ASL: Douai’s electrifying assembly line

Seven weeks of construction, 38,000m² emptied space, 100 heavy machinery units (robots and assistance equipment), and 400 redeployed workstations. These numbers give some insight into the extent of the challenge of installing the new ‘Alliance Standard Line’ assembly line at the Douai factory. A necessary transformation for the historic Renault factory – which once made the Renault 5, Renault 14, Renault 19, Renault 21, Megane and Scenic – to now accommodate production of the All-new Megane E-TECH Electric. Nicolas and Vincent, Assembly Project Managers, reflect on their grand adventure.

The Douai factory assembly line: where performance and versatility unite

“In a factory, more than anywhere else, time is precious. We couldn't tolerate a single delay,” says Nicolas. The tone is set. Any day lost to down-time was to be avoided at all costs. "One exception: any necessary repairs and improvements are done at the weekend, or at night… or in August during the summer holidays. If each section of the old assembly line were put end to end, the assembly line, with all 400 workstations, would be nearly 1,700 meters long! The line’s gigantic size can be explained by its age: the last time it was fully modernized was back in 1986,” Nicolas recounts.

The Douai factory has been making Renault since 1975. With more than 10 million iconic vehicles having left the factory doors. “It’s not as if the assembly division at Douai was old and dated. Prior to the recent work, the factory’s production capacity was very good. The line had to be replaced in order to produce both ICE and EV models. We kill two birds with one stone by bringing the whole line up to the highest level of European standards,” explains Vincent.

On paper, the objective is clear: create a brand-new assembly line using state-of-the-art technology from within the Renault-Nissan-Mitsubishi Alliance while keeping anything that can be kept. I concrete terms, that meant completely emptying the assembly building with a floorspace covering 38,000m², removing the 1^st floor, while also replacing more than 100 pieces of heavy machinery (robots and assistance equipment) and 400 workstations along with all necessary equipment.

“It took a year to get the job site ready. After close analysis, we determined that 20% of the old production line could be kept over,” recalls Nicolas.

The Douai factory’s sheet metal and assembly lines are now ‘Alliance Standard Line’ compliant – the most advanced production standard within the Renault-Nissan-Mitsubishi Alliance. The highly versatile facility can now produce both ICE and EV vehicles on the same line, with three different platforms, and the best safety and output standards possible.

A state-of-the-art design for improved workstation ergonomics and safety

Contrary to what one might think, the production capacity of the Douai factory was not the reason behind the recent upgrade. The output of 60 vehicles per hour prior to the works remains unchanged. The primary rationale behind upgrading the industrial complex was to improve efficiency of the production process for enhanced ergonomics of workstations and improved operator safety.

“The best example is how body heights vary according to the type of vehicle. On sections where the interior and exterior panels (CT1-CT2) are mounted, the vehicle is laid on skillets that act as a base. It can be raised or lowered between 20cm and 1.3m high to make it easier for operators to work. A lot has been done to improve conditions for those working on the undercarriages,” Vincent explains.

This massive upgrade was a unique opportunity for Renault Group ergonomic experts to thoroughly improve or optimize workstations in order for tasks to be carried in an easier, more fluid manner. “Tool trolleys have been integrated into the line and follow it much like the parts that are now delivered by robots known as ‘AGV’ (for Auto Guided Vehicle). Operators don't have to move about as much as they have everything at their fingertips. Less travel and less handling mean less fatigue and more productivity. Without the risk of wrong or damaged parts. The quality is improved!” says Nicolas.

The icing on the cake is that the recent upgrade has also brought on energy savings with the installation of LED lights.

Only seven weeks of construction

Work on the project took just under two months to complete, from November 25^th, 2020, to January 18^th, 2021, when production started up once again. A total of 1,200 people worked tirelessly on the upgrade, even right up to the festive season.

“We kept everyone motivated by making sure the ambiance was friendly. On Christmas Eve, we set up a 3-metre-tall Christmas tree with the must-have Christmas lights inside the building. What a special memory! ”, Nicolas and Vincent muse with a smile.

The faultless mobilization and organization paid off: the actual works for the upgrade only lasted seven weeks. What better reward for the conscientious effort put in by all those who took part in such a technically challenging adventure that brought people together.

The new assembly line is more compact than the previous one. The 20,000m² of floor space freed up by the works have been reused to set up a battery assembly shop.

As such, the sites external and internal logistics have been completely redesigned. The lorry depot and parts logistics department are now adjacent to the assembly line. The use of comprehensive  kits for each vehicle means it is now faster and more efficient to get operators the parts the need.

Emotions and nerves were running high on January 18^th when the assembly line was reopened for the first time since the upgrade began. “We celebrated the successful re-start by all having dinner together on site. We ordered in 200 pizzas. It tasted of victory!” Nicolas and Vincent fondly recall.

The line is still being broken in. It recently hit the threshold of 60 vehicles/hour. Since reopening, 30,000 Megane E-TECH Electric cars, renowned for the quality of their manufacturing, have come off the line. “The All-new Megane E-TECH Electric has been crowned with a Euro-NCAP 5-star rating. A recognition of the car's quality design and manufacturing. An exceptional car born in ideal conditions. Quality is there. That is our greatest reward,” Vincent states proudly.

An electrifying future for the Douai factory

Since the upgrade, the factory has been gradually picking up pace. It just recently reached its ‘normal’ production baseline of 60 vehicles/hour. This type of output means the Douai factory, which celebrated its 50^th anniversary in 2020, has a bright future ahead at heart of ElectriCity.