02/28/2018 11h25

GM invests R$ 1.2 billion to expand and modernize its plant in São Caetano do Sul

Unit’s facilities were reorganized to accommodate innovative manufacturing technologies

Investe São Paulo
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    The governor of Sao Paulo state showed some programs available for the automotive sector

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    13 thousand people are currently working at GM in São Paulo state

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    Expansion is focused on sustainability

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    Governor talked about the support providade by Investe SP

On February 20, 2018, General Motors Mercosur showed the expansion works of its Industrial Complex in São Caetano do Sul (SP), resulting from the latest investments of R$ 1.2 billion in the unit. A new building integrates the unit, with translucent tiles, LED lights with dimer automation, natural ventilation, among other concepts of sustainable construction, now covering 432,300 square meters of built area. As part of the project, the unit will have all its internal facilities redesigned and will incorporate new 4.0 manufacturing technologies.

The event was attended by Governor Geraldo Alckmin, the Minister of Industry, Foreign Trade and Services, Marcos Jorge de Lima, and the Mayor of São Caetano do Sul, José Auricchio Júnior.

Carlos Zarlenga, president of GM Mercosur, announced that the factory will have its annual capacity expanded from 250,000 to more than 330,000 vehicles per year.

“GM celebrates 93 years in Brazil in an accelerated process of growth and innovation. The new investments will transform the Industrial Complex of São Caetano do Sul into one of the most efficient and modern in the industry. The new facilities will allow Chevrolet to continue delivering high quality products and technology to continue leading the Brazilian market,” said Zarlenga.

“General Motors is the first choice of customers in Brazil, and that evidences the quality of its products and the efficiency of its work,” said Alckmin. For the new facility, the company should hire approximately 2,000 people at the peak of the works, which is expected to take place between February and March this year. In the state of São Paulo alone, the automaker has 13,000 formal employees.

The investment of R$ 1.2 billion made by GM in the plant is part of the company’s largest investment plan in its entire history in Brazil, with a total of R$ 13 billion being invested in the country from 2014 to 2020.

Investe SP has contributed to the project by guiding the project, together with the municipality, for the renovation of Viaduto Independência, which provides access to the plant. And also by giving advice on the procedures to apply for the use of ICMS credits through the Pro-Vehicle Program.

GM submitted the required calculations to SEFAZ, and once the directions are given by the body, it should apply for the Pro-Vehicle Special Regime in the next few days. According to Investe SP, the accumulated credits of the company amount to R$ 373.4 million.

 

Manufacturing 4.0

One of the most versatile and flexible factories of GM, which produces several models such as Cobalt, Onix, Spin and Montana from the same line, the Industrial Complex of São Caetano do Sul will receive new intelligent manufacturing technologies (4.0), including state-of-the-art presses, laser welding, new engine and transmission assembly system, new plastic injection molding machines, new bodywork process and new vehicle conveyor on the assembly line.

 

The transformation that the plant is undergoing was made possible thanks to the partnership with the Metalworkers Union of São Caetano do Sul, said Marcos Munhoz, vice president of GM Mercosur. “The support from the union was crucial in the decision-making on the new investments, which will raise the plant in São Caetano do Sul to a new level of competitiveness,” Munhoz said.

 

Increasingly sustainable complex

Both the demolition of the old building and the construction of the new facility were guided by sustainability and large part of the rubble generated in the demolition was recycled and reused in the new building itself, thus reducing the environmental impact.

In addition, in 2017, GM launched in the Complex the largest solar heating system of the automotive industry. There are 560 square meters installed on the roof of the plant in São Caetano do Sul to supply hot water to the showers of the plant, equivalent to supplying the daily consumption of 900 houses.

The system has 280 solar panels and heat pump systems, with capacity to supply 300 showers, eliminating the need to use steam and avoiding the consumption of natural gas. These and other actions in the field of sustainability and the support to social projects have always been part of the company’s history over the past nine decades, especially in recent years and increasingly in the future.

In São Caetano do Sul, for example, an industrial wastewater reuse system has been implemented since 1989, which is used in industrial processes, avoiding the consumption of potable water. These systems have enabled the reuse more than 628 million liters since 2005, with 121 million liters only in 2016.

In Mercosur, GM already has four factories certified pursuant to ISO 50001, the energy management standard, and the plant in São Caetano do Sul was certified in January 2017.

Among the global acknowledgments, the factories in São Caetano do Sul, Mogi das Cruzes and Gravataí were selected by the US Environmental Protection Agency for having reduced energy consumption within the Energy Star Challenge for Industry Award, the only automaker to have this recognition in Brazil.

The company’s environmental policy was recognized with important awards, such as the recertifications of the Wildlife Habitat Council (WHC), for the preservation of green areas and the environmental education in Gravataí (RS), Joinville (SC) and São José dos Campos, São Caetano of South, Mogi das Cruzes (SP). In addition, GM awards the best projects of its suppliers, dealers and employees in the area of sustainability with the “GM Sustainability Award”.

 

Historical milestones of GM São Caetano do Sul

1927

  • Beginning of plant construction in the city of São Caetano do Sul.

1930

  • 50,000th Chevrolet car produced in Brazil and, on October 1, the assembly of vehicles began in São Caetano do Sul.

1934

  • In 1934, the first bus with a wooden body made in Brazil  is produced in São Caetano do Sul.

1968

  • In November 1968, the first Chevrolet passenger car produced in Brazil, the Chevrolet Opala four-door, rolls off the line. The factory underwent several renovations to make this possible.

1979

  • On December 12, the plant celebrates the production of the 1.5 millionth vehicle.

1982

  • In 1982, plant begins manufacturing the Chevrolet Monza. A few years later, the model became the best-selling model nationally for three consecutive years.

1988

  • On February 2, the company opens its Technology Center in São Caetano do Sul.

1989

  • On October 5, opening of the Acid-Alkali Industrial Wastewater Treatment Station of São Caetano do Sul.

1992

  • In April 1992, after 23 uninterrupted years of production and almost 1 million units produced, the Opala is discontinued, giving rise to the Omega.
  • This same year, the plant began its industrial wastewater treatment plant for oil.

1993

  • GM celebrates the production of the 5 millionth Chevrolet, a Vectra GSi sports edition, newly launched and also produced at the plant in SCS.
  • The Chevrolet Training Center of São Caetano do Sul opened on December 13, along with Chevrolet Customer Service Center.

1995

  • In February, the passenger car plants in São Caetano do Sul are ISO 9002 certified. GM is the first automaker in Latin America that receives the certification for two plants at the same time.
  • On June 5, the plant in São Caetano do Sul celebrates the production of the 3 millionth vehicle.

1998

  • In September 1998, the Kadett is discontinued at the plant in São Caetano do Sul, and the plant begins to make the Astra and Vectra. The Astra had a particularly long run, being in production until 2011.

2008

  • In 2008, with a further expansion of the plant, new employees needed to be hired and a third production shift started.

2010

  • The factory in São Caetano do Sul goes through a major overhaul and starts manufacturing the new Montana, Cobalt and Cruze Sedan.

2012

  • Spin and Cruze Hatch join the new product line of the plant.  

2013

  • In March, at the industrial complex of São Caetano do Sul, GM celebrates the production of the 100,000th Cobalt.
  • São Caetano do Sul receives Energy Star Award (US Environmental Protection Agency) – EPA Challenge for Industry
  • The General Motors plant in São Caetano do Sul is recognized by the Wildlife Habitat Council (WHC), an international non-profit organization dedicated to nature conservation.

2014

  • In 2014, the complex reaches 6 million cars produced, a historical record for GM in South America.

2015

  • Logistics Center for Receiving and Sequencing Production Materials (MASC) is inaugurated in São Caetano do Sul, where it uses an innovative management method for the automotive industry standards and aims at increasing productivity.
  • GM complex in São Caetano do Sul celebrates its 85th anniversary, becoming Brazil’s longest-running factory in the automotive sector.
  • Operation in São Caetano do Sul is certified by ISO 50001.

2017

  • Operation in São Caetano do Sul is recognized by Aterro Zero (Landfill Free Program).
  • Opening of the industry’s largest solar energy system with 560 square meters of solar system installed at the São Caetano do Sul plant
  • Spin reaches the mark of 200,000 units produced in São Caetano do Sul
  • Recognition of Energy Management Insight Award from the Clean Energy Ministerial (CEM).
  • Complex receives Environmental Award from the Corporation
  • Implementation of the Ecogren project, aimed at the environmental education of children in the city.

 

 

Check out the main models manufactured in São Caetano do Sul since its opening:

 - Opala

- Monza

- Omega

- Vectra

- Corsa

- Kadett

- Astra

- Montana

- Cobalt

- Cruze

- Onix Joy

- Spin

 

About GM

Founded in 1911, in Detroit, Chevrolet is one of the world’s largest car brands, doing business in more than 100 countries and selling more than 4.0 million cars and trucks a year. Chevrolet provides customers with fuel-efficient vehicles that feature engaging performance, design that makes the heartbeat, passive and active safety features and easy-to-use technology, all at a value. More information on Chevrolet models can be found at www.chevrolet.com.

In 2017, the operations of Argentina and Brazil were integrated into GM Mercosul. In 2017, Chevrolet sold 517,127 vehicles in the two markets, 394,157 in Brazil and 122,970 in Argentina. GM Mercosur has four Industrial Complexes that produce vehicles, engines and components in São Caetano do Sul, São José dos Campos and Gravataí, Brazil, and in Rosario, Argentina. It also has units in Joinville (production of engines and aluminum heads), Mogi das Cruzes (production of stamped components), and Indaiatuba (Test Field), Technology Centers in São Caetano do Sul and Rosário, and Logistics Centers in Sorocaba and General Rodriguez, Argentina. For more information, please visit http://media.gm.com/brasiland on Twitter: www.twitter.com/GMBPress