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What does it take to build one of Russia's most prestigious automobiles?
In this special report, we go inside the AURUS production facility to see how luxury vehicles move from raw materials and components to fully assembled premium automobiles. From body construction and painting to final assembly and quality control, every stage of production is designed to meet the demanding standards expected of Russia's flagship automotive brand.
The report also explores the growing role of automation in modern manufacturing. Domestic robotic systems now assist engineers and technicians with welding, assembly, precision positioning, and quality assurance tasks, helping improve efficiency while maintaining strict production standards. These technologies are transforming how vehicles are built and demonstrating the increasing sophistication of Russian industrial manufacturing.
Viewers will get a rare behind-the-scenes look at the people, machinery, engineering processes, and advanced production techniques that power the AURUS assembly line. The program highlights how traditional craftsmanship and modern robotics work together to create luxury vehicles intended for government officials, business leaders, and private customers.
From cutting-edge automation to meticulous final inspections, this exclusive factory tour reveals the scale, precision, and innovation behind one of Russia's most recognizable automotive projects.
Watch as we follow the journey of an AURUS from the production floor to the finished vehicle and discover how engineers and robots are shaping the future of automotive manufacturing.
#AURUS #Russia #LuxuryCars #CarFactory #AutomotiveIndustry #Manufacturing #FactoryTour #Robotics #IndustrialRobots #Engineering #AutomobileProduction #MadeInRussia #Technology #Industry #ProductionLine #AutomotiveEngineering #FutureFactory #Innovation #Russia24 #Automotive
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0:05
The entire process and our Russian built
0:06
automobile are genuinely captivating.
0:13
An impressively high-quality machine
0:15
that adheres to global standards of
0:17
excellence.
0:23
>> Brand, our brand.
0:31
This is Russia's gold.
0:48
>> Metal structures stand here, though many
0:50
assume it's unclear how such pillars
0:52
endure. Suspensions are being
0:53
re-engineered here, allowing machines to
0:55
hang for operators to assemble them from
0:57
below in the future.
0:58
>> Alexander Smirnov is an engineer by
1:00
specialty, but recently he often
1:02
conducts excursions to his native Aurus
1:04
plant in Tatarstan, because he knows the
1:06
enterprise thoroughly, but he has been
1:07
working here since the day I was
1:09
founded.
1:10
>> It must be somewhere here. I am still
1:11
wearing glasses. I'm sitting.
1:14
>> This photo is very special to Alexander.
1:16
It was made during the opening of the
1:18
plant, and this year the enterprise
1:19
celebrates its first anniversary. May
1:21
31, serial production of Aurus cars
1:24
turns 5 years old. Production.
1:26
>> Commence large-scale serial
1:27
manufacturing operations.
1:29
>> Permission.
1:32
>> Well,
1:39
>> The plant operates in the Alabuga
1:40
special economic zone, employing 250
1:43
people who manufacture the Aurus Senat
1:45
sedan and the Komendant SUV, showcasing
1:48
their production expertise.
1:50
>> Here, right in front of you, the Senat
1:52
is gathering in a car. Can you see how
1:53
they are?
1:55
>> Alexander recalls that when he learned
1:56
that the production of Auruses would be
1:58
launched in Tatarstan, he immediately
2:00
wanted to work there. One of the main
2:02
reasons the president drives cars of
2:04
this brand.
2:05
>> As you know, I drive such cars regularly
2:07
enjoying their performance and design.
2:10
I have been driving myself several
2:12
times.
2:13
>> Indeed, Vladimir Putin can often be seen
2:15
driving the Aurus. Here he personally
2:18
stops by his teacher Vera Gurevich to
2:20
take her to dinner in the Kremlin.
2:24
>> influence
2:28
>> But he offers a ride to the presidents
2:30
of Kazakhstan and Uzbekistan
2:31
Kassym-Jomart Tokayev and Shavkat
2:33
Mirziyoyev.
2:36
>> Aurus
2:38
Of course, it was created for the task
2:40
of maximum strength. [music]
2:41
For example, we have a platform
2:43
solution. It was originally designed for
2:45
an armored vehicle. This [music] means
2:47
that all purchasers of serial cars that
2:50
we produce in the Republic of Tatarstan
2:52
have basically the same characteristics
2:54
as armored vehicles in their platform
2:57
solution.
2:58
>> In world history, the formation of
3:00
expensive [music] car brands took a
3:02
decade. As for Russia, work on the
3:05
creation of a unified modular platform
3:07
Aurus began in 2013, and the plant was
3:09
opened in 2021. And this path from
3:12
project to serial assembly was not easy.
3:15
Russia did not launch automobile
3:16
enterprises for a long time.
3:19
>> A large number of foreign brands that
3:21
were present in Russia launched their
3:22
enterprises, but they already had a
3:24
trail button. And they were engaged more
3:27
in what is called scaling. When you have
3:29
12 plants and you have 13 or you have
3:31
24, you have 25.
3:34
In our case, we had to build a factory
3:36
that didn't [music] exist.
3:37
>> The start of serial production was also
3:39
complicated by the pandemic.
3:40
>> Our whole journey is a path with
3:42
obstacles because we opened a factory
3:44
when we were
3:46
at the height of COVID. This certainly
3:48
left its mark on work, both actual and
3:50
in the everyday sense work. Yes, and in
3:52
how employees of communists and so on.
3:55
>> Many employees had to be retrained
3:57
because they had no experience with
3:59
luxury cars.
4:00
>> Igor, well, how are you? Everything is
4:01
fine? Everything is fine?
4:03
>> Correctly developed instructions help
4:05
employees to perform their work clearly,
4:07
says the leading engineer technologist
4:08
[music] Evgeny Zdobin. My role involves
4:11
designing technological processes, which
4:12
essentially means crafting detailed
4:14
assembly cards [music] to streamline
4:15
production.
4:16
>> Where are the steps for the operator?
4:18
What should he do and how should he do
4:20
it?
4:22
>> Eugene chose his profession thanks to
4:23
his mother. She [music] worked for
4:25
Presto in the Iranian Kamaz plant. Her
4:27
stories are interesting and accessible
4:29
to the understanding of every person,
4:31
even not connected with the automotive
4:32
industry, still help to teach young
4:34
colleagues, says Evgeny. It helps.
4:36
Activation, do I understand correctly
4:38
that every employee has a tablet like
4:40
this? Why do you need it?
4:42
>> This is a digital car assembly
4:44
instruction.
4:45
>> All software is domestic, creating
4:47
software. The developers [music] tried
4:49
to take into account the various
4:50
requests of engineers. For example,
4:52
through the tablet, you can order the
4:53
delivery of parts to your site.
4:56
Many parts of the car are assembled
4:58
manually, but still sometimes [music]
4:59
without the help of robots cannot do.
5:01
For example, why carry heavy loads when
5:03
you can entrust them to a Russian
5:04
robotic cart? It will deliver everything
5:06
you need directly to the workplace and
5:08
no extra load on the person. This shop
5:10
is also equipped with robots.
5:12
>> Here we can now observe one of the two
5:13
advanced robotic systems diligently at
5:15
work. It's functioning seamlessly now.
5:17
The production process of aluminum hoods
5:19
boasts a unique characteristic, the
5:20
omission of traditional welding
5:22
techniques. Instead, aluminum riveting,
5:24
a cutting-edge method, has been
5:25
innovatively termed as wedding. What
5:27
does this marriage metaphor signify?
5:29
>> Here we go. The engine and the body are
5:31
friends with each other, therefore it's
5:33
called the wedding.
5:40
>> Head of the Republic of Tatarstan,
5:41
Rustam Minnikhanov, believes that the
5:43
enterprise has become successful largely
5:45
thanks to highly qualified specialists.
5:47
>> This automobile embodies the pinnacle of
5:49
modern technology. To conceptualize,
5:51
design, and launch mass production
5:52
within such a condensed time frame is a
5:54
testament to the extraordinary
5:55
dedication of so many talented
5:57
individuals.
5:58
>> During the grand opening day of the
5:59
facility, a multitude of distinguished
6:01
guests arrived. They were introduced
6:02
with professionalism, and Raisa herself
6:04
interacted personally, shaking their
6:06
hands. A profoundly memorable and
6:08
exhilarating moment that may remain
6:09
forever etched in my heart.
6:12
A valuable award for me
6:14
>> In 2022, did the plant face another
6:16
sanction problem?
6:18
>> We had certain partners who persistently
6:19
sought collaborations, yet these
6:21
interactions were heavily constrained.
6:22
Consequently, we were compelled to
6:24
swiftly pivot to alternative
6:25
partnerships, identify trustworthy
6:27
collaborators, and rigorously ensure the
6:29
quality standards essential to our
6:31
operations.
6:32
>> Supplying components from abroad is a
6:34
common practice in the automotive
6:36
industry. For example, German companies
6:38
often order spare parts from Asia or
6:41
Eastern Europe. It came out cheaper.
6:43
Russia went another way, and it turned
6:46
out to be even [music] for the better,
6:47
say scientists of the Central Automotive
6:50
and Automotive Institute NAMI.
6:53
>> We have honestly developed our own
6:55
industry with the possibility of using
6:57
materials that were not previously used
6:59
in our car engine building.
7:03
>> Each Aurus car is more than 4 and 1/2
7:05
thousand parts. They are provided by
7:07
more than 300 Russian suppliers. So, the
7:10
reluctance of Western companies to
7:11
cooperate with the plant has led at
7:13
least to the development of a domestic
7:15
ecosystem of auto component
7:17
manufacturers. Just look at the 600
7:20
horsepower Aurus engine.
7:22
>> Each element of the engine has a certain
7:25
set of materials there, their
7:27
properties. [music] For example, the
7:29
engine is all aluminum. It's not just
7:31
aluminum. This is an aluminum alloy of
7:34
materials, but the working surfaces have
7:37
certain coatings. Yes, for example, the
7:40
surface of our cylinder is a cast-iron
7:42
insert of 2.5 mm, which allows us to
7:46
ensure the necessary [music] reliability
7:48
and strength.
7:51
>> The Ministry of Industry and Trade
7:53
helped to find reliable domestic
7:54
suppliers. For example, veneers from the
7:56
root of black poplar. This tree grows in
7:58
the European part of Russia, and leather
8:00
for interior upholstery is produced in
8:02
Ryazan.
8:03
>> Also, the highest quality of the highest
8:05
category leather.
8:07
>> The employees of the plant are sure that
8:09
the use of exclusively their Russian
8:11
materials affects the appearance of the
8:12
car. What is the nature of the Senate?
8:15
>> Remarkably formal, I must say.
8:18
>> Alexander Dushkin, engineer mechanic
8:20
with 30 years of experience. Over the
8:22
years, he managed to work at automobile
8:23
enterprises Togliatti, Izhevsk, and also
8:26
Ulyanovsk. Thanks to the launch of the
8:27
plant, Aurus returned home to Tatarstan.
8:30
Working in this company is called a
8:31
great success.
8:33
>> You know, it's like a seagull, right?
8:34
That is, this is the seagull that we
8:36
once had. The actual government seal, a
8:39
little angular, but it also had a lot of
8:41
technical solutions, and the seagull is
8:43
really beautiful.
8:46
>> We took a luxury perception from the
8:48
seagull. This one, as young people now
8:50
say, is a luxury vibe, but in our case,
8:53
we were still inspired by the ZIL-110
8:56
car.
8:57
>> ZIL-110, one post-war car for the
9:00
highest officials of the state in SSSR.
9:03
It became a symbol of Soviet
9:04
technological progress. Its production
9:06
began in 1945. The same values are
9:09
conveyed by Aurus, eliminating
9:11
dependence on foreign car manufacturers.
9:14
>> When assembled, the car goes through all
9:16
the stages inherent in the technological
9:18
process. Uh, this inspection and testing
9:21
is a small mileage test when leaving the
9:23
factory. It fully meets all safety
9:25
requirements.
9:26
>> Additional protection is also created by
9:28
special speed switching technologies.
9:31
>> In modern cars, almost everywhere the
9:33
lever is finished. The transmission is
9:35
no longer electronic, and you perform
9:36
the mechanical actions using this or
9:38
that transmission. In fact, you just
9:39
send an electronic signal which through
9:41
the module interacts with the box and
9:42
the box understands that the owner wants
9:44
to make a movement there forward and
9:46
backward and so on.
9:47
We have this cable switching which for
9:49
example in this sense provides safety in
9:52
some emergency situation.
9:54
>> Such nuances are one of the reasons for
9:57
the demand for cars. Most often the
9:59
Senat and Commandant are purchased by
10:01
men older than 5 years in Moscow, St.
10:03
Petersburg and Kazan.
10:04
>> Of course, it's already difficult
10:05
[music] to surprise them in something.
10:08
But the opportunity to look at your own
10:09
car during the assembly process and even
10:12
participate somewhere, we gave you the
10:14
key there which means we added several
10:15
fasteners. Fix it already. Well, that's
10:17
great. And this is something that many
10:19
brands cannot provide including in
10:21
global practice.
10:23
>> The individuality of the cars is
10:24
manifested including in the coloring.
10:26
The color of Russian gold is exactly how
10:28
the name Aurus is deciphered. Bring cars
10:31
to the shine of precious metals. Alina's
10:34
task with Mogilev.
10:35
>> In front of you is the hood. Now we will
10:37
polish it.
10:38
>> Alina has been painting cars for 9
10:40
years. The profession came by accident
10:42
on the advice of a friend who noticed
10:44
that Alina likes to draw.
10:45
>> This profession is deeply meaningful to
10:47
me.
10:48
>> What do you like about her?
10:50
>> I like to see my result.
10:52
>> It turns out all the diseases that we
10:53
have seen in this enterprise.
10:55
>> Here they are.
10:56
>> Such brilliant shining because for them
10:59
>> You took it.
11:00
>> Well, not just me.
11:02
Do I have my colleagues?
11:04
>> Colleagues supported Alina when she
11:05
decided to participate in the republican
11:07
competition of working professions. This
11:09
year she took second place. Alexander
11:11
Smirnov believes that in order to
11:12
attract young people, it is important to
11:14
properly promote the work at the plant
11:16
especially if it is such an innovative
11:17
enterprise as Aurus. Not everyone knows
11:20
that even the glacier is turned on here
11:22
with the help of smart technologies.
11:24
>> It will rotate in the event that the
11:26
operator takes a special scanner, scans
11:28
the VIN number of this car, that is what
11:30
car he will now collect. This allows us
11:33
to follow a fully assembled car.
11:35
>> Today, the plant is preparing for the
11:37
release of the restyling version, and
11:39
recent changes in the technical
11:41
capabilities of the car are still kept
11:43
secret.
11:44
>> New cars are appearing there. We will
11:45
definitely show them literally in the
11:47
coming months.
11:48
>> To release the updated Senate of the
11:50
enterprise for 2 months slowed down the
11:52
pace of production on the internet. This
11:54
event did not go unnoticed. Rumors
11:56
spread that the factory closed, and now
11:58
we find out how it really happened.
12:00
>> Can you pinpoint the exact time frame
12:01
when the equipment began to arrive?
12:03
>> As a result of the new equipment and
12:05
machinery, all labor activities were
12:07
temporarily halted to facilitate
12:10
modernization efforts.
12:12
>> Engineers talk about constantly
12:13
improving cars, inspiring the
12:15
opportunity to personally conduct test
12:16
drives.
12:17
>> I feel immense pride that our incredibly
12:19
talented Russian designers achieved such
12:21
remarkable implementations.
12:23
>> I'm deeply immersed in engineering
12:25
ideas, crafting exceptional cars, and
12:28
filled with pride to be part of this
12:30
endeavor.
12:32
I design, refine, and strive to innovate
12:34
in automobile creation.
12:38
>> More comfortable.
12:39
>> Evgeny hopes that the family dynasty
12:41
will continue the daughter, despite the
12:43
fact that she is only 8 years old
12:44
interested in Aurus Senat. For example,
12:46
carefully watches the victory parade.
12:49
>> Greetings, dear friends. Today is a
12:51
celebration of togetherness with family.
12:56
>> I brought her to this venue where she
12:58
explored and sat in every car with
13:00
curiosity.
13:01
>> As befits the luxury segment, each Aurus
13:03
car is the result of jewelry work.
13:06
>> The factory is doing great with it.
13:09
>> Serial production ensures [music]
13:10
painstaking manual labor, scientific
13:12
research, and introduction of advanced
13:13
technologies, and also the willingness
13:15
to educate new generations of
13:16
specialists, because it is on them that
13:18
the further development of the Russian
13:20
automotive industry depends.
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