Production

Tofaş
Akın Ergür
TOFAŞ A.Ş.
Purchasing Directorate
Strategic Sourcing & Project Administrator
Agenda
• Tofaş overall
• Tofaş R&D
TOFAŞ TÜRK OTOMOBİL FABRİKASI A.Ş.
Established
Production
Partnership
Structure
: 01 October 1968
: 12 February 1971
: FIAT AUTO S.P.A.
KOÇ HOLDİNG A.Ş.
OTHERS
: 37.86%
: 37.86%
: 24.28%
FACTORY LAYOUT (1970-2008)
2008
1970
Total Area
Total Covered Area
: 734.000 m2
: 62.000 m2
933.832 m2
346.275 m2
TOFAŞ PRODUCTION UNITS
SUSPENSIONS
PRESS SHOP
ASSEMBLY SHOP
PAINT SHOP
BODY SHOP
TOFAŞ PLANT OTHER UNITS
PROTOTYPES
SUPPLY CHAIN
RESEARCH &
DEVELOPMENT
DIES PRODUCTION
SPARE PARTS
INVESTMENTS ( € MILLION )
400
366.5
316.8
350
300
244.6
250
200
150
103.2
123.5
123.9
107.9
76.4
100
58.1
70.9
14.4
50
19.6
0
1997
1998
1999
2000
2001
2002
2003
2004
2005
2006
2007
2008
Bgt
EMPLOYMENT
TOTAL TOFAŞ
YEAR
BLUE COLLARS
WHITE COLLARS
TOTAL
Dec-06
4339
919
5258
Sep-08
7493
1254
8747
BLUE COLLARS
WHITE COLLARS
TOTAL
EXPERIENCE
7,7
9,8
8,0
AGE
30
36
31
PRODUCTION CAPACITY (1972-2007)
450,000
400,000
400,000
350,000
300,000
250,000
250,000
200,000
200,000
150,000
100,000
100,000
50,000
280,000
20,000
50,000
0
1972
1986
1990
1994
1995-2005 2006-2007
2008
TOFAŞ PRODUCTIONS (1971-2008)
0
15
x1000
2008 Bdg
196
2007
2006
2005
142
2004
96
2003
111 110
2002
2001
110
2000
60
55 59
1999
85
1998
1997
89
1996
116
1995
107
1994
200
1993
150
1992
1991
100
1990
1989
1988
1987
1986
1985
21
1984
1983
1981
12 13
1982
21 19 22
1980
1979
1978
26
1977
25 29 30
1976
1975
18
1974
50
1973
8
1972
1971
PRODUCTION (1971-2007 )
350
324
300
250
197
171
141
153
121
102
78
61
29 30
42
Sales 2000-2007 (m €)
3,500
3,166
3,000
2,500
2,053
1,751
2,000
1,500
1,105
992
1,190
1,424 1,543
1,000
500
0
2001
2002
2003
2004
2005
2006
2007 forecast
2008
Yearly Purchasing (m€)
Realized Total
Purchasing
GERÇEKLEŞEN
TOPLAM
SATINALMA
2500
( LOCAL+ SHEET IRON+EXT STD+INDIR MATER+SPARE PARTS )
2254
INDIRECT MATERIAL
S PARE PARTS
2000
S HEET IRON
1660
EXTRA STD MATERIAL
1439
LOCAL MATERIAL
1500
1000
500
0
983
164
833
10
30
36
28
4
366
20
31
4
415
179
633
556
500
444
130
1180
1057
909
812
1.338
69
45
32
57
8
558
32
46
8
479
25
41
7
438
37
61
16
704
2002
2003
2004
2005
2006
2007
55%
55%
53%
54%
58%
59%
Local Supplier Purchasing %
76
104
59
969
2008
budget
59%
New Projects - Fiat Linea
• Production start : May/07
• Annual production volume : 60.000 units (1/3 export)
• The total investment for the project : 170 m€
New Projects - Mini Cargo
•
•
•
•
light commercial vehicle for Fiat, Peugeot & Citroen brands
Annual production volume : 165.000 units, 95% to be exported
The investment : 380 m€
Tofaş has the product development responsibility and owns the intellectual property right.
P263 Project
passenger
MPV
Passenger car +
Commercial vehicle +
MPV
?
• intelligent and safe vehicle
commercial
• Low fuel consumption
• Low emission
• Environmental friendly
Agenda
• Tofaş overall
• Tofaş R&D
Automotive Industry Vision:
with annual production of 2 million vehicles;
- #10 in the world and #3 in EU total motor vehicle production
- Be one of the top 5 R&D investing country in EU
Tofas Vision:
The leading Turkish automotive company and the preferred regional R&D
and manufacturing center of Fiat
Tofas R&D Vision :
Become Fiat Auto's most competitive and self relient LCV and
Passenger vehicle develop
development center by 2010
R&D History
• Established
– in 1994
– with 8 members
Mekatro
(in Tubitak MAM)
Tofaş R&D
• Today
– 25 m€ total facility investment
– 410 members
– 4 different location
R&D office
(in METU)
Platform
•Bursa Demirtaş – R&D Centre
•Bursa Görükle – Platform
•Gebze – Mekatro
•Ankara – METU Teknopark
(in Tecnopark)
• Office Area
• Labr Area
• Proto shop
• Office Capacity
:
:
:
:
2.400 m2
6.000 m2
6.000 m2
310 people
Tofaş R&D Capabilities
•Vehicle Design
§body design
§chassis design
§trim design
§electrical design
§pwt integration
§packaging
Prototype and
performance tests
Tool design
and manuf
•Prototype Manufacturing
•Performance Testing
§road tests
§NVH tests
§bench tests
•Material Engineering
•Tool Design & Manufacturing
•Vehicle Homologation
Production
preperation
Product design
High quality
production
è Tofas is targeting to be self relient development centre by 2010
Toward 2012 ～Steps of local development～
re-styling
Proje 1
New model
SOP
SOP
re-styling
Proje 2
New model
SOP
re-styling
Proje 3
New model
SOP
Vehicle Concept
Interior & Exterior Design
Fiat
Proto Drawings
Production Drawings
Proto Parts and Vehicle
Tofas
Prod Preparation
è
è
2006
2008
2010
2012
Tofas responsibility will be expanded in phases.
Local Suppliers are expected to develop their codesign capabilities in line with this plan
Thank You...