JAN SVERMA PLANT OF MOTORLET IN PRAGUE-JINONICE

• Document Type: CREST
• Collection: General CIA Records
• Document Number (FOIA) /ESDN (CREST): CIA-RDP80-00810A005700900001-2
• Release Decision: RIPPUB
• Original Classification: C
• Document Page Count: 6
• Document Creation Date: December 20, 2016
• Document Release Date: December 5, 2007
• Sequence Number: 1
• Publication Date: February 24, 1955
• Content Type: REPORT

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coma INTEUJOINCE AGENCY
INFORMATION REPORT
CONIDIMAL
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COUNTRY Czechoslovakia
WSW laan Sverma Plant lf Motorist in DATE DISTR.
24 February 1955
Prague-Jinonice 25X1
2.1easek
Mat at Motorist in
iMmosieleslav
NO. OF FADES
6
DATE OF INFO.
REQUIREMENT
PLACE AC Quanc
11.1eINCIS
This is UNEVALUATED
Information
MS SOURCE EVALUATIONS AN uS 11P0 ARE DEFINITIVE
MI APPRAISAL OF maw NINIATIVL
NON illy SIN 4110/111)
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1. Production of new jet engine;
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1
A nevetype jet engine was to go into the first stage of pioduction by 12 SepteMW
1953 at the Jen Sverma Plant of Motorlet National Ebterprise in Prague-Jinonice.i
Source believes that this engine was designed for a twin-engine aircraft. The new
type would be of similar construction to the MiG.15 engine but larger and more
powerful. While the MiG 15 engine had the factory code n4ber MD 5 (am all plans,
workshop sketches, etc.),the new-type engine was coded as MD 6. The first six new
MO 6 engines were supposed to be completed by the end of the year 1953. Assembly-
line production was to start by the beginning of l95. Te was a lot of pressure
and burry to select skilled personnel ihd switch certain machines to the first-
stage production of MD 6 and at the same time to make all preparations for the 1954
asseMblpmline producti2n. For this the. menufacturing of so-calial "preparatory items"
was of key importance.' Since the current production of JO, 5 amines meth be
continued, first-stage production of MD 6 was to start immediately* and furthermore
the "preparatory items" for MD 6.assealairaine production were to be manufactured
as quickly as possible, the burden on the pleat capeetty was toe high. Therefore
a large number of the "preparatory items" were ordered at the lisebine Tool Factory
in Turcansty Svaty Martin, 8lovakia..3 ?The other still considerable number of these
items was to be manufactured in Mbtorlet. In spite of all plans, programs, and burry
source did not see any castings, forging', or small parts of the ND 6 in the work-
shops in early September 19537
2. Bottlenecks in productionP
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The production of the ND 5 engine in Motorist suffered from various shortcomings and
bottlenecks from the very beginning. Ihese could be divided into three categories:
First, the plant had a limited =her at skilled Craftsmen. The craftsmen were
all needed at routine work as foremen, machine settlers (adjusters), supervisors,
and advisers of the unskilled worker rooks. Bence an switch of craftsmen tc other
jobs connected, for instance with the introduction of new-type production or enlarga-
ment of current production instance,
c trOdbles and acteally slowed down
current asseably-Line production. Second, :was a,permanent shortage of tools
and special inetrumeets (such as fine 4petrumente). The foremen and store-
, .
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keepers were constantly busy assigning then: to and withdrawing them from the workers,
and there were continual quarrels about which worker was more in need of a certain
item. The instrument and tool situatiOn was always tense, and any new-type
production would require a new supply of instruments and tools as well as new
machinery. Third, considerable bottlenecks developed from short supply or halt
of supply of special materials. In 1953 such bottlenecks affected most strikingly
the production of shafts and vanes as described below:
a. Bottleneck in sheftsyroduction: The forgings for
Poldina roundry in nano. The forgings were made
The supply was going smoothly until about November
shafts were supplied by the
of special Vitrix steel.
1952. 25X1
it had been the last shipment 25X1
of shafts for the year 1952; the next shipment was to be expected in January 1953.
The workshops finished all shafts in stare before Christmas 1952, and beginning
in January they had nothing to work an. At a meetingoorkers were informed
that shipment of shaft forgings was expected by 15 January,, and therefore the
line of shafts was temporarily stopped, workers being assigned to another, sub-
stitute (rather unimportant) job. However, the forgings did not come in January
1953 nor at the beginning of February, and the workers started to murmur and
protest at the routine meetings, since by the substitute work they earned sUb-
stantially less than on a qualified job such as shaft production'. They were
calmed down by the factory managerieho assured them that the fOrgings shipment
was already on its way. But in fast the new shipment arrived only at the be-
ginning of April 1953. The delay 1168 exactly three monthe. With the new
supply a real turmoil occurred. Sale workers had to work 16 boors daily to
catch up. But soon, in fact at the very first operation, it became evident
that the new forgings were of defective material, since they were much easier
to machine. When the 'first 50 shafts were completed and underwent chemical
testing, it Was found that the material had numerous cracks. All 50 shafts
had to be throWn away. Some defects were found also in the next shipment,
but finally the forgings were again all right. However, certain changes
In the material were noticeable on the shafts, ball pivots) and traction tolts,
all these originally from Vitrix. Also the material of blowers was changed.
Originally the blowers were made of. light alloy with aluminam. When some new
alloy was used, the first 50 blowers had to be rejected because their vanes were
cracking at the last stage of the operation (at bending). .All improved with the
next shipment. Nevertheless source thinks that the resistance of the material
was worsened by these changes.
b. Bottleneck in rotor-blade producti : BY 1 June 1953 the line of blades for
turbine rotor production was la1ted. 25X1
the halt was caused by the shortage of cobalt. Later on it 25X1
had been decided to continue the production of rotor blades with a lesser amount
of cobalt. This wculd shorten the lifetime of blades but plans were made to
exchange the blades of rotors more often. Pertinent tnitructions had to be in-
cluded in the maintenance regulation. However the blades production bad not
been resumed as of September 1953. It looked as if coSalt was lacking even for the
production of substitute blades.
3. The effect of the 1953 bottlenecks on the production of MO 5 engines was quite
apparent. Whereas the normal capacity of the plant would allow production of about
six MO 5 engines daily, by Jay 1953 the output was hardly three engines per day. At
the same time the shortage of important ingredients such as cobalt and emergency
changes in materials such as special steel and alloys worsened also the general quality
of the products .This certainly affected unfavorably the performance of MO 5 engines.
A considerable number of MO 5 engines were manufactured for and shipped to the USSR.
The Soviets were informed of the shortages but apparently were not able to provide
the ingredients needed. They were also aware of the worsened quality of the epgines.
?
4. MiG 15 engines,produced outside Czechoslovakia:
In 1952
and Hungary. Liter
the Hungarian plant was
machining requirements.
?
MiG 15 engines were manufactured also in the USSR, Poland, 25X1
thee's production in Hungary was cancelled, because 25X1
allegedly incapable of copingh high metallurgical and
manufacture of engines,
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In addition to 25X1
Motorlet overhauled and repaired both its own MO 5 engines
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and MIG 15 engines of Soviet manufacture. 25X1
The center of the gear was of 22 mm. diameter. Per- 25X1
mitted tolerance was pluspinus 5/100. Overdosing the tolerance on the Czech
engine by more than 5/100 was subject to investigation by the control commission and
could lea( to a penalty. At the repair or overhaul job the gear center could be ground
to'a maximum of , 22 mm. minus 13/100. That was possible on the Motor3et MO 5
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rotor gear. But when overhauling or re ring the same on the Soviet engine
the difference minus 3/10.115y the Motorist standard and 25X1
technical regulation this difference would be considered to make the part defective.
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There was much discussion 25X1
among workers, foremen, and even technicians about the quality of Soviet engines
and all agreed that the engines of Soviet origin were far behind the Notorlet
products even with all their own (Motorist) shortcomings taken into account.
5. Testing of MD engines: Finished MD 5 engines were originally tested (broken in)
in Motorlet. laxly in 1953 a new testing station was completed near Stara Boleslav,
and finished engines have been shipped there since then. The testing station
has several underground chambers, so that noise of engines is damped. Ten engines
can be tested simultaneously. The location of this testing station is as follows:
Following the highway from Prague beyond Brandys nad Labem (Mlada Boles law- Liberec),
about 20 kilometers northeast from Prague, the testing station is in woods, about
one kilometer from the small town of Stara Bolerlav, about 500 meters north-
west of the highway. The place is connected with the main highway by a one-half
kilometer solid concrete road and is not distant from the railroad station Brandys
nad Lab= on the line from Melnik to Lysa nad Lebem. The whole area is fenced
and is guarded by the Army.
6. After the testing the MO 5 engines are shipped to various customers:
a. Czech Air Force: A certain number of MO 5 engines are sent to the Rudy Letov
Aircraft Factory in Prague-Letnany where they are built into NIG 15 planes
produced by the same factory. Then the aircraft are flown to the jet-testing
airfield at Panenske Brezany (051/F70) near Prague for test flight. u After-
wards they are taken over by the Czech Air Force.
b. USSR: Certain numbers of MO 5 engines are shipped to the USSR. In 1952, when
the motors were still tested (broken in) at Motorlet, they were shipped to the
USSR straight from the ",lent. They were packed into massive Cases 2.5 meters
x 2 meters x 3 meters and marked in 10-centimeter capitals
in Cyrillic lettering. ',1!ney were packed in the Motorlet shipping department
and carried away by large trucks. Since 1953 the tested motors have been
shipped to the USSR directly from the testing station.
c. Shipment to North Korea: In 1952 manager Cingros (fnu) told workers at a
meeiing that each engine produced by Motorlet would be of great help to the
comrades in Korea. At about the same time a North Korean delegation spent
several days at the plant and inspected the production there.
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2bAl
7. Supervisors of production.in Motorlet:
The plant is supervised by a group of Czech Air Force officers. They have their own
office at the plant (in the concrete building)?. At the inspection or during
testing of finished components these officers were usually accompanied by a few
civilians. Source was not able to learn the nationality of these civilians.
8. Construction of underground halls:. Underground halls have been under construction
since 1953 on Cerny vrch Mack Rill) in Prague-Kosire (see annex). By September 1953
the work Was not yet completed, though day and night work shifts could be Observed.
The construction was hidden behind a high board fence and was off limits. However, the
place could be Observed from a certain distance. The entrance is from Vrchlickeho ulice.
oppositea cemetery (Malostransky hrbitov). 25X1
there were persistentrumors that Motorlet 25X1
would be moved into the underground hal41C in case of war. There were no signs of any
' production or manufacture being started or going on in the inetalletion. A villa on
Cerny vrch is occupied by a group of soiSiers'who execute day:.round guard duty on the roof.
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Tim have one antiaircraft machine gun.
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8 O OR means parts (components) 20A1
ori emgine are amaufacrered individually by stilled specialists
,accerdlog t0.Dlani (deals, sketaime) without so-called "preparatory items"
(see below Comment: 2). Comarary to it, assembly-line production means 25X1
automatic production where all workers of the factory can participate, since
each has a very limited job. ?portables: an a specific particle. For this he is
provided with a corresponding "properatery item" with wh111:bn wer,:s or which is
fixed on his lathe, adjustea for that special but automatie operation..
t: Before the asseiblpwline production could be started, the eachine:25X1
and iVibri must be provided with "preppretory items" and tools. ler nearly
every perSele or componiat of the esw-type motor there woad have to be a
corresponding preparatory item. Zr the particle or compomert has to undergo
several machining operation:0km there mast be another preparatory item for
Mak operation. There are many huadred, even thousand:poi:if leeparatcry items
for produstion of i jet motor. They include fixtures jigs, jaws, etc.
Preparatory items are stored in a preparaterrltems store. Seerebeginning
a nee operation each worker has to. ask the foreaaMor the pectins:it design
on uhich,the necessary tools and preparatory.iteme for the oPeratien are listed.
Tools are listed as: Knife Scree tap Me...,wheresis preperatorriteme
have no names but only nuibers; for instance Preparatory Item's.... 'The worker
has to pickup the preparatory items and tools at the store sad after-completing
the operation or shift he most return thee to the Store.
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[IM soon such items might have been in 25X1
storloas famines and castings wore supplied from outside metallurgical 25X1
work, the firet.stame production 'of MO 6 could have started 25X1
by or ahott 12 September. 25X1
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From 12 8epta:16er until 31 December 25X1
1953 there were about 90 working deys (excluding Seeders emd C)ristmas). The
first.stage production (without preparatory items) depemds_solaly on skilled
specialists and craftsmen, whose member is limited. The majoritor of plant workers
are retrained people from other civilian jabs (white-ooller carters, waiters,
etc.). They are without special skills ant can be used oftip in Owes. ellar-
line work. So, even if the management offered extra pa* for Overtime shift* to the
skilled craftsmen (as they Aid in emergencies) the time until Christmas was very
short. rather by the end of Jammer,? Or in Pareary 1954 25X1
the first six MD 6 could have been eomplated if some other heblambeek did not
develop la the meantime. As for the asseshly.line production of MD 6 engine:5
it :Mad not have started by the teeinning of 25X1
1954. First of 'Mahe takes it far granted that the prepayabley items could not
be ready by the end of 1953, ovum thank many of them were ordered in Tarcanela
Svaty Martin. To manufacture preperstory items, again only foremen and skilled
craftsmen can do the job. Dat most of the craftsmen are lomdby needed as machine
settlers or adjusters at the routine work and to supervise end advise the ranks
of skilled workers. VIthout that there weald'be memerele defeats and
difficulties. Therefore not me ay skilled craftsmen coUld be jetitehed to a
special job. Secondothe plans, shetehesand processei email* corked out
for eackismicbdne and worker. Third, mew new instruments had to be provided.
Te was a constant shortage of thma eves for the current preduction lines.
Above all, the new MD 6 prodectiaevould definitely'reqpire apply and installation
of addition:a machinery. Th1.0 maa-ialfe604-ilammed Nave ilmrlia-la wars constructed),
but there was no, indication yet 0110 Oa frail where the nealiMAiDery would elms.
the asseiblyi-Linct i!ireinetion of MC 6 could25X1
not helms started earlier than sometime in June-ftly 1954. 25X1
even if the assesdarilne prodectida of NO 6 should have been iMOMMWMily 'bane or
July 1954, still some preparatory items would have been missiog amd some of the
operation would have had to be done by bandeork of or-enamel.
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in 1953 BONO 25X1
special preparatory items did not yet exist eed.several operations therefore had
to be.dome'bybmmdeork, though the production of-DO 5 was already in its second year.
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UrCrground halls under construction at Cerny Vrch,
Prave-Kohire.
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Underground halls under construction at Cerny Vrch, Prague - Kosire
See Plan of Prague section 19 (Not further identified)
of underground
in construction
gjs PublAA
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On Black Hill