There, in Resende, Volkswagen built one of the most modern plants in the world for trucks and buses. At a cost of 250 million dollars, the plant was built in 153 days only. Twelve years later, it has beaten record after record. It has already passed the mark of producing 300 thousand trucks and buses.
It is in this area that Volkswagen World Center for Development of Trucks and Buses is also located. It is a space for research and design of new models as well as for the development of new technologies to be used in the products. The results of the work of this center are shared with the engineers of Volkswagen Commercial Vehicles in Germany and applied to vehicles produced by the company in other world regions. One of the latest advances that is due to the Center is a group of models capable of functioning with up to 5% of biodiesel mixed with regular diesel, without altering the original characteristics of the plant.
4,500 people work in the plant, being 92% from local areas. In addition, the plant stimulates the creation of 20,000 indirect jobs. The daily production is 220 vehicles, a number that should grow due to increases in the size of shifts. As the creation of a second shift in October 2004 already created 400 new jobs, the implementation of a third shift, planned for September, should generate up to 1,300 openings. This is possible due to an investment forecast of 1 billion reais by 2012.
Life Quality
The production line manufactures truck models with mechanical and electrical propulsion systems. In the assembly of the chassis, conveyor belts and cranes are used to save effort by the assembler and increase productivity. Another proof of the attention dedicated to the quality of work conditions is this is the first air-conditioned assembly line in Brazil – the temperature inside is maintained between 6 and 9 degrees lower than outside. Doors controlled by laser prevent the loss of cooled air.
Efficient Communication
Communication with the outside world is also taken very seriously. The data are transmitted rapidly, via fiber optic cable. Nothing less than fifty-two computer systems are used in Resende, including on the plant floor, where the assembly workers control production on easy-to-operate screens.
Care with Nature
Located 30 kilometers away from the Itatiaia National Park, the oldest in Brazil, Volkswagen respects the environment. The company follows rigorous technical standards for the treatment of effluents. The manufacturing building does not have pollution sources. In the painting building, a treatment plant guarantees that the water discharged into the river is drinkable. In the areas of pre-treatment, E-Coat (painting by electrodeposit) and Sealers are controlled by post-burning of waste gases. Solid waste passes through a biological process and only water with a neutral Ph is discharged into the river. This care extends beyond the plant. Since 2003, the company has invested in research and tests with alternative fuels, such as biodiesel.
Address: Rua Engº Alan da Costa Batista, 100 - Pedra Selada – Resende/RJ
Innovative Management
More than just an innovative project in terms of technology and respect for the employee and for the environment, the Volkswagen Truck and Bus plant in Resende has adopted an innovative management mode, which has proved to be a success throughout the years. It is called a Modular Consortium.
It functions as follows: eight partners assemble complete groups of parts. They are Maxion (which takes care of the chassis assembly), Arvin Meritor (axles and suspension), Remon (wheels and tires), Powertrain (engines), AKC (outfitting of the cab), Carese (painting) and Continental (tires). Volkswagen is totally responsible for the product quality control. For its part, the Modular Consortium tries to reduce the production costs, investment, stock levels, production time and, principally, increase the flexibility in the production of specialized vehicles.
The partners do not participate in the final profit of the products. They continue being suppliers, with the great difference that they also assembly the parts they sell. They share with Volkswagen all the infrastructure of the plant, which includes the restaurant and infirmary. This strategy increases productivity and makes the assembly more efficient and flexible. Beyond this, by sharing production with its partners, the company can concentrate more on other aspects of its business, such as logistics, marketing strategies, customer service and especially the development of new products.
