Important series production start at Brose Hallstadt

(Hallstadt, 18.11.2003). A few days ago, the automotive supplier Brose put its most automated production line into operation in its Hallstadt plant. Brose is using this to produce the basic door systems which the Ford Group will utilize on a cross-platform basis in the car models Ford Focus, Focus C-MAX and the Volvo S40.

This is the first time Ford is using door systems from Brose. The automotive manufacturer is confident in the know-how of the automotive supplier who not only produces the door systems but is also responsible, as a full-service supplier, for developing the product. The Brose door system integrates a window regulator, door control unit, loudspeaker, wiring harness and the complete latch module onto a carrier base plate. All functions are pre-checked and ensure the highest level of quality.

A modern and highly automated production line totaling 1,500 square meters has been set up in the Hallstadt plant. A seal is initially fixed on the carrier base plate, separating the wet and dry area of the car door. The advantage of this design principle is that only the mechanical components of the latch and the window regulator are located in the wet area of the door. This innovative concept increases functional safety and cuts costs as it eliminates the necessity of sealing electrical and electronic components.

The window regulators are produced in cycle times of mere seconds and then assembled onto the basic door systems. These are then delivered by truck on a just-in-time basis to two plants of the Brose Group: Saarwellingen and Gent in Belgium. There, additional components like the loudspeaker and the latch are added to the door systems. Once they are fully assembled in one-minute cycle times, the door systems are subsequently delivered to the Ford plant in line with the automaker’s own vehicle production schedule.

“With this production concept, we have managed to achieve an innovative leap forward in the production of window regulators and door systems. The pricing pressure of our customers has meant that we have had to come up with a new approach regarding equipment automation,” is how plant director Matthias Drewniok justifies the investment entailing seven million euro.

The equipment is currently assembling some 4,000 basic door systems per day. Next year, this figure will increase to a rate of 12,000 units per day for more than 3,000 vehicles. More than 50 employees are working on this production line in a three-shift operation.

Modular door systems based on the Brose concept of separating wet and dry areas are currently being developed worldwide for 17 automotive brands. Brose has the greatest experience in the development and production of door systems. Since production of the first door systems started in 1987, more than 40 million units have been delivered on a just-in-time or just-in-sequence basis from Brose plants in Europe, America, Africa and Asia.


Press Contact:
Alexander Flieger
Tel: +49 9561 21 1567
Fax: +49 9561 21 1704
E-Mail: alexander.flieger@brose.net