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Opel Astra Factory Tour EXPLAINED 🇩🇪 | How the New Astra Is Built

🚗🇩🇪 Opel Astra Production | How the New Astra Is Built in Germany This is the explained version of the Opel Astra factory tour from Rüsselsheim, with detailed commentary about every major production process — press shop, body shop, paint shop, final assembly, chassis marriage, quality checks and test drive. This full factory documentary shows how the new Opel Astra is built at one of the most historic automotive production sites in Germany. The Rüsselsheim plant is the home of Opel manufacturing, where modern production combines press shop technology, robotic body construction, advanced paint processes, flexible final assembly, and detailed quality control. In this video, you will see the complete Opel Astra production process: 🔹 Press shop and steel coil preparation 🔹 Die preparation and press tool change 🔹 Stamping of body panels 🔹 Robotic panel handling and green room inspection 🔹 Body-in-white construction 🔹 FANUC robotic welding and framing 🔹 Roof, door, fender, and hood installation 🔹 Body shop quality inspection 🔹 Corrosion protection and rinse process 🔹 Robotic tack cloths and seam sealing 🔹 Paint booth and modern multi-wet paint process 🔹 Final paint inspection and two-tone roof checks 🔹 Door removal for assembly access 🔹 Opel Pure Panel cockpit installation 🔹 Windshield installation 🔹 Hybrid, diesel, plug-in hybrid, and electric Astra powertrain preparation 🔹 MacPherson front suspension and torsion-beam rear axle 🔹 Chassis module preparation 🔹 EMP2 platform body-to-chassis marriage 🔹 Headlight, bumper, wheel, seat, and door installation 🔹 Quality Shop checks 🔹 Rain test chamber 🔹 Final inspection and factory test track ⚙️ The new Opel Astra is built on Stellantis’ EMP2 platform and is produced with several powertrain options, including the 1.2-litre Hybrid, 1.5-litre diesel, 1.6-litre Plug-in Hybrid, and Astra Electric. ⏱ Key moments: 00:00 🇩🇪 Intro — Opel Astra production begins in Rüsselsheim 00:39 🏭 Press Shop 01:01 🏗 Press tool preparation and die handling 02:25 ⚙️ Steel stamping and robotic panel transfer 04:40 🔍 Green room surface inspection 05:56 🤖 Body Shop 06:10 🔩 Body-in-white: robotic framing and welding 07:14 🚗 Body-in-white: roof installation / roof joining 08:05 🚪 Body-in-white: robotic door installation / closure fitting 08:54 👷 Body-in-white: manual precision fitting inside the body shop 10:51 🧰 Body-in-white: hood installation 11:46 ✅ Body-in-white quality check before paint 12:48 🛁 Paint Shop — E-coat / cataphoretic priming 13:39 💧 Paint Shop — rinse shower 14:12 🌬 Paint Shop — robotic tack cloths area 14:56 🛡 Paint Shop — sealing 16:41 🧪 Paint Shop — coating stage 17:42 🎨 Paint Shop — exterior colour coating 19:18 🔥 Paint Shop — drying chamber / paint curing 19:55 👀 Paint Shop — after-coating checks 20:37 💡Eagle Eye paint-quality inspection area 20:58 ✨ Paint Shop — polishing 22:15 🔍 Paint Shop — Manual final quality checks 22:40 🏭 Assembly begins - body arrive 22:56 🚪 Assembly Shop — temporary door removal 24:11 🖥 Assembly Shop — dashboard / cockpit module installation 25:37 🪟 Assembly Shop — windshield installation 26:45 ⚡ Assembly Shop — preparing diesel, hybrid, and electric drive units 27:23⚙️Assembly Shop — installing the transmission to the engine 27:59 🌫 Engine exhaust aftertreatment installation 29:00 🔧 Astra chassis module preparation 29:58 🏗 Petrol hybrid powertrain installation into the chassis module 30:20 🛢 Diesel powertrain installation into the chassis module 30:45 ⚙️ Diesel Engine, Exhaust System and Fuel Tank Assembly 31:18 ⚡Petrol hybrid powertrain, Exhaust System and Fuel Tank Assembly 32:51 ✅ Chassis module quality check 33:38 🔩 Assembly Shop — body-to-chassis marriage 34:42 🚗 Assembly Shop — overhead body transport system 35:07 💡 Front headlight installation station 35:45 🧩 Front and rear bumper installation 36:41 🛞 Wheel installation 37:37 💺 Assembly Shop — front seat installation 38:52 🚪 Door reinstallation station 40:00 🏁 Final assembly line 40:14 ✅ Fully assembled Opel Astra arrives at the Quality Shop 40:21 💡 Quality Shop — headlight and electronics settings 40:59 🌧 Quality Shop — rain test for tightness 41:33 🔍 Quality Shop — final exterior and interior checks 42:36 🛣 Factory test drive 🔔 Subscribe to Automotive Garage for more full factory tours and behind-the-scenes manufacturing documentaries. Watch the full version with real factory sound: https://youtu.be/LyCeQD5ktxQ #howitsmade #opel #factorytour #documentary #madeingermany