Sub-Assembly and Powertrain Assembly

Using it’s sub-system and powertrain assembly skills and experience MAHLE Powertrain can support OEM’s in a variety of ways offering flexibility and complexity minimisation. In providing sub-assembly services, the process of customer final assembly is faster and simpler so that the vehicles and associated powertrains are produced more efficiently overall.

Sub-system assemblies shipped directly to line side reduces the inventory management that would otherwise have to be accommodated, therefore saving on warehousing and supply chain planning resources. MAHLE Powertrain’s logistics operation are equipped to manage the downstream supply chain activities leaving the OEM to focus on achieving added value at it’s own plants. Quality assurance systems and processes ensure compliance and function of products for immediate use by the customer at line side thereby achieving complexity and risk reduction with flexibility in change management and options planning.

MAHLE Powertrain's powertrain 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 computerised 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 programmes 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.