Drive for cross-border collaboration - SABIC and the Toyota Aygo, Citroen C1 and Peugeot 107

The production of the new Toyota Aygo, Citroen C1 and Peugeot 107 involved SABIC in one of the most complex, international automotive projects in its history. On 28 February 2005 the first 'mini cars' rolled off the production line, the culmination of years of hard work and cross-border collaboration between four companies: Toyota, PSA, SABIC and Peguform Bohemia.

Cross-border co-operation
In 2001 Toyota and the French PSA group (Peugeot-Citroen) formed a 50/50 joint venture for the production of small cars. SABIC and the French company PSA had been working together for many years and had already built up an excellent working relationship. The Czech components manufacturer Peguform Bohemia persuaded Toyota to outsource the production of its major components such as dashboards and bumpers and use SABIC materials in the production of these components. Peguform Bohemia's decision to work with SABIC on the Toyota/PSA project was based on SABIC's experience, dedication, (technical) support, excellent product portfolio and competitive prices. SABIC's involvement in the project started in August 2002.

A brand-new assembly plant was built at Kolin in the Czech Republic, with Toyota in charge of development (in Japan) and production (in the Czech Republic), and PSA handling sales and logistics.

A first for the French market
The Toyota Aygo, the Citroen C1 and the Peugeot 107 share a lot of their interior components. Various SABIC PPs are used in the manufacture of bumpers, instrument panel, central console and interior trims.



SABIC developed a completely new material for the upper part of the instrument panel: the 10%-talc-filled SABIC® PPC7603 compound. This is the first time that an aesthetic talc-filled SABIC®PP compound has been used for the instrument panel in the French market. This material has an excellent scratch-resistance and a unique mechanical profile.

Safety first
The lower parts of the instrument panel, as well as all interior trims, are made out of SABIC® PP CX03-81, a high crystalline PP grade. The "SABIC" instrument panel passed all crash tests required by Toyota, who is known to set very high standards when it comes to passenger safety.


An unusual choice
The material, proposed by SABIC for moulding bumpers was unusual for Toyota: in Japan highly complex compounded materials are used, whereas PSA uses a straight PP for their bumpers. Tests performed on SABIC® PP108MF10 convinced Toyota that this super high impact PP grade is the best choice for all three new "minis".

Close teamwork
Peguform Bohemia and SABIC worked closely together on the development and component design from the initial drawing right through to the end product, with the Peguform development team, based in Japan, working intensively with SABIC's Computer Aided Engineering and material and processing specialists. Thanks to SABIC's commitment, flexible approach and international orientation this complex project resulted in the successful start of production.

By end of 2005 the plant in Kolin will be running at full capacity, turning out more than 300,000 Peugeots, Citroens and Toyotas a year.

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