In a rear-end impact the body structure is similarly utilised and in a side collision, the B-pillars, reinforcements in the doors, the seat  cross-members between the centre tunnel and the sills, and the substantial side sills themselves, resist impact and intrusion.


Design details keep repair costs low

Minor frontal or rear-end collisions are easily, and more cheaply, repaired. The front-end panels, for example, are in three sections, so  that sections can be replaced or straightened at moderate cost. At the rear, the sturdy side members can also be replaced  separately.


Vauxhall Astra 5 Door Quality and economy - Designed To Be Reliable, Service-Friendly

- Long service intervals
- Maintenance costs down
- Easy-to-repair construction

Vauxhall's ongoing product offensive of the past few years is bearing fruit. As a result, the level of expenditure by Vauxhall following  warranty claims has dropped substantially.

The new Astra is guaranteed to follow that pattern as it sets out to satisfy the highest demands in terms of quality, reliability and  durability - points that were given top priority right from the start.

When the specifications for the new car were drawn up, the main focus of attention was not on offering something new at any price  and in every area, but rather on offering customers the technology they need.

As a simple example, in the car itself the engineers and designers placed particular emphasis on key areas like the instrument panel  and frequently-used switches. Standard test guidelines for each element ensured that the highest levels of appearance and 'feel' were  satisfied before the parts were signed off.


UKP 700 million investment for new Astra

Production of the five-door hatchback version started on schedule in early January in Antwerp, Belgium and will begin at Ellesmere  Port in March. The estate version will be built later at Bochum, Germany.

General Motors has invested over one billion Euros (UKP 700 million) in modernising the production facilities for its Astra models,  making further improvements to quality management and thoroughly training its employees. For Ellesmere Port, which had already  been modernised to produce Vectra, another UKP 80 million has been invested. 

A series of quality initiatives in the production process guarantees top product quality. As part of the implementation of the "zero  defects principle", each work station in all three plants is equipped with an Andon system (Andon = light signal).

This ensures that no vehicle is incorrectly manufactured and contains no faulty components. Each work station has a cord known as the Andon line. If an employee pulls it, an alarm sounds to summon the team-leader to solve the problem. If this does not take place within a predetermined time frame, the production line stops. Specific quality control checks, known as audits, are also integrated into the production lines.

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