Chery relies on automation in Wuhu

When you visit the Chery factory in Wuhu, the most surprising thing is the high level of machinery. (Image: Chery)

The first minute has something scary. Anyone entering the so-called giant factory of Chinese carmaker Chery at its headquarters in Wuhu is unlikely to see a soul past the gatekeeper. Outside you are looking for free parking spaces for employees and those that are common in China Residential buildings for a large workforce. Inside the factory you can see lonely corridors, through which one worker passes every fifteen minutes. And it’s not really because there’s nothing to do here. After all, a new car rolls off the assembly line here every minute, and Chery estimates annual capacity to be around 300,000 assembled and another 200,000 to be produced at other CKD plants.

Chery relies on an unparalleled level of automation

The reason for the stability seen in the Wuhu factory is the unprecedented high level of automation: “98 percent of all jobs here are done by robots and machines”says Zhang Guibing, as automated industrial trucks move freely through lanes as if controlled by magic, ensuring material flow to assembly robots. He is the boss of Chery International and wants to make sure that the 662 robots and only 2,000 workers, who are mostly employed in the final assembly and quality assurance, soon have more to do.

To maintain Chery’s double-digit growth rates, the company is now entering Europe and wants to launch in the old world next year with three brands and, in the medium term, around a dozen models. And unlike many competitors from the Middle Kingdom, they rely not only on electric cars, but also combustion engines and hybrids with or without plugs – which does not make the processes in the mega-factory any easier. “Because most models here run on the same conveyor regardless of the car”adds Bing Yu from the global sales team and lists three platforms with eight models.

Chery has been an international player for a long time

Going abroad is nothing new for the Chinese. The company, founded in Wuhan in 1997, exported its first car to Syria in 2001. It is now present in 80 countries – mainly in Asia, Latin America, Africa and Arabia – and exports more cars than any other manufacturer in China: in the first half of 2023, the share of exports was more than 50 percent. for the first time. With a volume of 1.2 million vehicles last year and a forecast of 2.0 million this year, a lot comes together. Chery builds about a fifth of these cars at its main factory in Wuhu, which was converted from an old car factory to, to use Tesla’s term, for the equivalent of a cool 500 million euros. “Mega” The ennobled factory was renovated and opened in spring 2023. “The foundation walls did not stand and we rebuilt the factory.”Says Bing. “And all in less than two years.”

The factory is located on an area of ​​830,000 square meters and has a construction area of ​​550,000 square meters. And even if most of the work is done by robots and you see few people, there are many workers: 2,000 workers, with an average age of 23 and almost surprisingly young, stand on assembly lines and test benches in a large area. -factory and work monitoring example of modern changes: “Normally we work two shifts here, each for ten hours. But at peak times the factory also works three shifts for eight hours per cycle.”, explains Bing. And while the robots have to work 365 days a year, workers have three days off every two weeks.

Bing likes to demonstrate how the production is highly developed in the body shop, where more than 300 robots are controlled and monitored by what is said to be the most powerful artificial intelligence in the world: Here the speed of machining is 100 percent, the cycle time is very short. and the accuracy of the control robots is approximately the same in some stations to check the thickness of the material 0.1 mm. “And we do all this with renewable energy and zero emissions”activates Bing and attaches other attributes to the large plant: “This is also a green factory.”

Chery does not compromise on safety

In and around the plant, the Chinese have integrated everything needed for the construction of cars: not only are there presses and stamping, assembly and painting, but the engine and transmission are also built on site. And a stone’s throw away is a large part of the development and one of the largest test centers in the entire region of Asia: Indeed, climate chambers. and EMC test benches are everywhere, as are torture vibrators for NVH protection. But no one has an accident hall like Chery, says owner Wuhai Zhong of the security center that opened in 2010 for 1.6 billion yuan. 1,000 engineers work here alone, driving 300 to 400 cars into a wall or collision each year on a 260-meter-long crash course and radial collision tracks. Not counting the many sled tests and features.

The international aspirations of the Chinese are also reflected here in the hall – and not only because the flags of all countries hang from the ceiling: “We can perform any crack test required anywhere in the world”says Wuhai proudly, counting more than 200 accident configurations and without stopping for public demand: “Because of course we can expect a lot more from our cars than lawmakers and testing agencies.”

This applies to combustion engines as well as electric models, which have an increasing part in Wuhai’s accident program and have forced him to further change the center: Since then, he has had a large swimming pool in one corner where damaged electric cars are found. The protected waterfall should be submerged so that they can subside and do not put a fire station.

Chery is currently building one big factory after another in China and opened the next one in Qingdao a few weeks ago – right at the port, of course, which is especially smart for an export dealer. But that does not mean that Chery would not also look abroad. That’s why they already have ten assembly plants in Africa, Asia and Latin America. You are in Europe they have also been searching for a long time, says Zhang: “Because if we are serious about our commitment to Europe and our growth plans are working, then the potential should not fail.”