New Opel Vectra and Signum

Signum: Highly Successful with Athletes and Managers

 

Everything in Frank Piroth’s life is about sport. He earned his first pocket money as one of the best young tennis and hockey players in Hesse, went on to earn a little more money by giving lessons as a trainer, and when he started university, what other subject could he choose apart from sports science? After finishing his degree, he soon found a job as a sports editor at the popular private radio station “Hit Radio FFH� in Bad Vilbel in Hesse. And when he chose to change his car brand after owning six different Audi models (“The last one was an A4 Avant,� he says), it comes as no surprise that he did not buy just any variant of the Opel Signum, but rather the “Sport� version.

 

“The car not only looks great, it is also an absolute space miracle, and its versatility is incredible,� the 37-year old sports enthusiast says about his new all-rounder. It holds everything the sports fan needs for a relaxing weekend with his girlfriend and “Baba�, the mixed-breed dog he brought home from India: all their luggage, two mountain bikes, a golf bag, water skis, etc. And the space and chassis of the Signum are great both for when he goes golfing with his good friends Jürgen Grabowski and Bernd Hölzerbein, the Frankfurt soccer heroes and members of the German national team, and when he goes to an away game with his ice hockey team mates and their bulky sports bags.

 

The Signum’s chassis with the 3.0 V6 CDTI engine earns high praise from the sporty driver, too: “Better than everything I had previously been used to; absolutely first-class; it drives as if on tracks,� is the verdict from the frequent driver, who drives a distance of between 30,000 and 35,000 kilometers every year for both personal and professional reasons. “I have been driving for 19 years and have never caused an accident,� he says.

 

Sports editor Frank Piroth is also impressed with the price/performance ratio of his Opel Signum (“an incredibly attractive car for the money�). An opinion that more and more people seem to share. Michael Gergen, market researcher at Dataforce in Frankfurt, has observed that the Signum is increasingly popular as a company car. An interesting result of his analysis: in the first half of 2005, the versatile car with the elegant body line accounted for a share of nearly ten percent of all Opel sales in the fleet market segment.

 

The Signum was especially successful in the company car parks of service providers. “It is mainly driven by field staff and the management�, says the Dataforce expert, and his analysis is confirmed by studies by the Opel marketing department, which determined that the largest buyer group (around 21 percent of all Signum buyers) is comprised of managers and directors. And, just like in the case of Frank Piroth, the main buying motives of these customers are the car’s design (34 percent) and spaciousness (20 percent).

 

Lightweight construction and passive safety

 

Body: High-Strength Materials, Crash-Optimized Structure

 

• Clever mix of materials: high-strength steels, aluminum and magnesium
• Extensive safety equipment for all passengers as standard

 

One of the few similarities between the 2005 Opel Speedster turbo and a 1965 Opel Rekord 6 is their curb weight. A comparison between the Speedster, which boasts an extremely lightweight construction, and the six-cylinder sedan built 40 years ago is an impressive example of the challenge that lightweight construction poses to modern automobile development. High demands on safety and comfort, and to a certain extent the increase in size, would have made modern cars even heavier, had it not been for the increased use of lightweight materials. The Opel Vectra (curb weight 1375 kg) and Signum are examples of a consistently lightweight construction with no compromises in passive safety.

 

High-strength materials guarantee rigid passenger cell

 

The new generation Vectra and Signum are impressive proof that it is possible to combine lightweight construction and safety with high quality. Thanks to the extensive use of lightweight yet extremely high-strength materials, both models have very rigid passenger cells that provide a large survival area in all accident scenarios. In the event of a collision, the energy is absorbed by a number of main load paths, high-strength cross bars, as well as predefined deformation zones behind and on the side of the extremely rigid passenger cell. In a frontal crash, the impact is absorbed by the frame structure, the front axle subframe and the wheelhouse braces, while in a rear end collision, the energy is absorbed by the frame under the passenger cell and directed over the highly stable C and D-pillars as well as the wheelhouses into the roof structure. Crash boxes bolted onto the frame create an additional buffer between the bumpers and the frame.

The design and construction of the doors minimize the consequences of a side collision thanks to their integrated steel barriers and additional high-absorption cushioning elements, B-pillars made of high-strength boron alloy steel, a B-pillar/roof cross member structure made of high-strength PHS (Press Hardened Steel) as well as large, stable door sills. The higher rigidity of the high-strength steels used for plates and crossbeams means that they are thinner and, consequently, lighter. These high-tech materials make up 52 percent of the body-in-white weigth.

 

Light and stable: Aluminum and magnesium reduce car’s weight

 

Opel engineers also achieved weight reductions through the use of aluminum and magnesium. Aluminum bumpers, for example, weigh as much as 14 kg less than steel structures. The hood is also lightweight aluminum, making it 45 percent lighter than conventional sheet steel hoods. Numerous chassis components of the Vectra and Signum, including all transverse control arms, are also made of aluminum. The instrument panel cross member is made of magnesium, which is even lighter and stronger. It weighs only 6.2 kg.

 

Signum: Active head restraints now also for rear seats

 

Standard safety equipment includes front and side airbags, head curtain airbags in front and rear, three-point safety belts for all seats, seat belt pretensioners in front (also in the rear of the Signum with sliding rear seats), belt-force limiters in front and rear, as well as height-adjustable safety belt pivot points in front and rear. This is complemented by the Opel SAFETEC safety system, which includes the patented automatic Pedal Release System (PRS) and, in the Vectra, active head restraints in front with seat back support to further reduce the risk of whiplash. As the first automaker worldwide, Opel also offers this innovative protection system in the Signum’s outer rear seats as standard. Head restraints on all seats are height-adjustable. The extensive passive safety equipment is rounded off by the Interactive Driving System (IDS), which has been improved especially for the new Vectra and Signum models and provides a high standard of driving precision and active safety.

 

As an option, the Vectra and Signum are also available with a seat occupancy detector for the front passenger seat, which prevents the two front passenger seat airbags from deploying when the seat is not occupied. Additionally, a sensor in the seat detects whether an Opel child’s seat that is equipped with a transponder has been fitted in the front passenger seat. When a child’s seat is detected, the system deactivates the front passenger seat airbags, while the side head curtain airbag remains activated.

Chassis and Active Safety

 

IDS Chassis: Improved Driving Dynamics, Comfort and Safety

 

• More agile handling, increased comfort
• Innovative IDSPlus chassis now also available with 2.2 Direct

 

While the chassis of the Opel Vectra and Signum was already exemplary in its comfort and safety, the new models boast even more agile handling, improved comfort and more precise steering. Further development of the chassis has produced impressive results: distinctive driving dynamics for even more driving fun with added comfort.

 

With the Vectra and Signum’s IDS chassis system (Interactive Driving System), already known for its comfort and safety, Opel engineers had an ideal basis for their modification work. So when it came to the modifications for the new mid-size class models, they were able to concentrate on precision fine-tuning. For example, the vehicle suspension compresses more easily, due to the newly positioned stabilizer which reduces friction on the front axle, thereby better aligning it to the damping of the car. It is most noticeable during slow driving on bumpy roads. The front wheel drive cars now glide even more smoothly over bumps and uneven surfaces.

 

More sensitive response to all road conditions

 

The design of the mid-size class range’s four-link rear suspension also helped to reduce friction, which consequently enables easier suspension compression. This was achieved with the help of a total of six new bushes in the wishbones. With additional intermediate plates, the bushes enable a noticeable improvement in the movement of the axle – which leads to considerably more smoothness, especially in the case of one-sided suspension compression. The next stage of the chassis modifications involved the alignment of the shock absorbers to the lower breakaway torque of the springs, which results in more direct suspension response. Chassis specialists at the International Technical Development Center (ITDC) in Rüsselsheim thereby achieved increased comfort, without compromising agile handling.

 

But not only were the dampers of the IDS chassis re-tuned - no fewer than the around

130 parameters in the software of the adaptive electronic IDSPlus chassis with Continuous Damping Control (CDC) were adjusted to correspond to the modified chassis. The increased driving dynamics are also a result of the modified rack-and-pinion power steering, noticeable in improved steering precision in the straight-ahead position.

 

Electronic Stability Program ESPPlus to safely stay in lane

 

The basic design of the IDS chassis, which combines the different control and safety functions of the individual chassis components, remains unchanged in the new Vectra and Signum model year. IDS is comprised of a MacPherson strut front axle anchored to the subframe, and a four-link rear axle, both with aluminum components to reduce unsprung mass. Additional features of the IDS system include four-channel ABS with Cornering Brake Control (CBC) and Electronic Brake Force Distribution (EBD), Traction Control TCPlus with engine and brake intervention (from 1.8), as well as brake assist.

 

A particular highlight is the Electronic Stability Program ESPPlus, which is standard in the latest generation (from 1.8) and ensures even greater driving stability and increased active safety. The "Plus" refers to the enhancement of conventional systems. Braking forces are applied to up to three wheels to compensate extreme understeer situations. As a result, course correction is carried out much more sensitively and more effectively. All Vectra model variants have large disc brakes and the front discs are internally ventilated for optimal heat dissipation.

 

Comfortable and safe thanks to the unique IDSPlus chassis

 

The adaptive IDSPlus chassis with electronic Continuous Damping Control (CDC) ensures a constant optimum balance between driving comfort and stability. This networked high-tech chassis system, which is unique in the mid-size class, is standard with the new

2.8 V6 turbo gasoline engine and the 3.0 V6 CDTI unit.

 

It is available as an option for the ECOTEC 2.2 Direct, the 2.0 turbo models and the

110 kW/150 hp 1.9-liter common-rail diesel engine. The electronic CDC is based on four shock absorbers controlled by solenoid valves, which precisely and continuously adjust the shock absorbers to ideally adapt to prevailing road conditions, vehicle movements and individual driving style within milliseconds.

 

This ensures the highest possible suspension comfort and optimal road grip under all driving conditions. IDSPlus  networks all dynamic driving systems such as ESPPlus, TCPlus, ABS and CDC via CANbus (Controller Area Network), forming an integrated chassis control system.

 

This networking forms the basis for optimized handling performance in terms of comfort, safety and dynamics on an even higher level. Calibrated damper adjustment improves steering performance, allowing later and thereby significantly more sensitive ESP activation. When braking, the system adjusts the shock absorber settings to adapt to the road surface for optimal ABS control, which improves braking characteristics, especially on bumpy roads. Thanks to minimized wheel vibrations, braking distance on roads with loose or uneven surfaces is reduced by up to five percent – a decisive advantage, considering the deteriorating quality of roads. In addition, IDSPlus enables a measurable increase in safety when individual wheels are on a different type of surface, or on wet roads, ice or snow.

 

Sport function: More fun with sporty driving at the touch of a button

 

The IDSPlus chassis system also offers the choice of a tighter, even more agile setup at the touch of a button. The SportSwitch function not only regulates damper characteristics, it also enables more direct gas pedal response and the map-controlled electro-hydraulic power steering switches to a more sporty, higher steering effort level. In conjunction with automatic transmissions, the gearshift points are set at higher rpm to allow for a sportier driving style.

 

Better visibility thanks to AFL – enhanced safety for night driving

 

The Adaptive Forward Lighting (AFL) system with bi-xenon headlamps, an Opel innovation for mid-size class automobiles, makes a significant contribution to safety. This advanced system, which was introduced in 2003 and is still leading-edge, is the first to combine dynamic curve light with static cornering light and adaptive highway light. In curves, the steering-linked headlamps swivel up to 15 degrees into the curve the car is traveling through – a considerable plus in active safety and comfort.

 

An additional reflector provides wide-angle illumination of intersections and tight curves, dependent on turn signal, steering wheel position and speed (up to 40 km/h).

 

AFL also features a special highway light function: on straight stretches at speeds above around 120 km/h, the low beams automatically shift slightly upward to ensure optimal illumination without blinding oncoming traffic.

 

All Opel mid-size class models feature adaptive brake lights as standard, ensuring added safety. In the event of heavy braking and deployment of ABS above speeds of 30 km/h, any following traffic is warned via the flashing of all three brake lights at a frequency of five hertz. If the car comes to a standstill, the flashing brake lights remain active for three seconds; if the car does not brake to a standstill, the lights continue to flash for two seconds when the brake pedal is pressed. Opel is the first carmaker to introduce this technology into the mid-size class. More comfort and safety is also offered by the Automatic Lighting Control system ALC: with the help of two sensors in the windshield, the headlights are automatically turned on in tunnels, parking garages or as darkness approaches. When the car returns to a brighter environment, ALC automatically turns them off. Opel offers this system together with rain sensors, photochromatic rearview mirror and automatically regulated instrument panel illumination in the Visibility package.

Interview: Horst Bormann, Chief Engineer, Chassis

 

"The Vectra takes a leading position in its class in terms of comfort"

 

The Vectra and Signum’s IDSPlus chassis has been highly praised by both customers and testers. And yet you have modified it for the new generation...

 

Thank you for the complement. However, we did not want to rest on our laurels; we wanted to become even better. We were mainly focused on optimizing handling and making the chassis more comfortable, but with the very clear objective of not compromising agility for better comfort. On the contrary, the stability limit should even be increased. And I believe that this is exactly what we have achieved with increased steering precision, detailed work on the front and rear axles, and the dampers adjusted to the modified to the chassis.

 

How much time did this modification work take?

 

Between seven and eight months, taking into account all of the modifications. I would like to mention one statistic to underline the extent of this work. For the electronic damping control alone, there are 130 parameters that can be varied. Any change to one element, affects all the others. To put it simply, if one screw is turned, then all the others must also be turned in order to achieve the desired harmony.

 

How can the changes to the chassis be recognized then, compared with the previous model?

 

One example is the so-called slow-speed comfort. This applies to driving on bumpy roads. The new Vectra runs noticeably smoother in this situation. The reason for this is the reduced friction in the bearings and bushing, which allows the suspension to compress more easily.

 

How do you assess the quality of the Vectra chassis compared with the competition in the mid-size class?

 

If I am to agree with the opinions of professional testers, then we are taking a leading position with this range with regards to comfort. And, at the same time, with superb handling. The big challenge for us chassis people is with this exact combination. Linking the two aspects together harmoniously is the true art of chassis design.

 

Do computer calculations and simulations today play a greater role in the development of the chassis than the engineer’s experience and testing?

 

Absolutely not. As important and timesaving as the computer work is, what we call the "popometer", in other words evaluation in practice, is irreplaceable.

 

Will systems such as ESPPlus and electronic Continuous Damping Control (CDC), which are already available in the Vectra today, play an even more important role in chassis design in the future?

 

The systems are already extensively networked today. For instance, when braking, the damping automatically becomes firmer to act against any dipping of the vehicle. I can imagine that the steering will also be incorporated into this adaptive network in the future, which would enable automatic counter-steering if the vehicle breaks away. Or an automatic change to the steering ratio in city traffic to make parking and maneuvering easier.

 

What is generally the most important criteria in chassis design?

 

I can answer that in one sentence: above all, a chassis must be safe, even without electronic aids.

 

Engines and Transmissions

 

State-of-the-art: Powerful, Fast, Economical and Pro-Environmental

 

• Brand new 230 hp high-tech V6 turbo gasoline engine
• Additional 1.9 CDTI variant with 100 hp
• 3.0 CDTI now with more power and performance
• Particulate filter with all diesel engines as standard
• Five and six-speed manual and automatic transmissions

 

A wide range of modern, powerful gasoline and diesel engines is available for all new Vectra and Signum models, turning the promise made by their distinctive design into action on the road – outstanding driving dynamics, economical fuel consumption and optimal emission purification. This applies not only to the top-of-the-line unit, the new 230 hp V6 turbo gasoline engine that makes the mid-size class Opel faster than ever before with a top speed of 250 km/h (electronically limited), but also to the advanced CDTI diesel engines with common-rail direct injection and Diesel Particulate Filter (DPF) as standard. For the new edition of the Vectra and Signum, the 1.9-liter CDTI range has been extended with a 100 hp entry-level version. The power output of the 3.0-liter V6 CDTI, the most powerful diesel in the range, has been increased by seven hp, now boasting 184 hp. There are now more engine/transmission combinations to choose from, with the front-wheel drive cars available with both five and six-speed manual and automatic transmissions.

 

The top-of-the-line engine for the Vectra and Signum models is the 2.8-liter unit, newly developed by GM Powertrain, with numerous high-tech features. The turbo unit shares many of these features with the two six-cylinder naturally aspirated engines (2.8 and 3.6-liter), which are also part of the new fully aluminum range, used worldwide by General Motors. As well as a classic cylinder angle of 60 degrees and overhead camshafts driven by dual chains, common features with the 24-valve unit include variable valve control and a four-bearing crankshaft made from micro-alloyed forged steel – a material also commonly used in racing engines.

 

Details such as friction-reducing coated pistons highlight the extensive design work that went into the V6 engines. The pistons are equipped with hard anodized ring slots for a longer life cycle, run in cast iron bushes and are oil-spray cooled. Sintered connecting rods, exhaust valves filled with sodium for better cooling, and the oil sump, which is especially rigid due to its die-cast aluminum construction, also represent state-of-the-art technology.

 

Top turbo: Twin-scroll turbocharger and variable camshaft control

 

The twin-scroll turbocharger is reserved for the 9.5:1 compression ratio top-of-the range unit for the Vectra and Signum. The intercooler system, which is centrally mounted above the transmission, has an integrated waste gate and supplies the engine with a maximum of 0.6 bar excess pressure. The turbine wheel is made of a high-quality special steel composition. Due to its twin-scroll design, the turbine is fed simultaneously from both rows of cylinders. Separate channels – one for each bank of cylinders – separate the exhaust gas pulses. On the one hand, the operating principle minimizes turbocharger energy losses and, on the other hand, it has a positive effect on the exhaust gas flow and efficiency.

 

Rapid response and excellent torque even at low engine speeds are also provided by the continuous, electronically controlled, hydraulic phasing of the inlet camshafts. They can be adjusted over a range of 50 degrees with respect to the crankshaft, in order to optimally vary the valve timing and thus optimize the charge cycle to suit the engine load and speed. Like the outlet shafts, the inlet shafts are also made from high-strength aluminum. This makes them particularly light, heat-resistant and durable.

 

250 km/h top speed: New record for Opel mid-size class

 

Along with the turbocharger response, the rapid and smooth power development is mainly thanks to the 32-bit Bosch Motronic engine management system. The control unit software, which has been specially adapted to suit the Vectra and Signum models, controls all key functions such as ignition timing, fuel injection, turbocharger pressure, air mass measurement and the throttle valve position. Like the technical data, the new engine’s power development is also impressive. The 2.8-liter unit provides 90 percent of its 330 Nm maximum torque at only 1500 rpm. This top figure in its displacement class is then available over a wide range of 1800 to 4500 rpm. The engine’s driving performance is equally impressive.

 

Only 7.3 seconds are required for the zero to 100 km/h sprint, and top speed is 250 km/h (electronically limited) – a new record in Opel’s mid-size segment range. This is all complemented by an MVEG average consumption of only 10.3 liters of gasoline per

100 kilometers.

 

Pro-environmental use of fuel is also a matter of course for the four other ECOTEC gasoline engines in the Opel mid-size class range, as the following overview of consumption and performance data shows (data from Vectra sedan):

 

* with five-speed transmission, ** with six-speed transmission,  *** electronically limited

 

100 hp common-rail diesel engine extends 1.9-liter CDTI range

 

State-of-the-art common-rail diesel engines are playing an increasingly important role in the sales success of the mid-size class models and are now ordered by the majority of mid-size segment customers. Consequently, Opel has extended the diesel range with a new entry-level version: the new 1.9-liter CDTI variant has a power output of 100 hp. It uses the same modern diesel technology as its 120 and 150 hp 1.9-liter counterparts, although the engine electronics are controlled by different software. Like the 120 hp version, this new engine also has two valves per cylinder, while the 150 hp unit is equipped with four valves per combustion chamber. The core of all three common-rail units is a highly efficient multiple direct injection system (injection pressure: 1600 bar), which ensures low fuel consumption, excellent exhaust gas values and smooth, quiet running.

 

The top-of-the-line diesel engine in the Opel mid-size class range is still the 3.0 V6 CDTI. However, the power output of the new generation of the six-cylinder fully-aluminum engine with common-rail direct injection is now 184 hp, an increase of seven hp, and its maximum torque has risen by around eight percent from 370 to 400 Nm.

 

Like the 1.9-liter turbo diesel, the powerful V6 is also fitted with a Diesel Particulate Filter (DPF) as standard. The system is maintenance-free and thanks to its innovative technology, does not require additives.

 

The following overview details the power and economical fuel consumption of the individual CDTI engines (data from Vectra sedan).

 

All with six-speed transmission

 

Automatic transmission with additional manual function

 

Apart from the two entry-level gasoline engines with displacements of 1.6 and 1.8 liters, all units are combined with a six-speed manual gearbox as standard. For the more powerful engine variants, a five-speed automatic (2.2 Direct) or a six-speed automatic with ActiveSelect function (2.8 V6 Turbo, 150 hp 1.9 CDTI and 3.0 V6 CDTI) are also available. In addition to the fully-automatic mode, ActiveSelect gives the driver the option of changing gear manually in a second shift gutter by simply tapping the gearshift lever. Both transmission units are adaptive, adjusting automatically to prevailing driving style and road conditions. The increased ratio spread in sixth gear improves performance, while reducing fuel consumption. Light transmission oil, which has been newly introduced and does not need to be changed during the unit’s entire life-cycle, also contributes to optimal fuel consumption.

 

In focus: From Two to Six-Speed – The Successful Progress of Opel’s Automatic Transmission

 

It was something that car drivers of the early Sixties could only dream about: a five or six-speed automatic transmission, with the option of changing individual gears manually. Something that is optionally available to Vectra and Signum buyers today, thanks to the automatic transmission with ActiveSelect function, was inconceivable in Germany at that time. With the launch of the Kapitän A and Admiral A in 1964, Opel drivers rejoiced that the automatic transmission was available with Opel cars for the first time – with two speeds. "Hydra-Matic" was the magic word for the technical achievement concealing the Powerglide transmission from General Motors (GM), which had now been modified for Opel’s  luxury class to suit European traffic conditions and driving habits.

 

"With the new Hydra-Matic", according to one Kapitän advertising brochure of the day, "you can conduct the whole score from slow train to express train speed with virtuosity. You can hardly imagine it being easier and more convenient." But this was, in fact, to happen. In 1969, with the Kapitän B, the first three-speed automatic developed by Opel came onto the market. Incorporated shortly afterwards into the Rekord, Ascona and Manta models, it made no small contribution to the success of Opel’s mid-size class range in Europe over many years. With the launch of the Omega in 1986, Opel sparked off the next phase, and for the first time produced a four-speed automatic. This was also to become a feature of the smaller Corsa and Astra models at a later date.

 

These automatic transmissions were and are mainly built in Strasbourg, in the factory of the 100 percent Opel subsidiary "General Motors Alsace", founded in 1968. Since then, however, the manufacturing facility has not only supplied transmission units to Opel and Vauxhall, but also to Cadillac (USA), Holden (Australia), and to other companies including BMW.

 

In focus: Developed, Built and Used Worldwide – New GM V6 Engines

 

The whole world is talking about globalization. General Motors (GM) – the largest automobile manufacturer in the world – doesn’t only talk about it, but has been operating globally for decades. The latest example of the company’s thinking across countries and continents is the new top-of-the-line engine for Opel’s mid-size class range, the 230 hp 2.8-liter turbo gasoline engine. This state-of-the-art, fully aluminum engine is part of the V6 range, which has been developed in close cooperation between GM Powertrain engineers in America and their European and Australian colleagues (Holden). Along with the turbo version, this collaboration has resulted in two six-cylinder naturally aspirated engines with 2.8 and 3.6-liter displacements, which are produced in factories in Canada (St. Catharines) and Australia (Melbourne). More internationalism required? As well as the Vectra and Signum, the engines – carefully adapted to suit the requirements of the respective brands – ensure high performance and low fuel consumption, for example in the Cadillac CTS, some American Buick models, the Saab 93 Aero and several Holden models.

 

In order that the engines, the costs of which are minimized by sharing up to 90 percent of their parts, could be used throughout the world, they were designed to fulfill the different requirements of the markets around the globe. Depending on the location or model, they have different valve timing in order to ensure optimum power development and best-possible emission behavior in the respective traffic and climate conditions. A further indication of the versatile and worldwide application of GM’s new V6 range is its intelligent basic design. It allows engines to be mounted transversely or longitudinally, and enables variants with intake-manifold fuel injection, turbo versions and variants with direct injection. Overall, the state-of-the-art, six-cylinder units cover a power output and torque range from 203 to 320 hp and 267 to 485 Nm respectively.

Quality and Economic Efficiency

 

Quality: Prerequisite for Affordable Mobility

 

• Signum: Best German model in customer satisfaction
• Two-year manufacturer’s warranty instead of mandatory guarantee
• Longer service intervals and affordable service-friendly solutions
• State-of-the-art manufacturing facilities and strict quality control

 

In the latest German study carried out by the renowned institute J.D. Power & Associates, an Opel takes first place in customer satisfaction (Customer Satisfaction Index – CSI), ahead of all other German automobiles: the Opel Signum. Other studies, as well as

30 victories in comparison tests carried out by the European automotive press since 2004, also confirm that Opel has re-joined the group of top automakers in terms of quality. Opel has focused on high quality and exemplary economic efficiency with a wide range of different measures for the new Vectra and Signum. This is underlined by state-of-the-art manufacturing processes in the new Rüsselsheim plant, as well as a two-year manufacturer’s new car warranty, which goes well beyond the mandatory guarantee requirements. Additional highlights include an extensively galvanized body, a 12-year anti-perforation warranty, favorable insurance categories, and long service intervals - high quality is a prerequisite for affordable mobility.

 

The repair-friendly body concept plays a key role when it comes to costs. The three-part frontal design and bolted-on crash boxes with aluminum crossmembers front and rear provide effective protection for load-bearing body structures in the event of minor collisions. Consequently, fast and cost-effective repairs can be carried out.

 

System inspection with software update

 

Longer service intervals and low maintenance requirements minimize the running costs of the new Vectra and Signum. Now, all models require their first main inspection only after two years or 60,000 kilometers (previously: gasoline 30,000 and diesel 50,000 km) and an interim service after one year or 30,000 kilometers.

 

Interim service includes oil change, a visual inspection, and a new system inspection with the possibility of updated software being installed. If, for instance, an optimized engine management system is developed and introduced in production vehicles, customers can have the new software version installed in their car, and are only charged for the labor costs. A large number of components are completely maintenance-free, such as the battery, clutch and belt drive. It is also not necessary to change the coolant for the engine or air conditioning system, or the transmission oil during the entire life-cycle of the car.

 

Modern production of Vectra and Signum leading-edge automobile manufacturing

 

Opel mid-size class range buyers also benefit from the high manufacturing quality implemented in the state-of-the-art production facilities at the new Opel plant in Rüsselsheim, where the zero-error principle is adhered to by all employees and comprehensive, strict quality controls are carried out. The manufacturing facility at Opel’s headquarters is one of the most modern plants in the world, and remains exemplary in automobile manufacturing. Approximately 750 million euros were invested in building the plant, which also sets standards in terms of quality.

 

The efficiency of the Opel production system is confirmed by outstanding results achieved by Opel models in many comparison tests and independent quality surveys. In the “AutoBild Quality Report 2004�, the brand came out on top of all German and European automakers. This comprehensive study of long-term quality, reliability and customer satisfaction focused on the 20 most important automobile brands in Germany and took into account a representative survey of around 25,000 car drivers, as well as the results from seven million technical inspections, the quality of the manufacturer’s repair and service, and warranty performances.

 

Front runner: Opel models top in customer satisfaction

 

The latest J.D. Power customer satisfaction survey produced an equally positive result. After Opel emerged above the average for all brands in the previous analysis, in 2005 the company again surpassed its previous best position. Among the volume brands, it boasts the largest improvement since the initial survey in 2002, having improved by 5.1 percentage points with a continuously increasing trend.

 

This steady upwards trend with regard to quality is also underlined by a survey conducted by The Automotive Research Center at the University of Bamberg. In their Dealer Satisfaction Index (DSI), which they have conducted since 1995, Opel excelled in “New Car Quality� with an excellent second place, well ahead of all other German automakers.

 

Unique Opel warranty is the best insurance

 

A further benefit offered by the Opel brand is, while many other car manufacturers refer solely to the dealers’ liability for defects, Opel offers its customers a two-year new car manufacturer’s warranty in addition to the mandatory guarantee. This is an apparently minor difference with major significance, as the mandatory guarantee only makes the seller liable for defects that the vehicle had at the time of purchase. After six months, the customer must prove that the defects existed at the time the vehicle was purchased. In contrast, Opel’s voluntary new car warranty entitles the customer to free-of-charge repair work (at all Opel service partners) for defects falling in the manufacturer’s area of responsibility – regardless of the car’s mileage and when the problem occurs within the two-year period.

In focus: How Quality is Made in Rüsselsheim

 

The rain is beating against the windows, the wipers are on high speed, and the dark blue Opel travels at a maximum of 20 kilometers per hour. It is a brand new Signum, which is covering its first few meters without the protective roof of Hall K 170, where it has just been built. The reason for the extraordinarily restrained driving is certainly not due to the weather, but to a sign that does not permit a higher speed. Be that as it may, it is just undergoing its final factory quality test, which is today second to none, on a so-called squeak and rattle track. To drive faster on it would not be a problem for the car, but would be for the driver.

 

In any case, the person behind the wheel sits comfortably in a dry car in all weather, as the quality process which the car has undergone also includes an extraordinary water test. Water at high pressure, sprayed from 300 nozzles from all directions, literally puts the car under water for a good two minutes. Highly sensitive electronic sensors then probe for any leaks so that these can be repaired – one of the procedures from the new Opel plant in Rüsselsheim which has been shown to be so successful that it has become  standard at General Motors throughout the world.

 

As the new Rüsselsheim plant project – the production facility for the Opel Vectra and Signum – entered the concrete planning phase at the end of the nineties, apart from the precedence of work safety, there were four priorities defined in comparison with the earlier facility at Opel’s headquarters, which had been modernized time and time again over the years. These were productivity, flexibility, ergonomics – and above all quality. Opel has not only set new standards in terms of technology, but also in terms of organization. All staff had already been trained two years before the start of production in January 2002 as part of "dual", the largest training program in the company’s history. Part of the training took place in the company’s own internal training school; the rest, for deeper familiarization with operational practice, was carried out on-site.

 

The Rüsselsheim plant represents the latest stage of evolution of the standardized Opel production system, which has influenced automobile manufacturing in its entirety.

 

Its most important elements are the principle of lean manufacturing and group work.

 

This was therefore the name of the first "subjects" on the timetable for standardization – as a reproducible basis of any quality work – and the zero-error principle. In practice, this principle means that no employee in the whole of the production process may accept errors from a previous station, produce errors himself, or pass these on to the following station. If an employee discovers that there is a quality problem or that he himself cannot carry out his task within the allotted time, he pulls the "Andon cord", which runs above all stations of the assembly line. This intervention initiates a visual and audible signal, and thus summons the group supervisor to provide assistance. Faults are rectified immediately by the team on the spot. If necessary, the belt is also stopped.

 

Before the new cars reach the final station in the hall, the CARE belt, there are integrated "quality gates" they must pass through in the production process, which ensure that all work to the vehicle was completely and properly carried out. In the final quality check, CARE specialists then have over 200 individual positions on the car to check. They do this with a critical view through the customers’ eyes, only allowing a car to leave the hall when the check has a fault-free result. And then it is on to the squeak and rattle track to ensure that the new Opel does not make any impermissible noises.

 

The outstanding marks achieved today by the Vectra and Signum regarding quality in comparison tests are therefore not chance occurrences. In an assessment of customer satisfaction 2005 (Customer Satisfaction Index - CSI) in Germany by J.D. Power, the Opel brand achieved an above-average position and – since the start of the survey in 2002 – has improved by 5.1 percentage points on a continuously upwards trend. This is the greatest improvement amongst German manufacturers. The Opel Signum was named best German car in this survey; taking all brands into account, it came in sixth of 119 international competitors.

 

In focus: Stress and Strain on Patrol – the Vectra as a Police Car

 

Marathon runner? Shift worker and manual laborer? They all apply when one looks for an appropriate description for those Vectra models that pass the hardest everyday test. Location: the roads in the German states of Brandenburg, Hesse, North Rhine-Westphalia, Rhineland Palatinate and Saxony-Anhalt. Time: Round-the-clock in three-shift operation. We are talking about a total of more than 2000 Vectra sedans and Vectra station wagons being used by the German police. They are identified by their silver-green coloring, although some are already silver-blue as the European standard colors.

 

When the patrol cars are used in cities, they cover around 40,000 kilometers per year. If, on the other hand, they are used for motorway driving, they quickly run up 100,000 kilometers over the same period. There is always a different driver behind the wheel, the work schedule calls for constant getting in and getting out, and grueling braking and acceleration are the order of the day. Regardless of where they are used, since 2004 all police Vectras have been fitted with the 150 hp 1.9-liter CDTI diesel engine and automatic transmission.

 

The police Vectras are prepared for the strenuous work involved in car chases and traffic control by engineers at the International Technical Development Center (ITDC) in Rüsselsheim in cooperation with Opel subsidiary Opel Special Vehicles GmbH (OSV). Here, the engineers implement the useful and necessary additional equipment for police vehicles that the technicians have previously devised. And, at the same time, the designers not only take into account the special wishes of the police experts, but also call upon their vast experience, gained with, for example, the Vectra A that was the most common patrol car in Germany until the mid-nineties.

 

The OSV staff need about 30 hours to carry out the special modifications to the vehicles, which are built as part of the regular production process in the neighboring Vectra plant in Rüsselsheim. Due to the extra weight, they are equipped with more powerful brakes (16 instead of 15-inch). In addition, they have a more rigid and 20 mm higher chassis, plus a protective mesh for the engine so that driving on rougher roads does not present a problem.

 

A more powerful alternator and battery are fitted to supply the more comprehensive range of additional equipment. Special radio interference suppression and a reinforced roof for mounting the brackets for the flashing blue light and siren complete the conversion.

 

The patrol cars are also given their two-tone paint finish in the OSV workshops. However, the word "paint" is now no longer correct. For what looks like green (or blue) paint is, in fact, film. The reason for this is that when the silver-colored police vehicles are resold after the expiry of the two-year leasing period, they can be made to look just like civilian vehicles thanks to the removable film. Any buyer dreaming of driving with the siren sounding and blue light flashing is therefore sadly misguided. Both of these items are fitted so that they can be removed without a trace. As a consolation, the more powerful brakes, batteries and alternator remain...

 

 “Authoritative studies show that Opel and its quality are on their way to the top. This was also confirmed in the latest German J. D. Power Report, a survey that also named the Signum today’s best German car when it comes to customer satisfaction. But that’s not enough for us. We don’t just want to be one of the best in the world in terms of quality – we’ve accomplished that already. We want to be number one.�