Renault’s Re-Industry: Innovation and Efficiency at the Bursa Factory in Turkey

2023-12-11 11:00:05
In front of the Renault automobile factory in Bursa, Turkey, May 21, 2015. MURAD SEZER / REUTERS

To continue its recovery and, above all, to face competition from Chinese manufacturers, Renault announced, Thursday, December 7, a plan to transform its factories called Re-Industry, which should allow it to reduce its industrial costs by 30% per year. thermal vehicle and 50% by electric car by 2027. Its deployment is already well underway. Thierry Charvet, industrial director of the group, assures that it has already made 270 million euros in savings this year.

Demonstration in Bursa, Turkey, in the Clio factory. Renault produces one Clio 5 per minute here. A total of 1,260 vehicles come off the assembly line every day, which runs six days a week, twenty-four hours a day, with three shifts. Operators work forty-five hours a week. The site, born from a partnership with Oyak, the Turkish army pension fund, in 1969, to produce R12s, is not yet 54 years old. The factory is “the most compact of the group”, according to Kaan Ozkan, the director of Oyak-Renault, which means that the space and facilities are hyperoptimized.

It is very automated: Turkish engineers display their determination to have the most efficient technologies. To journalists who visit the factory, they demonstrate the numerous industrial innovations developed here, before spreading to the rest of the group. Four hundred million euros of additional investments, particularly in research and development, are planned by Oyak and Renault on the site.

An industrial application of artificial intelligence

Bursa, where 5,423 people work, has started to connect all its machines to the group’s metaverse: it is not a video game where avatars walk around, but a gigantic computer server to which the machines, equipped with sensors, send messages. data. These are processed by four employees in a digital control tower installed in the former factory in Flins-sur-Seine (Yvelines), which stopped producing Clio for the benefit of Turkey in 2019.

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Around the world, 12,000 machines send it 3 billion pieces of data per day. Flins can thus monitor the “digital twin” of each factory in the group and detect, using algorithms, the warning signs of possible breakdowns. This is one of the industrial applications of artificial intelligence.

In the Bursa stamping workshop, Vincent Gouedard, vibration analyst in Flins, appears on the screen of Cüneyt Gençeli, workshop manager. He shares the press control document 31 with him. Abnormal sounds and vibrations appear on a graph. By analyzing their frequency, he recommends checking the motor pulley. This will be done well before a technical incident forces the machine to be immobilized. Avoiding production stoppages is one of the keys to the cost reduction plan.

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