Located in the central region of São Paulo state, São Carlos factory is the only one in Brazil responsible for components production. In this unity are manufactured all the engines for the internal market. Since 2016, São Carlos is also responsible for the crankshaft production.
Since November 2021, Ricardo Augusto Cutigi has been the Plant Manager of São Carlos Unit.
He started his career at Volkswagen São Carlos in 1998 and during the first 19 years in the São Carlos Plant, he has experienced working 3 years as an assembler in ZP4 Line, 2 years as a Quality Technician, 10 Year in the Logistic Area as an analyst, coordinator, supervisor and manager and also 4 years as Production Manager from 2014 till 2018.
After that Ricardo was transferred to Taubaté Plant as Fertigungsleiter and after 2 years he became responsible for all Production Areas in Anchieta Plant, at this time for 2,5 years.
São Carlos unit produces the EA211 engines family in the versions: 1.0l MPI, 1.6l MPI, 1.0l TSI and 1.4l TSI, that are used in T-Cross, Polo, Virtus, Gol, Voyage, Saveiro Cross, Jetta, Tiguan e Audi A3 models. For the internal market, 100% of the products receive the Total Flex fuel technology. Since 1996, the plant produced more than 12 million engines at São Carlos. Daily production amounts to about 1,270 engines.
Material movements and flow of good
Every day, around 6 trucks and 2 containers leave the São Carlos plant to the others Brazilian factories and to Mexico. Every day, to Anchietaplant are sent around 678 engines; 470 to Taubaté and 556 to São José dos Pinhais.
The unit has around 781 incoming deliveries of part numbers and 89 suppliers. From this total, 60 are local suppliers.
São Carlos plant has stood out in the Volkswagen Group and among companies in the region for its work in the environmental area and for projects focused on sustainability. Designed to produce with the same quality as the best European industries, São Carlos was the first plant of the Volkswagen Group, outside Europe, to earn the ISO 14.001 environmental certificate, in 1997, and became a reference in environmental management for other units in America southern.
The unit has the largest green area among Volkswagen do Brazil factories, with a total of 746,000 m². It has 18.6 hectares of legal reserve area, with preservation of the Cerrado biome, with the reforestation of native forest as one of the permanent sustainable practices aimed at environmental preservation.
In 2019, the plan received further recognition for its efficiency in the use of energy (electric / natural gas / diesel) by achieving the ISO 50001: 2011 certification of its SGE (Energy Management System), which aims to continuously improve energy performance, contributing to the reduction of energy consumption and carbon emissions.
São Carlos plant started production in 1996 and since then has been achieving important milestones. In 1999, produced the first turbo engine in Brazil, in 2003 produced the first 1.0l engine with Total Flex technology in Brazil.
In 2012 implemented a new engine block machining line and increased production capacity; in 2013 inaugurated a new production building for manufacturing the EA211 family. In 2015, started the production of the first 1.0l TSI Total Flex produced in Brazil, with investments of R$ 460 million.
São Carlos unit is one of most important component factory of Volkswagen Group. With high technology processes it, has an important presence in the external market; exporting EA211 engine blocks (2015); crankshafts (2018) and cylinder heads (2019) to the Chemnitz plant, in Germany.