In Rennes La Janais, in the aisles of the PSA plant, we say thank you to the C5 Aircross. The “C84”, as Citroën’s new vehicle is called internally, made it possible to ensure the durability of a site born in the 1960s but whose future seemed rather gloomy before 2015. “It is now the the most modern factory of the group! “Enthuses Gilles Saliou, who led the transformation of the site started almost two years ago.
On the night of May 18 to 19, the historic assembly line, which has seen many mythical Citroën vehicles, has definitely closed. Since then, all the Peugeot 5008 and C5 Aircross that come out are made using methods and with the latest technologies. “We have moved into another world – not without emotion,” says Thérèse Joder, the plant’s director.
Some sacrifices
This revolution required immense energy and some sacrifices. “We come back from far! “Recalls Jean-Marie Bertho, CFE-CGC delegate in Brittany. After having produced nearly 400,000 cars in the 2000s, the historic Citroën plant almost closed during the 2012 crisis. It will be saved in 2013 by the decision to award the Peugeot 5008, but it must a second vehicle to ensure its durability.
“To get production of the C5 Aircross in Europe, it was necessary to significantly improve its competitiveness,” says Thérèse Joder. In 2016, the main unions accept a wage freeze over three years, in return for an investment 100 million (of which 15% is borne by the local authorities) and the hiring of 100 temporary workers. An agreement, which is superimposed on that signed by PSA at the national level.
Transform the production process
The group had already invested 90 million euros in 2015 to host the 5008 but, this time, the site is of another magnitude: it is a question of completely transforming the production process. Today, dozens of shelves with white plastic compartments surround the cars being assembled: “full kitting” has been generalized, consisting in preparing all the parts necessary for a vehicle upstream, instead of having to pick them up at the edge of the line.
Throughout the bays, the ballet of AGV (Automated Guided Vehicles) is impressive: these small autonomous trucks, which are responsible for a multitude of logistical tasks instead of drivers, are now 180 in Rennes. “We have also adopted a system of variable heights, allowing operators to no longer have to bend down or lift their arms to insert the components,” said Gilles Saliou. Here, it is a rising and falling floor, on which is placed the car. Further, it is a swing, to which it is suspended.
“Compact” production
The transformation must also make it possible to “compact” the production: by gaining on the surface, it is a question of limiting the fixed costs. In total, the site will grow from 220 hectares including 53 covers, to 83 hectares including 35 covered. One part has already been sold, another is rented, in particular to some suppliers who come to settle closer to the production. Faurecia now manufactures its seats here, “a world first”, insists one in Rennes.
With the C5 Aircross, the production of the plant could go up to 150,000 cars a year against just over 100,000 expected this year. If the 5008 continues to work well (86,000 sales in 2017 for a launch in March), it will even transfer part of its production to Sochaux _ about 40,000 units would be kept in Rennes.
A terrible pressure
What reassure employees – even if for now they suffer from overheating that wins PSA in France. “There is a terrible pressure, especially on the middle hierarchy”, insists Jean-Marie Bertho, recognizing that it is now “problems of the rich.” Rennes has started hiring, for the first time in fifteen years: 12 people in 2017, about twenty planned this year. With 2,500 employees, including 900 in interim, the plant remains far from the 15,000 employees of the 2000s.