History of the factory

Zawolzhsky Motorny Zawod has got the name after the name of "Zawolzhje" city located on the right bank of Volga river in 450 km from Moscow and in 60 km from the largest industrial centre of Russia - Nizhny Novgorod.

OAO “ ZMZ” is connected by railway with all regions of Russia, CIS and foreign countries.

Date of ZMZ establishmentis the 17-th of April 1958. At the beginning in 1956 as the branch of GAS, the future giant of engine building produced auto spare parts and aluminum castings for Gorky and Moscow automobile factories. However in two years it was reorganized by the Commission № 442 of USSR Council of Ministers into a factory for manufacture of engines for assembly of the vehicles produced by Gorky, Ulyanovsk and partially by Moscow automobile factories and was named as "Zawolzhsky Motorny Zawod".

From the very beginning of the activity ZMZ invariably paid significant attention to development of progressive technologies. The history of the factory was accompanied by development of essentially new designs, introduction of advanced techniques and own innovations.

The first melting process of aluminum casting was comleted at ZMZ in November 1958.

In 1966 the factory for the first time in global practice had mastered mass production of large-sized cylinder blocks from aluminum alloys employing die-casting that allowed it to join in one line with well known world companies

In November 1959 the first 4-cylinder engine for "Volga" GAS – 21 vehicle was assembled at ZMZ.

In 1960 with the purpose of new engine models development the design - engineering department which included R&D department with research laboratories equipped with test beds, and with control and other equipment.

In 1961 batch production of 4-cylinder engines was launched.

In 1963 batch production of 8-cylinder engines for trucks of Gorky automobile plant was also launched at ZMZ.

The enterprise extended and increased capacities both due to construction of new shops, (such as foundry, engine production site, press shop, bearings and strip production site, steel and iron parts manufacturing site, heat treatment shop, engine assembly and test shop), and due to upgrade of current manufacture.

1967. Supplies of 8-cylinder engine had been started also for assembly in "PAZ" buses made by Pavlovo bus factory.

In December 1968 1000000-th 4-cylinder engine has been manufactured.

In 1971 general reconstruction of the production had been started. By 1978 engine production capacity was increased up to 450 thousand units per year.

In December 1972 the factory was awarded with the name “Zawolzhsky Motorny Zawod" after the 50-anniversary of the USSR” by Decree of Supreme Soviet Presidium of RSFSR.

In April 1975 the 1000000-th 8-cylinder engine was made.

In February 1976 ZMZ was awarded with “Labor Red Banner” award as per the Decree of Supreme Soviet Presidium of RSFSR.

The 1980th were the period of growth of production capacities, reorganization of the enterprise.

In 1992 the shop of small series production was put into operation in which trial manufacture of new engine family - ZMZ-406, 4-cylinder, 16-valve, fuel controlled injection was organized.

In 1990th ZMZ designers developed a design of ZMZ-514.10 high-speed diesel engine (2,24 l), "Euro - 2" for cross-country vehicles and minibuses for the first time in Russian history.

In 2000 ZMZ became the first in Russia engine building enterprise, which certificated quality management system of the total manufacture meeting ISO 9001, the international standards requirements.

The new stage of Zawolzhsky Motorny Zawod development is related to a name of the new proprietor of the enterprise

In 2001 OAO "ZMZ" has become a part of JSC "Severstal - auto" holding.

In 2002 the manufacture of first trial production lots of ZMZ-514 diesel engine was launched at ZMZ jobbing plant for field trials in the secondary market.

In 2002 the unique automated system of planning and expense accounting was introduced. The system has no analogues at the mass production enterprises of Russian mechanical engineering.

In September 2003 ZMZ has certificated quality management system of the total production on conformity to requirements of international standards ISO 9001, versions 2000.

In November 2003 the design and pre-production models of the first series of ZMZ-215.10, 4-cylinder petrol engine (2,5 l), "Euro - 3" were developed and made at ZMZ.

In 2003 the introduction of the industrial system based on Toyota Production System components have been initiated at ZMZ.

On the 28-th of April, 2004 the 13000000-th engine has left ZMZ main assembly line.

In November, 2005 new assembly line was applied in production and industrial production of ZMZ-5143 diesel engine, economy class (2,24 l), meeting "Euro - 2" for UAZ-HANTER vehicles was launched at ZMZ jobbing plant.

On the 8-th of November, 2005 1000000-th engine of ZMZ-406 family was assembled.

The reorganization was completed at ZMZ in 2005.

Six subsidiary production units were established on the basis of tool, press, foundry production sites, plane bearings production site, equipment repair and maintenance service, transportation department: "Spetzinstrument" Ltd., " Factory " Metalloform » Ltd., " Foundry " RosAlit » Ltd., «ZMZ-Plane Bearings» Ltd., " ZMZ-Transservice" Ltd.

The main target of the enterprise, engine manufacture is focused at OAO "ZMZ».

On the 8-th of August 2006 the 1000-th ZMZ-5143 diesel engine (2,2 l), "Euro - 2" for " UAZ-HUNTER " vehicle of Ulyanovsk automobile factory was made at ZMZ.

On the 29-th of November, 2006 the state commission at final session at OAO "ZMZ" having examined total cycle of acceptance tests for pre-production models of ZMZ-5148 diesel engine equipped with “Common Rail”, "Euro - 3" confirmed availability of the engine design developed at ZMZ, for industrial production.

On the 21-st of December, 2006 the memorandum of intentions to create joint venture for manufacture of diesel engines, F1A series in Russia was signed between JSC "Severstal - auto" and Fiat Powertrain Technologies at ZMZ at the presence of the governor of Nizhniy Novgorod region V.Shantzev. The project will be realized at industrial site of Zawolzhsky Motorny Zawod.

In May 2007. OAO " ZMZ ", on results of an ecological rating of 137 Russian leading companies carried out by the International social and economic union (ISEU) and Independent ecological rating agency (ANO "NERA"), was in first 10 leaders by four of six variants of ranging on ecological business efficiency

 

In September, 2007 in ZMZ within the framework of joint venture " Severstal - auto " with Fiat Powertrain Technologies scale works on preplanning for engines F1A had been carried out in production site of the plant.

In order to locate new production the actual factory building №6 had been emptied with total area of 30 thousand sq.m. In short time without a stop of the main assembly conveyor and keeping rates of product manufacturing 678 units of equipment had been moved from the sixth building and remounted in other shops of the plant. Then civil works had begun at once.

 

In OAO "ZMZ" with the purpose to expand applicability of output production the mock-up of "Euro - 3» petrol engine ZMZ-4054.10 (2,5 l) for light duty vehicle " Ducato " was made.

 

On 29th November, within the framework of the ecological requirements "Euro - 3» introduction into action in territory of Russia since 1st January 2008 the first trial lot of "Euro - 3» 4-cylinder petrol engines for vehicles of GAZ and UAZ had been assembled on ZMZ main assembly conveyor.

 

In December 2007, the project on enterprise future development was realized. Within 1 year the development and improvement of a new product design that was "Euro - 3" petrol engine families- had been done in parallel with preplanning in ZMZ.

 

Since January 2008 in ZMZ within the framework of the "Euro - 3" requirements introduction into action in territory of Russia, the large-scale output of "Euro - 3"4-cylinder petrol engines for vehicles of GAZ and UAZ automobile plants was started.

 

In February 2008, ZMZ was acquired Conformance Certificate ensuring that ecological management system of enterprise corresponds to requirements of international standard ISO 14 001-2007.

 

In March 2008, OAO «ZMZ» got approval from Fiat for installation of engine ZMZ-405 (2,5 l) in vehicle Fiat-Ducato, as correspondent one on technical performance to European requirements.

 

In March 2008, in 3 rd shop of OAO «ZMZ» a new conveyor of ZMZ-5143 diesel engine industrial assembly that had been moved from shop №6 was put in full capacity.

 

16^th April 2008 14ooooooth engine was produced in main conveyor of ZMZ. The “14 million»-anniversary engine was “Euro-3” petrol engine 406 of family ZMZ-409.04 (2,7 l).

 

13^th August 2008 the trademark “Double life” was officially registered.

 

In September 2008, 3 prototypes of “Euro-4” diesel engine ZMZ-51432 equipped with fuel system Common Rail made by «BOSCH» in compound of vehicle UAZ-Hunter were prepared.

 

Since 1^st October 2008 Organization Management System (OMS) was introduced in ZMZ, corresponding to requirements of international automotive standard ISO/TS 16 949 version 2002.

 

18^th February февраля 2009 OAO «ZMZ» signed a contract with ZАО «Ford Motor Company» (FMC) on supply of parts – 4 types of brackets – for vehicles «Ford-Focus», that are assembled in enterprise Ford in Vsevolzhsk.

For Zawolzhsky Motorny Zawod the contract with FMC is the first project in the history of enterprise in such direction of activity as production of automotive components under orders of foreign automotive companies working in the territory of Russia.

 

In may 2009 in experimental shop of ZMZ new V-form 8-cylinder engine with increased displacement to 5,05 l has past the evaluation tests and successfully confirmed stated technical performances on power and torque

ZMZ designers under order of Pavlovskiy autobus plant have developed V-8 Version (5,05 l) with increased power characteristics. Singularity of new «eight» is in a potential of work with compressed natural gas.

February, 2010. The new license for educational activities was given to JSC "ZMZ" with validity till 2015. The enterprise has the right to carry out the advanced training, training and retraining of workers with respect to 47 professions of machine-building branch.

 

March, 2010. Certificate of conformity of organizational management system (JSC "ZMZ") with ISO/TS 16 949, international automobile standard (2009 version), was handed over to JSC "ZMZ" with validity till February, 2013. ZMZ became the first engine plant which was given the certificate of ISO/TS 16 949 conformity of its organizational management system.

April, 16^th, 2010. JSC "ZMZ" was awarded by the Diploma of the first-degree by name of I.P. Kulibina in the nomination of "The best industrial prototype in the sphere of the land transportation" for diesel engine such as ZMZ-5143.10 and five Diplomas of the second-degree and the third-degree in the nominations of "Land transportation", "Transportation" and "Mechanical engineering" for the automobile components' patents such as a driven disks, a piston, a valve cover, a valve spring cap, a washing drying machine for cleaning of case-type parts according to results of IV regional competition of subjects of intellectual property named "The patent of the year".

 

Sergey P. Urasov was appointed as the general director of JSC "ZMZ" beginning from May 6^th, 2010 by the decision of the meeting of the board of directors of ОАО "ZMZ" on May 4^th, 2010.

The decision of formation of unified management structure of JSC "ZMZ" was adopted with the purpose of optimization of key management processes, increase of effectiveness of communications and business management efficiency.

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June, 2010. The status “Q1-supplier - guaranteed quality of Ford” was received by JSC “ZMZ”. JSC “ZMZ” was introduced in the global supplier database in this status.

"Q1-supllier" is a very high-level, dynamically developing supplier that meets the international and specific requirements of “Ford” according to suppliers’ rating of “Ford”.

 

June, 2010. ОАО " ZMZ " and its associated companies such as " RosАLit " and «Metalloform» passed successfully the industrial audit for reception of the status of the potential supplier within the bounds of the joint project of this company with “AvtoVAZ” to be carried out by  "RENAULT-NISSAN" company. 

 

July 2010. The test center "Motor " ОАО" ZMZ" confirmed the validity of the Certificate of accreditation on technical competence in certification system of GOST R and the international standard ISO to be given out in 2009, which give the right to carry out the certification test of products of automobile production both domestic and foreign auto makers.

Prototypes of engines to be run with gas fuel used in the combined electric power plants according to the agreement with NAMI (Research automobile and motor institute) in the bounds of the government contract were manufactured at ОАО "ZMZ".

August, 2010. ОАО "ZMZ" carries out the certification of gasoline V-shaped eight-cylinder engine ZMZ-52342.10 for "PAZ" buses on conformity to the requirements of Euro-4 (ecological class 4) by the agreement with "Pavlovsky bus" Ltd.

September, 2010. Preproduction of control arms for UAZ cars was fulfilled at ОАО "ZMZ".

The first-off production batch of brackets CD for Ford cars was manufactured at ОАО "ZMZ" and supplied to the plants of Europe (Germany, Spain) on September, 30^th.

October, 2010. ОАО "ZMZ" proceeded to the projects of R&D and preproduction of a diesel engine of the ecological class "Euro-4" for perspective models of UAZ cars. Prototypes are produced and their tests are carried out on the experimental base of ZMZ, UAZ and divisions of "BOSCH" company.

Inspection audit of organizational management system in national system of GOST R on confirmation of the validity of the given out Russian Certificate for a year passed successfully at ОАО “ZMZ” on October, 21^st.

Inspection audit of organizational management system on confirmation of the validity of the given out Certificate of conformity to requirements of international automobile standard ISO/TS 16 949 of version 2009 for a year passed successfully at ОАО “ZMZ” on October, 29^th.

The diploma confirming the status of Q1-supplier of Ford company was handed over to ОАО "ZMZ" on November, 9^th, 2010.

ОАО “ZMZ” was awarded by the Diploma and the movable goblet for the champion according to the inspection results for the best organizational work with the youth among the enterprises of municipal education of Nizhniy Novgorod region in the bounds of XII regional “Gold hands” competition in the November.

Pilot batch of the rebuilt clutch for gasoline motors of UAZ advanced car family of in-house design was manufactured on December, 2010.

Preproduction of stock gasoline engines to be run on twin fuel of ZMZ-409 (2,7 l) for UAZ cars of wagon-type cab and advanced car family to be equipped with gas tank equipment was completed on December.

The first-off batch of twin fuel engines was shipped to YAZ.

ОАО “ZMZ” was completed II stage of work for production of special purpose motors the combined power plant with NAMI (Research automobile and motor institute) successfully in the bounds of government contract on December.

Three four-cylinder engines viz.: the natural gas engine in the amount of one piece, diesel engines with Common Rail system in the amount of two pieces were manufactured.

Engines in the combined power plant were installed in LiAZ and PAZ buses and passed the testing successfully.

Government commission accepted the results of testing of the carried out testing positively.