A change at the Vrchlabí plant

We’ve Brought the Vrchlabí Plant to the Top

Ivan Slimák is behind the successful transformation of the Vrchlabí plant from car production to producing DQ200 automatic transmissions. As he prepares to retire, he looks back over his career at Škoda Auto, which he joined in 1992.

You have spent 14 years managing the Vrchlabí plant. What do you value most about this engagement?

Above all, how the entire plant team managed the transformation from car production to producing modern automatic transmissions. Everyone in production, logistics and quality control learned new technologies and methods. Dozens of experts emerged from their ranks, and they are now at the top of their field. That is what I’m most proud of. For example, we have an excellent team of electronics engineers who can perform optimisation tasks. This puts us at the forefront, allowing us to continuously increase our production volume and introduce innovations.

We started with 5,000 transmissions per week. Today, our plant in Vrchlabí produces three times as many. Almost two-thirds of them are supplied to other VW Group brands.

Could you highlight some of these technologies?

For example, the digital twin has enabled us to prepare robot programmes even before the robots were delivered (more about the technology in the August 2020 edition of Škoda Mobil – ed.). This has saved time and space on the assembly line. Another interesting technology is our collaborative robots working together with people. They have already installed more than 12 million pistons in transmission mechatronics.

Let us go back to our plant’s transformation. What was the greatest challenge?

Producing transmission parts is highly specialised work. With our dual-clutch transmission, there were two key requirements: cleanliness and precision. Automatic shifting is handled by highly sensitive mechatronics, and a high degree of cleanliness must be maintained during its production. The transmission also consists of gears and shafts with hundreds of different parameters with micrometre tolerances. A human hair is about 50 micrometres thick, and in some areas, we work with a tolerance of two micrometres. I have to emphasise automatic inspection as well. At the end of our production line, we have checkpoints where we simulate driving with every transmission and test all the gears, cornering and so on. The whole process takes place without human intervention.

Is the DQ200 direct-shift automatic transmission, which is manufactured in Vrchlabí, something special?

It enables sporty driving on the one hand and economical driving on the other. This was the main goal the VW Group had in developing it. Thanks to a greater number of gears, it can use the engine at optimal speeds. Demand for it continues to grow, which is why the Vrchlabí plant is increasing its production and will be running at full capacity for the next few years.

The Vrchlabí plant was the first plant at Škoda Auto to achieve carbon neutrality. How did you do it?

We needed to increase our plant’s capacity, so we had to optimise everything. And the best approach was to focus on energy savings. We implemented projects targeting large energy consumers, such as the hardening shop and machine tools, but in other areas as well. We have systems that monitor our consumption in relation to changes in ambient temperature, production volume and other variables. It was a multi-year effort and, of course, it involved cooperation with ŠKO-ENERGO on purchasing green energy. We are seeing positive results and continue moving forward.

What experience did you bring to Vrchlabí from your previous positions, including those in Germany and China?

I got to know a number of new technologies and experts around the world, which helped me to build our plant in Vrchlabí. I knew whom to turn to and where to find what know-how within the VW Group. When there was a problem, our colleagues from the Group came to help us. In China, in particular, I had the opportunity to see two plants being built from scratch. There, one learned how to do everything – selecting employees and suppliers, building a factory, installing machines and even dealing with customers. In Vrchlabí, it was different. Here, we received a lot of help from our colleagues in Mladá Boleslav. Surprisingly, it was much easier to find qualified engineers in China.

Is it difficult to attract specialists to Vrchlabí?

I was very concerned about that. It is difficult to find electronics engineers, for example. However, we’re mostly successful, as Škoda Auto has a very good reputation here. And for some positions, we decided to train our specialists ourselves. It takes longer, but it pays off.

What are your plans after retirement?

I would like to devote more time to my wife, family and children. We have dogs, so I want to spend time in nature, play sports and read books. Just the usual things.

Have you grown fond of the Krkonoše Mountains thanks to Vrchlabí?

I grew up in the Tatra Mountains, so I’ve had a relationship with nature since my childhood, and my wife, children and I go there from time to time. Quite often, I would go skiing even in the evening after work with a headlamp. I especially like the area around Zlaté návrší (Golden Hill) and towards the source of the Elbe River.

And one final question. Do you prefer automatic or manual transmission in your car?

I used to think that manual transmission was the best, but I now prefer an automatic transmission. It reduces fuel consumption and allows the driver to enjoy the ride more. However, I don’t want to try to convince anyone, as every person has their own preferences.

Lars Bürger headed to Vrchlabí

On 1 December, Lars Bürger became the new Head of the Vrchlabí plant, specifically the PKD – Transmissions DQ department. A manager with many years of experience in component manufacturing, he previously worked at BMW, Mahle and Bosch, joining Škoda Auto in 2011, where he has held numerous positions. In recent years, he led the PKM – Engine EA 211 department.