In 1967, Ebro moved to the Free Zone of Barcelona. 69 years later, we have seen how Ebro once again manufactures cars in it
Entering the 500,000 square meters that the Ebro Factory plant in Barcelona occupies is, in large part, a visit to the origins of the brand and its deep connection with the Catalan capital. The same naves and corridors that In 1967 they saw the last Ebro vehicles leave to become later at Nissan Motor Ibérica. In 2026, the factory that opened its doors in the Barcelona Free Trade Zone almost 70 years ago, manufactures vehicles again (and not just assembly) with the Ebro logo on its grille. Ebro has just opened its facilities to the press for the first time, and we have been able to see first-hand what it is like to manufacture a car. What we have found is a factory full of welding robots, automated parts supply lines and state-of-the-art assembly lines that They look more to the future than to the past. A plant with many stories The old Nissan factory closed on December 31, 2021 after 41 years of activity. The cessation of activity left some 2,500 workers on the streets. Three years later, Ebro confirmed his reindustrialization plan of the plant returning its activity. And he did it, to a large extent, with the same workers he had. Of the almost 2,000 employees that the company currently has, nearly 1,000 employees who work here today They were already with Nissan. Of them, about 400 are product engineers, 200 process engineers and 200 welding and assembly line specialists. These employees know every hallway, every corner and, according to those responsible for the factory, they have played a leading role in the start-up of the plant. The factory occupies 500,000 m2 Our guide throughout the visit was Paco DuranDirector of Production Control and Logistics. According to what he said, he himself started at this same plant in 1998, when the Nissan sign still hung on the door. When the Japanese stopped production he spent some time at Stellantis. When Ebro started his reindustrialization plan, he returned to what he considered his Alma mater. Durán is, in all likelihood, the person who best knows how these facilities work. Nissan veterans like him helped design each booth of the new assembly line based on the years of experience that the assembly of Japanese cars gave them. They knew exactly what had worked before and what had failed. That muscle memory acquired by years of automobile production has weighed more than any manual and has contributed to the Ebro Factory will start walking in record time. First as an assembly center, and now as the only Ebro manufacturing plant in Spain and Europe, in which the Spanish brand already manufactures four models with welding, painting, assembly and quality control processes. Barcelona outside and inside There is a very curious detail in how this factory is designed. It is inspired by Barcelona and the two rivers (the Besós and the Llobregat) that frame it. Being called Ebro, it makes sense. Like these rivers, the entire flow of supplies flows from mountains to sea. It is not the only inspiration that Ebro engineers have borrowed from Barcelona when designing it. The interior of the factory has the same structure as the streets of Barcelona Its interior is arranged in streets perpendicular to each other, well-defined islands, without intersections that block the passage or flows that collide with each other. The reference is the Cerdà Plan of 1859who created the orthogonal grid so characteristic of Barcelona that it ordered the Eixample of Barcelona. An urban model that is still a reference in half the world. A small Barcelona within an icon of Barcelona’s industrial past. Under this spatial arrangement, the materials enter at one end of the factory and advance in line to the other, without setbacks or countercurrents. As Durán explained, this flow “towards the sea” reduces errors, improves response times and, as an added advantage, facilitates the evacuation of the plant in case of emergency. The plant works on two levels. All the assembly of the different components occurs on the ground, while the automatic transports of parts and bodies circulate suspended in a complex logistics system that takes the bodies from one section to another without interrupting the assembly work below. To give us an idea of the magnitude of this aerial infrastructure, the equivalent of three days of production of components and bodies was circulating above our heads at all times. 696 meters of line and 20 cars per hour Since November 2024, the factory operated with the M0 assembly line, in which the cars arrived from China semi-assembled and the rest of the parts were assembled at the Ebro factory. However, the heart of the visit, and the new jewel in Ebro’s crown, is the M1 assembly line. There are 696 meters, 97 work stations and a cycle of 160 seconds per vehicle. That is, each operator has that time to assemble the elements assigned to that station. The body is welded in a 23,000 square meter warehouse with more than 150 robots. Around 95% of this process is fully automated. There the floor, sides and roof are welded until forming what is called the Body-in-Whitethe empty structure of the car before receiving any paint or components. From there it travels by air to the painting area which, for safety reasons due to the chemical agents used there, we were not able to visit (we needed PPE and additional protection). In this section, the car chassis go through degreasing baths, paint is applied through cataphoresis and an anti-corrosion treatment. Afterwards, the already painted bodies fly back to the assembly area, but not before disassembling the doors, which travel in parallel, to improve the workers’ access to the interior. Something that caught my attention was that all the cars I saw on the assembly line were Ebro S700 red in color (the Red Blood Stone, to be more exact). When we asked Paco Durán about the reason, he explained to us that instead of responding to color … Read more