How the 2027 Opel Astra Is Made | Full Rüsselsheim Factory Tour

2027 Opel Astra Production in Germany | Full Rüsselsheim Factory Tour

Step inside the Opel Rüsselsheim plant in Germany and watch the complete production process of the new 2027 Opel Astra — from steel coils and press shop stamping to body welding, paint shop coating, final assembly, quality inspection, rain testing, and the factory test track.

This full factory documentary shows how the Opel Astra is made at the Rüsselsheim plant, one of Opel’s most important production sites in Germany. Filmed with authorized independent access granted by Stellantis Group, this video follows the real manufacturing process inside the factory.

You will see the complete Opel Astra production line:
press shop, body shop, paint shop, assembly shop, body-to-chassis marriage, windshield installation, dashboard installation, engine and chassis preparation, wheel installation, seat installation, door installation, quality control, rain test, and final factory test drive.

This is a detailed behind-the-scenes look at modern car manufacturing in Germany, showing how a new Opel Astra is built from raw steel into a finished tested vehicle.

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0:00 Press Shop – Steel Coils
0:48 Press Shop – Press Die / Matrix Preparation
1:46 Press Shop – Press Die Transfer to the Line
2:51 Press Shop – Stamping Process and Panel Transfer
5:57 Press Shop – Green Room Panel Inspection
7:03 Press Shop – Pressed Panels Transport to the Next Station

7:48 Body Shop – Quick Walk Through the Body Line
8:12 Body Shop – Welding Body Panels
11:39 Body Shop – Roof Installation
12:19 Body Shop – Doors Installation
13:05 Body Shop – Front Wings Installation
14:47 Body Shop – Hood Installation
17:13 Body Shop – Body Quality Inspection

18:17 Paint Shop – Cataphoretic Priming, Post-Rinse and Drying
20:03 Paint Shop – Applying Sealant
22:44 Paint Shop – Coating Process
27:29 Paint Shop – Coating Process Part 2
32:34 Paint Shop – After-Coating Quality Check
33:40 Paint Shop – Polishing and Final Coating Quality Control

38:24 Assembly Shop – Painted Body Arrives
38:56 Assembly Shop – Removing Doors Before Body Assembly
41:05 Assembly Shop – Parts Delivery by Autonomous Transport Vehicles
41:45 Assembly Shop – Dashboard Installation
44:06 Assembly Shop – Windshield Installation
46:36 Assembly Shop – Engine Preparation for Installation
51:20 Assembly Shop – Chassis Assembly Area
52:46 Assembly Shop – Engine-to-Chassis Installation
53:48 Assembly Shop – Exhaust System Installation
55:40 Assembly Shop – Fuel Tank and Underbody Components Installation
56:22 Assembly Shop – Chassis Assembly Quality Check

57:33 Assembly Shop – Body-to-Chassis Marriage
1:05:16 Assembly Shop – Overhead Body Transport System
1:07:17 Assembly Shop – Front Headlights Installation
1:08:15 Assembly Shop – Front and Rear Bumper Installation
1:10:16 Assembly Shop – Wheels Installation
1:13:25 Assembly Shop – Body Transfer to Another Assembly Station
1:14:44 Assembly Shop – Car Seats Installation
1:17:35 Assembly Shop – Doors Installation
1:23:13 Assembly Shop – Vehicles Arrive to Quality Shop

1:24:04 Quality Shop – Headlight and Electronics Settings
1:25:01 Quality Shop – Rain Test for Tightness
1:26:22 Quality Shop – Final Exterior and Interior Quality Checks
1:28:37 Quality Shop – Factory Test Track
1:30:13 Opel Rüsselsheim Plant Exterior

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