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Jaguar Land Rover opens its Engine Manufacturing Centre

The opening of the state-of-the-art Engine Manufacturing Centre is a seminal moment for Jaguar Land Rover as it embarks on manufacturing engines in-house for the first time in a generation.

The Engine Manufacturing Centre will be home to the Ingenium engine family, which will power a new generation of Jaguar Land Rover products designed, engineered and manufactured in the UK. This starts with the 2-liter diesel engine in the Jaguar XE.

The machining hall represents the cutting edge of manufacturing technology, utilizing 150 state-of-the-art machines working across three lines. Everything from assembly robots and lasers to drilling and high-pressure wash machines operate in this area, representing an investment of more than US$238m.

The first line is where the aluminum block begins its transformation from a simple chunk of metal to the heart of the Ingenium engine. It is heated in an oven before undergoing a series of machining operations, always punctuated by high-pressure washes to filter debris away. The second line contains the cylinder head, which undergoes a similar process. The crankshaft line differs as it is machining forged steel, not aluminum. Here, the steel is milled, turned and drilled. Both automated and manual tests take place throughout each line, ensuring that each component is made to the highest standard of quality possible.

In the assembly hall, approximately 245 separate parts come together to form an engine derivative. It is also where Jaguar Land Rover’s commitment to people is most evident; more than 150 associates currently work here, across a total of 17 zones.

More associates will join the team when the petrol Assembly Hall also becomes operational. The aluminum block, cylinder head and crankshaft move through the zones, each one bolstered by additional components and rigorous testing, before finally joining together.

The engine is then cold tested, an eco-friendly procedure that ensures the highest quality standards are met, before leaving the assembly line.

The logistics department is tasked with coordinating the 71 suppliers that the Engine Manufacturing Centre utilizes – of which approximately 30% are based in the UK. Hundreds of individual parts will be required when both diesel and petrol divisions are operational. These will be delivered to two main receiving areas – five bays in the assembly area and two in the raw materials area. Once inside the facility, the parts will be transported on specially adapted cargo trains, making 133 movements a day, facilitating a huge volume of engines while never compromising on quality.

Ingenium engines will be Jaguar Land Rover’s most advanced to date. The new family of lightweight, four-cylinder units will utilize the most flexible engine architecture ever produced by Jaguar Land Rover, making them efficient, powerful and capable of producing up to 300Nm of torque while emitting as little as 99g/km of CO2.

The core of Ingenium comprises extremely strong and compact aluminum blocks, which will allow a range of engines to be developed, both quickly and efficiently, to meet the rigorous regulatory and competitive requirements of the future.

All variants will be equipped with high-tech turbochargers that improve performance, and help reduce CO2 emissions. Their modular design enables petrol and diesel engines to share many common internal components.

This reduces complexity, raises quality and simplifies manufacturing. Despite adding features and increasing power output, Ingenium engines weigh as much as 80kg less than equivalent engines of today. The Engine Manufacturing Centre will allow Ingenium engines to deliver outstanding low-end torque, effortless acceleration and class-leading emissions performance with low consumption.

Before the first Ingenium engine leaves the factory, it will have already undergone the equivalent of more than eight years of the toughest, most punishing testing that Jaguar Land Rover engineers could devise. These include more than 72,000 hours of dyno testing and 2 million miles of real-world testing.

5 November 2014


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