Nissan opens new plant in Brazil, will produce ‘Platform V’ vehicles

Nissan has officially opened its US$ 1.5 billion (Rs 9,040 crore) industrial complex in Resende, Rio de Janeiro, Brazil, marking one of the largest automotive investments by any manufacturer in the country. This investment is part of an effort to achieve a 5 percent market share by 2016 and to become the leading Japanese automotive brand in Brazil.

The Resende complex will produce Nissan's ‘Platform V’ vehicles and engines starting with the March/Micra hatchback and the 1.6-litre 16V flexfuel engine.

The new Nissan facility already employs about 1,500 people and is expected to grow to around 2,000. The complex includes all facets of automotive production – from the stamping of sheet metal into parts to vehicle assembly and road testing for the estimated 200,000 vehicles and 200,000 engines the complex will have the capacity to produce each year.

Speaking at the plant opening, Nissan chairman and CEO Carlos Ghosn said: “The Nissan Industrial Complex of Resende is fundamental to achieving our growth objectives in Brazil, which is the fourth largest automotive market in the world and a key part for our development in Latin America. Our goal is to achieve 5 percent market share and to lead Japanese automakers in quality and customer service in Brazil by 2016."

"Nissan's expansion of our manufacturing capacity throughout the Americas over the last two years, with new plants opened in the United States (2012), México (2013) and now in Brazil (2014) underscores the untapped opportunities that we foresee throughout the hemisphere and, specifically, in Brazil," said Jose Luis Valls, chairman of Nissan Latin America.

"Nissan began operations in Brazil in 2000, and the opening of the Resende complex consolidates its presence, launching a new phase for growth in the country. The new site in Resende will help Nissan to deliver more quality, and more technological and up to date products," said François Dossa, president of Nissan Brazil.

All Nissan Resende employees have undergone special training, and more than 300 have trained outside Brazil for three months at Nissan's plants in Japan, Mexico, the United States and England. The vehicle quality control team underwent six months of special training in Japan and Mexico. In the past year, Nissan has invested more than $4 million (Rs 24 crore) in technical training for the Resende workers.

Tech shows the way

The Nissan Production Way is in practice at the new plant, with the Brazilian employees complementing the technology of the most modern Japanese processes and equipment to ensure the highest quality vehicles and engines in a way that protects the surrounding environment.

In total, 88 robots carry out tasks that demand more precision or could incur safety or ergonomic risks. In most areas, Automatic Guided Vehicles (AGV) – small self-driven robots – move small carts of parts, eliminating the need for transportation belts with combustion engines or platforms activated by chains, making the operation safer and quieter.

The vehicle painting process follows the modern and sustainable ‘3Wet’ water-based paint system with base and varnish done soon after primer application, making the process shorter and reducing energy consumption. The robots use cartridges that reduce the waste of paint and solvents, reducing the emission of volatile organic components (VOCs) and making the operation more environmentally friendly.

The Resende facility is a green plant inside and outside. The buildings showcase natural illumination and ventilation systems, which reduce energy consumption and have low environmental impact. Production processes also reuse water by filtering solids for recycling or proper disposal. Nissan says a green ‘belt’ will be planted to surround the entire complex, which will help reduce both emissions and noise. The belt will reflect the region's natural habitat and occupy an area of more than 12 acres.

To accommodate additional growth, infrastructure for a supplier park has been set up adjacent to the complex. The supplier park already has six auto parts suppliers, which have moved to the region to support Nissan. They include Tachi-S (seats), Yorozu (suspension), Kinugawa (rubber seals), Calsonic Kansei (cockpit components), Mitsui Steel (plates) and Sanoh (brakes and fuels pipes). The Japanese carmaker aims to achieve nearly 80 percent local content in Resende by 2016.