Manufacturing - an extension to your plant

MAHLE Powertrain's assembly lines are tailored to customer requirements and can be called upon to help cope with production peak loads, handle specific model variants and build low volume niche engine types, thus freeing up the customer's plant capacity and reducing complexity issues in the normal high volume environment.

Each assembly line is configured according to product volume and complexity. MAHLE Powertrain uses a combination of manual and automated processes, including multi-spindle and other appropriate dedicated tooling. Intelligent tooling and on-line computerized data capture systems are employed to monitor key build functions and collect significant data for compiling engine build records to ensure full traceability.
Completed engines are functionally tested at end-of-line including hot testing or power-check dynamometer testing, according to customer requirements, before proceeding to final dress, packaging and dispatch. At a preset frequency, engines are also audit tested using in-house dynamometers, after which they are dismantled and checked for build integrity.

Closed loop quality review processes ensure that any anomalies are reported to the assembly or machining areas for immediate attention and remedial action. Engine assembly areas and associated cylinder head and block sub-system assembly lines are segregated from the machining areas to maintain a clean environment.

MAHLE Powertrain has a track record of high achievement in bringing together all the facets of an effective manufacturing program, so minimizing the need for customers to invest in additional resources.
We have a wealth of experience in taking programs from concept to manufacture; the adoption of existing customer products for end of life-cycle run-outs; adopting existing supplier bases to liberate the customer's own valuable productive resources; reducing plant complexity and management overheads; and delivering cost-effective solutions to our customers.

• Complete Powertrain assembly operations
• Extensive OEM experience
• Intelligent systems and data capture
• Prototype, pre-series and series production
• Sub-system assembly
• End of Production (ramp-down) scenarios
• Spares and service assemblies
• Complexity and resource minimisation options
• Functional testing resources
• Audit and Dynamometer resources