 2001- 2005 Production of engines for Honda
• 2001- 2008 Production of engines for Mercury Mercruiser motor boats
• 2002 GM took over 60% interest of Isuzu Motors Polska (ISPOL)
• 2004 Manufacturing of 1 million engines
• 2006 Start of production of NCL 125 - new generation engine
• 2008 The facility becomes a “Landfill Free Plant” (manage the plant's waste without sending material to a landfill depository)
• 2009 Manufacturing of 2 million engines and 10th anniversary
• 2009 ISPOL becomes part of the Opel/Vauxhall organization
• 2010 Start of production of D1 - new engine entirely designed by GM
• 2010 Start of production of NCL engine with automatic transmission
• 2011 8 million worked hours without lost work day case
• 2011 The plant received the national award of Employer Employees Focused